Lochinvar FTxl 400, FTxl 725, FTxl 500, FTxl 600 Operation Manual

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Page 1

FTXL-I-O Rev C

Installation & Operation Manual

Models: 400, 500, 600, 725,

& 850

 WARNING

Save this manual for future reference.

This manual must only be used by a qualiﬁ 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.

Page 2

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 ............................................................. 57-62

11. OPERATING INFORMATION

General ............................................................................. 63

Cascade ........................................................................... 66

Sequence of Operation ............................................... 67-68

FTXL Control Module ....................................................... 69

Status Display Screens ............................................... 70-72

12. MAINTENANCE

Maintenance and Annual Startup ................................ 73-77

13. DIAGRAMS

Wiring Diagram ........................................................... 78

Ladder Diagram ......................................................... 79

Revision Notes .................................................. Back Cover

Hazard deﬁ nitions

The following deﬁ 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.

Page 3

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 – 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 qualiﬁ 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 ﬁ 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 ﬁ re 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 ﬂ ammable 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 ﬁ re department.

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

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 ﬂ ow 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. The possible damage to a ﬂ ooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

• Thoroughly ﬂ ush the system (without boiler connected) to remove sediment. The high-efﬁ ciency heat exchanger can be damaged by build-up or corrosion due to sediment.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in boiler or piping must be repaired at once to prevent makeup water.

 CAUTION

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are speciﬁ 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 use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.

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The FTXL - How it works...

1. Stainless steel heat exchanger

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

2. Heat exchanger top plate

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

3. Blower

The 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

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

5. Venturi

The venturi controls air and gas ﬂ ow into the burner.

6. Flue gas sensor (limit rated)

This sensor monitors the ﬂ ue gas exit temperature. The control module will modulate and shut down the boiler if the ﬂ ue gas temperature gets too hot. This protects the ﬂ ue pipe from overheating.

7. Boiler outlet temperature sensor (limit rated)

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

8. Boiler inlet temperature sensor

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

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

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

10. Electronic LCD display

The 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 ﬁ ber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of ﬁ 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

Threaded 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

The 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 modiﬁ 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

The 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

The 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

The condensate trap is sized for a 1" 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

The quartz glass window provides a view of the burner surface and ﬂ ame.

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

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

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

Protects the heat exchanger from an over pressure condition. The 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 ﬂ 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

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

34. Transformer

The 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 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 ﬂ ue collector

Flue gas and condensate enter the stainless steel ﬂ ue collector through the ﬁ retubes. A 1" drain connection allows condensate to ﬂ ow 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

The 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 ﬂ ue vent which provides access for a combustion analyzer probe.

41. Burner plate (not shown)

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

Page 5

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

Models 400 - 850

Installation & Operation Manual

Front View

Rear View

Left Side (inside unit)

Right Side (inside unit)

Page 6

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. 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 sufﬁ 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 conﬁ 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. The 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 speciﬁ 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. 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 afﬁ xed to the unit.

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

Figure A High Altitude Label Location

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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

The FTXL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests speciﬁ 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. The pan must not restrict combustion air ﬂ 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 ﬂ ammable liquids.

 WARNING

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.

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

 WARNING

This appliance is certiﬁ 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.

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 ﬁ eld provided PVC vent ﬁ ttings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement speciﬁ ed in this manual to make the vent connections. Failure to follow this warning could result in ﬁ 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. This 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. 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 ﬁ 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.

Page 8

Installation & Operation Manual

1 Determine boiler location (continued)

Figure 1-1 Closet Installation - Minimum Required Clearances

 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 ﬁ re, personal injury, or death.

Figure 1-2 Alcove Installation - Minimum Required Clearances

 WARNING

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 ﬁ re, personal injury, or death.

Page 9

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).

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.

Flooring and foundation

Flooring

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

 WARNING

If ﬂ ooding is possible, elevate the boiler sufﬁ 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 ﬂ oor.

• 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 speciﬁ 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. 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.

Page 10

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/ﬂ uorocarbons

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 reﬁ 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 ﬂ 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 ﬂ ue 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 ﬁ 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 ﬂ 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 speciﬁ 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 ﬂ ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Page 11

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 deﬁ 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 ﬁ replace dampers.

Do not install the FTXL into a common vent with any other appliance. This will cause ﬂ 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 draft hood relief opening after

5 minutes of main burner operation. Use the ﬂ ame 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, ﬁ replace dampers, and any other gas-burning appliance to their previous conditions of use.

Page 12

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 sufﬁ cient volume to assure adequate combustion air and proper ventilation for all gas ﬁ red appliances in the equipment room to assure adequate combustion air and proper ventilation.

The requirements shown are for the appliance only; additional gas ﬁ 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 ﬁ 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). 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 speciﬁ 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 different stories: One or more openings should have a net free area of two square inches per 1000 Btu/hr (44 cm2 per kW).

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).

IMG01074

IMG01077

Figure 1-6_Combustion Air from Outside - Single Opening

Page 13

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). 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 ﬂ oor of the equipment room. Each opening must have a net free area as speciﬁ ed 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 ﬂ ammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are ﬂ uorocarbons 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, ﬂ ue 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 ﬂ 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

Same Story

Top

Opening, in

(cm2)

400

(2,581)

500

(3,226)

600

(3,871)

725

(4,677)

850

(5,484)

Space

Bottom

Opening, in2 (cm2)

400

(2,581)

500

(3,226)

600

(3,871)

725

(4,677)

850

(5,484)

*Outside Air from

1 Opening Directly from

Outdoors, in

(cm2)

(865)

(1,078)

(1,291)

(1,561)

(1,832)

134

167

200

242

284

Model

Number

FTX400

FTX500 FTX600

FTX725

FTX850

*Outside Air from

2 Openings Directly from

Outdoors

Top

Opening, in

(cm2)

100

(646)

125

(807)

150

(968)

182

(1,174)

213

(1,374)

Bottom

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)

The above requirements are for the appliance only; additional gas ﬁ 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 ﬁ 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 deﬁ 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.

Page 14

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):

a. Remove the lag bolts from the wood pallet inside the boiler (FIG. 2-1). b. Disconnect the ribbon cable and remove the bezel (no tools required for removal) before removing the boiler from the pallet or moving the boiler. c. Detach the boiler from the lag bolts in the front and rear of the unit, see FIG. 2-1.

NOTICE

Figure 2-1 Boiler Mounted on Shipping Pallet

LAG BOLTS (QTY. 3)

Gas conversions

 WARNING

Table 2A LP Conversion Kit

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

FRONT

LAG BOLTS (QTY. 3)

REAR

IMG00984

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.

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 off 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. 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.

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

 DANGER

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-ring 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.

Model Description Kit Number

400 - 500

LP Kit LPK30017

Page 15

2 Prepare boiler (continued)

Installation & Operation Manual

Figure 2-2A 400 Model_Venturi with LP Oriﬁ ce

Figure 2-2B 500 Model_Venturi with LP Oriﬁ ce

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 CO (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

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.

Page 16

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

Two Pipe Sidewall

See page 24 for more details

Direct venting options - Vertical Vent

PVC/CPVC Concentric Sidewall

Models 400 - 600 Only

See page 28 for more details

Two Pipe Vertical

See page 31 for more details

PVC/CPVC

Concentric Vertical

Models 400 - 600 Only

See page 33 for more details

Vertical Vent, Sidewall Air

Page 17

3 General venting (continued)

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

 WARNING

NOTICE

 WARNING

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 ﬁ 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.

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

PVC, CPVC or polypropylene pipe and ﬁ ttings listed in Tables 3E, 3F, and 3H for vent pipe, and ﬁ ttings. 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 ﬂ ue products into the

living space. Mixing of venting materials will void the warranty and certiﬁ 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 ﬁ re, personal injury, or death.

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 certiﬁ 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 ﬁ tting is provided on the unit for ﬁ 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 ﬁ tting is provided on the unit for ﬁ 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

 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.

Page 18

3 General venting

Installation & Operation Manual

Requirements for installation in Canada

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

2. The ﬁ rst three (3) feet of plastic vent pipe from the appliance ﬂ ue outlet must be readily accessible for visual inspection.

3. The components of the certiﬁ ed vent system must not be interchanged with other vent systems or unlisted pipe/ﬁ ttings. For concentric vent installations, the inner vent tube must be replaced with ﬁ eld supplied certiﬁ ed vent 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 FTXL uses model speciﬁ 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 (CVK3007) = 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.

The 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 CVK3007 5' (1.5 m)

500 - 600 CVK3007 30' (9 m)

Equivalent

Vent Length

Air inlet pipe materials:

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 speciﬁ ed in this section. Type “B” double-wall vent with joints and seams sealed as speciﬁ ed in this section. AL29-4C, stainless steel material to be sealed to speciﬁ 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 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.

Using air intake materials other than those speciﬁ ed 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.

Page 19

3 General venting (continued)

Installation & Operation Manual

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 ﬂ 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 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 ﬂ ue gas recirculation, spillage of ﬂ 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 ﬂ 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.

• 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

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

There 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 often contain ﬂ uorine 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 ﬂ 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 KIT30053

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.

Page 20

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

400 4" DRH30006

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

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

4. 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.

5. 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.

 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.

500 4” DRH30006 600 4” DRH30006 725 6” DRH30007 850 6” DRH30007

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

 WARNING

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 ﬁ eld provided vent ﬁ 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 speciﬁ ed in Table 3E to make the vent connections. Failure to follow this warning could result in ﬁ 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. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

Page 21

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, ﬁ ttings and cement/ primer must be ULC-S636 certiﬁ 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 ﬁ ttings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

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 ANSI/ASTM D2564 CPVC ANSI/ASTM F493

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

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

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

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

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

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

the ﬁ tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufﬁ 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 soften the pipe.

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

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

725 - 850

Page 22

Installation & Operation Manual

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 ﬂ 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

NOTICE

 WARNING

NOTICE

The installer must use a speciﬁ c vent starter adapter at the ﬂ ue 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.

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.

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

Table 3F Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems InnoFlue SW/Flex

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

Table 3G Approved Polypropylene Terminations

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

Centrotherm

400-600

725-800

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

Eco Systems

DuraVent

(M & G)

Centrotherm

Eco Systems

DuraVent

(M & G)

Innoﬂ ue PolyPro Innoﬂ ue PolyPro

Single-Wall Single-Wall Single-Wall Single-Wall

Flex Flex Flex Flex

Figure 3-5 Near Boiler Polypropylene Venting

Retaining Bracket /

ISAAL0404 IANS04 --

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

ISAAL0606 -- --

FSA-6PVCM-

6PPS

-- 6PPS-HLK --

ISTAGL0404

IATP0606 /

ISTAGL0606

Adapter*

IATP0404/

Page 23

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

NOTICE

Table 3H Stainless Steel Vent Pipe and Fittings

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 speciﬁ c vent starter adapter at the ﬂ 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

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

Approved Stainless Steel Vent Manufacturers

Manufacturer Model

Dura Vent (M & G) Z-Flex Z-Vent

Heat Fab Saf-T Vent Metal Fab Corr/Guard Security Chimney Secure Seal

FasNSeal Vent / FasNSeal

*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.

Table 3I Approved Stainless Steel Adapters and Terminations

Model Manufacturer

DuraVent (M & G)

(Fas-N-Seal)

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

400-600

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

Metal Fab (Corr/Guard) 4CGPVCA 4CGPVCA

Security Chimney

(Secure Seal)

DuraVent (M & G)

(Fas-N-Seal)

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

725-850

Metal Fab (Corr/Guard) 6FCGPVCA 6FCGPVCA

Security Chimney

(Secure Seal)

Flex*

Adapter Termination

Flue Intake Flue Intake

FSA-04-PVC F303759

SS4PVCU SS4PVCU

FSA-06PVC-06FNS

300538

SS6PVCU SS6PVCU

FSBS4

FSRC4 (R.C.)

0492

5400CI

2SVSTP04

2SVSRCX04

4CGSWHT

4CGSWC

SS4STU

SS4RCBU

F303759 FSBS6

6FCGSWMC

6FCGSWC

SS6STU

SS6RCBU

FSAIH04

303888

9414TERM

2SVSTEX0490

4CGSW90LT

SS4ST90AU

FSAIH04

303888

6CGSW90L

SS6ST90AU

Page 24

4 Sidewall direct venting

Vent/air termination – sidewall

Installation & Operation Manual

 WARNING

 CAUTION

NOTICE

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.

Determine location

Locate the vent/air terminations using the following guidelines:

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 ﬂ 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 ﬂ ue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of ﬂ ue 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.

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 ﬁ nishes.

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 ﬂ ue 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.

 WARNING

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

Table 4A Sidewall Vent Kits

Model Kit # Air Vent

400 - 600 KIT30046 4" (102 mm) 4" (102 mm) 5 5/8" (143 mm) 725 - 850 KIT30048 4" (102 mm) 6" (152 mm) 7 3/4" (197 mm)

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.

Centerline

Width

Page 25

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

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

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

NOTICE

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:

• 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.

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

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

Figure 4-3B Clearance to Gravity Air Inlets

Page 26

4 Sidewall direct venting

Vent/air termination – sidewall

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

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 ﬂ oors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

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

Figure 4-4B Clearance to Forced Air Inlets

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.

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 ﬂ 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.

Page 27

Installation & Operation Manual

4 Sidewall direct venting (continued)

4. Mount and secure the vent plate to the wall using stainless steel screws.

5. Seal all gaps between the pipes and wall. Seal around the plate to the wall assuring no air gaps.

6. Assemble the vent cap to the vent plate (see FIG.’s 4-5B and 4-5C). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.

7. Seal all wall cavities.

8. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.

9. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.

Figure 4-5B PVC/CPVC Sidewall Termination Assembly

Multiple vent/air terminations

1. When terminating multiple FTXL’s terminate each vent/air connection as described in this manual (FIG. 4-6A).

 WARNING

2. Place wall penetrations to obtain minimum clearance of 12 inches (305 mm) between vent pipe and adjacent air inlet elbow, as shown in FIG. 4-6B for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a FTXL is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 4-6A Multiple Vent Terminations w/ Field Supplied Fittings (must also comply with Figure 4-1A)

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Table 4B Sidewall Vent Centerline Dimensions

Model Air Vent Centerline Width

400 - 600 4" (102 mm) 4"(102 mm) 5 5/8" (143 mm) 725 - 850 4" (102 mm) 6" (152 mm) 7 3/4" (197 mm)

Figure 4-5C Polypropylene Sidewall Termination Assembly

Figure 4-6B Multiple Vent Terminations (must also comply with Figure 4-1B)

Page 28

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent: Models 400 - 600 Only

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#CVK3007 for 4" (102 mm) diameter - Models 400 - 600). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7.

The required combustion vent pipe materials are listed in Table 3E, on page 21 of this manual.

Figure 4-7 Concentric Sidewall Termination - Models 400 - 600

3. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007 installations into the structure to install the termination kit.

4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.

a. Cement the Y concentric ﬁ tting to the larger kit pipe (FIG. 4-8).

b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-8).

Figure 4-8 Kit Contents_CVK3007 - Models 400 - 600

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 4-7).

2. Reference the Determine Location Section on page 24 of this manual for general termination considerations.

Page 29

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent: Models 400 - 600 Only

Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 600

"A"

"C" DIA.

"B" DIA.

NOTICE

 WARNING

(76 MM)

(152 MM)

"G"

(537 MM)

"B" DIA. PVC VENT / EXHAUST

ABC D EF GH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

(1524 MM)

(102 MM)

Instead of cementing the smaller pipe to the rain cap, a ﬁ eld-supplied stainless steel screw may be used to secure the two (2) components together when ﬁ eld disassembly is desired for cleaning (see FIG. 4-10).

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

"H" DIA.

"D"

(76 MM)

"E"

"F"

(168 MM)

(254 MM) (194 MM)

5. Install the Y concentric ﬁ tting and pipe assembly through the structure’s hole from an inside wall.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

6. Install the rain cap and small diameter pipe assembly into the Y concentric ﬁ tting and large pipe assembly from an outside wall. Ensure small diameter pipe is fastened tightly into the rubber adapter for #CVK3007 installations.

7. Secure the assembly to the structure as shown in FIG. 4-11 using ﬁ eld-supplied metal strapping or equivalent support material.

 WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and ﬂ ow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 4-10 Rain Cap to Vent Pipe Alternate Assembly

STAINLESS STEEL SCREW

(FIELD SUPPLIED)

DRILL CLEARANCE HOLE IN

RAIN CAP & PILOT HOLE

IN VENT PIPE

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-7.

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, ﬁ eld-supplied standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9).

If assembly depth needs to be reduced, dimension D can be as short as possible.

Page 30

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent: Models 400 - 600 Only

Figure 4-11 Concentric Vent Sidewall Attachment

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

COMBUSTION AIR

VENT

STRAP

COMBUSTION AIR

VENT

CAUTION

DO NOT use ﬁ eld-supplied couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-11 for proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-12). When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-12. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gases.

Figure 4-12 Concentric Vent and Combustion Air Termination

Page 31

5 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

 WARNING

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

Determine location

Locate the vent/air terminations using the following guidelines:

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. Prepare the vent termination and the air termination

elbow (FIG. 5-1A) by inserting bird screens. Bird screens should be obtained locally.

3. The vent must terminate at least 3 feet above the highest

place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

4. The air piping must terminate in a down-turned 180°

return pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of ﬂ ue products into the combustion air stream.

5. The vent piping must terminate in an up-turned coupling

as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 1 foot above the air intake.

6. Maintain the required dimensions of the ﬁ nished

termination piping as shown in FIG. 5-1A.

Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” (610 MM) OF VENT PIPE

BIRD SCREEN

(TYPICAL)

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

VENT

COM,BUSTION AIR

8. 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.

7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting - Vertical Vent, Sidewall Air Section.

Page 32

5 Vertical direct venting

Vent/air termination – vertical

Prepare roof 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 (when required by local codes).

3. Space the air and vent holes to provide the minimum

spacing shown in FIG.’s 5-1A and 5-1B, page 31.

Installation & Operation Manual

Figure 5-2 Vertical Terminations with Multiple Boilers

Figure 5-3 Alternate Vertical Terminations with Multiple

Boilers

4. Follow all local codes for isolation of vent pipe when

passing through ﬂ oors, ceilings, and roofs.

5. Provide ﬂ ashing and sealing boots sized for the vent pipe

and air pipe.

Multiple vent/air terminations

1. When terminating multiple FTXL boilers, terminate each vent/air connection as described in this manual (FIG. 5-2).

 WARNING

2. Place roof penetrations to obtain minimum clearance

of 12 inches (305 mm) between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a FTXL boiler is part of a direct vent

connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of ﬂ ue products and the possibility of severe personal injury, death, or substantial property damage.

Page 33

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent: Models 400 - 600 Only

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and ﬁ ttings are required to complete the installation.

The required combustion vent pipe ﬁ ttings are listed in Table 3E, on page 21 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).

Figure 5-4 Concentric Vertical Termination

2. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007 installations) into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric ﬁ tting to the larger

diameter kit pipe (see FIG. 4-8, page 28).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-8, page 28).

NOTICE

 WARNING

Instead of cementing the smaller pipe to the rain cap, a ﬁ eld supplied stainless steel screw may be used to secure the two (2) components together when ﬁ eld disassembly is desired for cleaning (see FIG. 4-10, page 29).

Figure 5-5 Do Not Install U-Bend to Rain Cap

Page 34

Installation & Operation Manual

5 Vertical direct venting

Vertical termination – optional concentric vent: Models 400 - 600 Only

 WARNING

4. Install the Y concentric ﬁ tting pipe assembly up through the structure’s hole and ﬁ eld supplied roof boot/ﬂ ashing.

NOTICE

5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using ﬁ eld supplied metal strapping or equivalent support material.

Figure 5-6 Concentric Vent Roof Installation

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

CAUTION

6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is fastened tightly into the rubber adapter for #CVK3007 installations.

7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.

8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gases.

DO NOT use ﬁ eld-supplied couplings to extend pipes. Airﬂ ow restriction will occur.

NOTICE

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination

Ensure termination height is above the roof surface or anticipated snow level (12 inches (305 mm) in U.S.A. or 18 inches (457 mm) in Canada) as shown in FIG. 5-4, page 33.

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, ﬁ eld supplied standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9, page 29).

Page 35

Installation & Operation Manual

5 Vertical direct venting (continued)

Alternate vertical concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.

The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A.

The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as speciﬁ ed in Table 3E on page 21.

Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.

Figure 5-8 Concentric Vent Example 1

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

Figure 5-9 Concentric Vent Example 2

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.

If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A on page 10 for a list of corrosive contaminants and sources.

Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Model

400 - 600 4" 7" 725 - 850 6" 10"

Vent / Air Inlet Size

Minimum Existing

Vent / Chase Size

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

Page 36

5 Vertical direct venting

Existing vent as a chase

Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.

Figure 5-10 Existing Vent as a Chase

Installation & Operation Manual

*For concept illustration only. Individual installations

may vary due to job site speciﬁ c equipment.

Page 37

6 Hydronic piping

Installation & Operation Manual

System water piping methods

The FTXL is designed to function in a closed loop system pressurized to not less than 12 psi (83 kPa). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

It is important to note that the boiler has a minimal amount of pressure drop which must be accounted for when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation or basic service of circulator replacement, valves, and others.

Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

This boiler comes equipped with a low water cutoff device. On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-5 through 6-10), which will guide you through the installation of the FTXL (reference FIG.’s 6-3A and 6-3B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backﬂ ow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).

6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for speciﬁ c information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, ﬂ ow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system ﬂ uid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

 WARNING

Use only inhibited propylene glycol solutions, which are speciﬁ cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi (103 kPa).

10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

 WARNING

11. On any pre-existing system, it is good practice to install a ﬁ eld supplied strainer to prevent damage to the heat exchanger.

See the piping illustrations included in this section, FIG.’s 6-5 and 6-10 for suggested guidelines in piping the FTXL.

NOTICE

The relief valve, tee and any other necessary ﬁ ttings are shipped in the install kit with the boiler and are to be ﬁ eld installed (FIG.’s 6-1 and 6-2).

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 38

6 Hydronic piping

Installation & Operation Manual

Relief valve and temperature and pressure gauge installation

Basic steps are listed below to guide you through the installation of the relief valve, and temperature and pressure gauge provided with the unit.

1. Install the tee directly to the outlet connection of the heat exchanger with the 3/4 inch ﬁ tting positioned vertically and on the top (see FIG. 6-2).

2. For Models 725 - 850 install the 3/4 inch close nipple in the tee. Install the relief valve on the 3/4 inch close nipple (FIG. 6-2). For Models 400 - 600 install the relief valve directly into the 3/4 inch ﬁ tting on the tee (FIG. 6-1).

3. Install the close nipple on the downstream side of the relief valve tee (FIG. 6-1).

4. Install the tee with the 1 inch ﬁ tting positioned vertically and on the top (FIG. 6-1).

5. Install a ﬁ eld provided close nipple on the downstream side of the ﬂ ow switch (if used), see FIG.’s 6-1 and 6-2.

6. Install a ﬁ eld provided tee with the gauge ﬁ tting positioned vertically and on the top (FIG.’s 6-1 and 6-2)

7. Install the temperature and pressure gauge provided with the unit into the top ﬁ tting of the tee (a bushing may be necessary) installed in Step 6 (FIG.’s 6-1 and 6-2).

Figure 6-1 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 400 - 600

Figure 6-2 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 725 - 850

NOTICE

If using a ﬂ ow switch, be sure to install the ﬂ ow switch so that the arrow on the ﬂ ow switch is pointing in the direction of the ﬂ ow.

Page 39

6 Hydronic piping (continued)

Installation & Operation Manual

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 6B. Reducing the pipe size can restrict the ﬂ ow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on a full ﬂ ow application.

2. Boiler system circulating pump:

Field supplied. The boiler circulating pump should be based on system requirements.

3. Domestic hot water circulating pump:

Field supplied. The pump MUST be sized to meet the speciﬁ ed minimum ﬂ ow requirements listed in FIG. 6-4. Consult the indirect water heater operating guide to determine ﬂ ow characteristics for the selected product used.

4. Variable speed boiler circulator: FTXL boilers are capable of controlling a variable speed

boiler circulator. Variable speed circulators MUST be sized to meet the speciﬁ ed minimum ﬂ ow requirements listed in FIG. 6-4 on page 41 at full speed. To be used in primary/secondary systems only.

5. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

12. Boiler purge valve:

Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.

13. System temperature sensor:

Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. The sensor should be located far enough downstream to sense system diluted water temperature.

14. Y-Strainer:

Field supplied. A Y-strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems.

15. Motorized isolation valve (optional):

Field supplied. A motorized isolation valve can be used to isolate the boiler from the system piping.

Circulator sizing

The FTXL heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graphs in FIG. 6-4 for pressure drop through the FTXL heat exchanger.

6. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-5 through 6-10. Failure to install check valves could result in a reverse ﬂ ow condition during pump(s) off cycle.

7. Domestic indirect hot water isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

8. Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F (46°C).

9. Unions:

Field supplied. Recommended for unit serviceability.

10. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

11. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME speciﬁ cations.

Page 40

Installation & Operation Manual

6 Hydronic piping

Near boiler piping connections

Figure 6-3A Near Boiler Piping w/Y-Strainer

Figure 6-3B Near Boiler Piping w/Low Loss Header

Variable speed pump option

Variable speed pump setup

Before operation, ensure the following:

- Pump is set for an input signal of 0 - 10VDC by the dip switches on the pump control

- Pump is set for external signal control (if applicable)

- Pump is set for linear output (if applicable)

- If pump does not come equipped with a 0 - 10 VDC input option, an optional module will be required from the vendor

SMART SYSTEM / Multi-temperature loop control option

The FTXL boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop(s) from overheating. To help aid with this protection, Lochinvar offers the MultiTemperature Loop Control Board Kit (RLY30086).

 CAUTION

NOTICE

The maximum allowable water ﬂ ow rate through a single FTXL boiler is 105 GPM (Models 400 - 600) and 150 GPM (Models 725 - 850). Exceeding this ﬂ ow rate will result in damage to the heat exchanger and/ or piping.

Reference Table 6A1 for the minimum recommended ﬂ ow rate through a single FTXL boiler at full ﬁ re to maintain a 80°F temperature rise. Reference Table 6A2 for the absolute minimum ﬂ ow rate through a single FTXL boiler.

Table 6A1 Minimum Flow Rate with the Boiler at Full Fire

TEMPERATURE RISE APPLICATIONS MODEL FLOW RATE (GPM)

FTX(N,L)400 10

FTX(N,L)500 12

FTX(N,L)600 15

FTX(N,L)725 18

FTX(N,L)850 21

[Based on 80°F Temperature Rise]

Table 6A2 Absolute Minimum Flow Rate @ Low Fire

ABSOLUTE MINIMUM FLOW RATE

MODEL FLOW RATE (GPM)

FTX(N,L)400 4

FTX(N,L)500 4

FTX(N,L)600 4

FTX(N,L)725 4

FTX(N,L)850 4

Page 41

6 Hydronic piping (continued)

Figure 6-4 Pressure Drop vs. Flow

HEX Pressure Drop

(Full Flow Application)

FTX725-850 FTX400-600

Installation & Operation Manual

15 ft 14 ft 13 ft 12 ft 11 ft 10 ft

9 ft

(Feet of Head)

8 ft 7 ft 6 ft 5 ft 4 ft 3 ft

Pressure Drop

2 ft 1 ft 0 ft

FTX400-600

FTX725-850

Flow Rate

Table 6B Sizing Information for Temperature Rise Applications_20°F, 30°F, 40°F, 60°F and 80°F

TEMPERATURE RISE APPLICATIONS

20°F 30°F 40°F 60°F

GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD GPM FT/HD

Model

MINIMUM

PIPE

SIZE

15 ft 14 ft 13 ft 12 ft 11 ft 10 ft 9 ft 8 ft 7 ft 6 ft 5 ft 4 ft 3 ft 2 ft 1 ft 0 ft

80°F

400 2" 39 3.5 26 2.8 20 2.5 13 2.4 10 2.3

500 2" 49 4.8 33 3.4 24 2.9 16 2.5 12 2.4

600 2" 59 4.4 39 3.2 29 2.8 20 2.5 15 2.3

725 2 1/2" 71 4.9 47 3.5 35 3.0 24 2.7 18 2.6

850 2 1/2" 83 5.7 55 3.9 41 3.3 28 2.8 21 2.6

Page 42

Installation & Operation Manual

6 Hydronic piping

Figure 6-5 Multiple Boilers - Alternate - Fixed or Variable Flow Primary System Piping

Number of Units

Model

400 500

600 725 850

2 3 4 5678

Manifold Pipe Sizes in Inches (mm)

3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254)

4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

CAUTION

NOTICE

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 43

6 Hydronic piping (continued)

Figure 6-6 Single Boiler - Multiple Temperatures

Installation & Operation Manual

CAUTION

NOTICE

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 44

6 Hydronic piping

Figure 6-7 Single Boiler - Primary/Secondary Piping

Installation & Operation Manual

CAUTION

NOTICE

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

System ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Page 45

6 Hydronic piping (continued)

Figure 6-8 Multiple Boilers - Multiple Temperatures

Model

400 500

600 725 850

Installation & Operation Manual

Number of Units

2 3 4 5678

Manifold Pipe Sizes in Inches (mm)

3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254)

4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

CAUTION

NOTICE

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 46

6 Hydronic piping

Figure 6-9 Multiple Boilers - Primary/Secondary Piping

Model

400 500

600 725 850

3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254)

4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

Installation & Operation Manual

Number of Units

2 3 4 5678

Manifold Pipe Sizes in Inches (mm)

CAUTION

NOTICE

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

System ﬂ ow should always remain higher than the required ﬂ ow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Page 47

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-10 Single Boiler - Multiple Temperatures with DHW Piped as a Zone

CAUTION

NOTICE

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

Page 48

7 Gas connections

Connecting gas supply piping

Installation & Operation Manual

1. Remove the top access panel and refer to FIG.’s 7-1 and 7-2 to pipe gas to the boiler.

a. Install ground joint union for servicing, when

required.

b. Install a manual shutoff valve in the gas supply

piping outside boiler jacket when required by local codes or utility requirements.

c. In Canada – When using manual main shutoff

valves, it must be identiﬁ ed by the installer.

2. Install sediment trap / drip leg.

Figure 7-1 Gas Supply Piping - Model 400 - 600

3. Support piping with hangers, not by the boiler or its accessories.

 WARNING

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks.

a. The appliance must be disconnected from the gas

supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

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

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

Figure 7-2 Gas Supply Piping - Models 725 - 850

 WARNING

6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas ﬂ ow.

Do not check for gas leaks with an open ﬂ ame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Page 49

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

Figure 7-3 Inlet Pipe with Backup Wrench

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at boiler (FIG. 7-3), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

USE BACKUP WRENCH TO

PREVENT PIPE FROM ROTATING

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).

a. Table 7A is only for natural gas with speciﬁ c gravity

0.60 inches, with a pressure drop through the gas piping of 0.3 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.5 kPa) with no ﬂ ow (lockup) or with boiler on.

• Minimum 4 inches w.c. (.99 kPa) with gas ﬂ owing (verify during boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa) maximum.

NOTICE

Maximum inlet gas pressure must not exceed the value speciﬁ ed. Minimum value listed is for the purposes of input adjustment.

Propane Gas:

 WARNING

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. (3.2 kPa) maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.2 kPa) with no ﬂ ow (lockup) or with boiler on.

• Minimum 8 inches w.c. (1.9 kPa) with gas ﬂ owing (verify during boiler startup).

FTXL boilers are typically shipped ready to ﬁ re on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing a LP venturi or by making a gas valve adjustment (see pages 14 and 15). In order to operate on LP gas, a LP venturi MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the appliance.

Page 50

7 Gas connections

Table 7A Natural Gas Pipe Size Chart

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour

(based on .60 speciﬁ c gravity, 0.30" w.c. pressure drop)

Installation & Operation Manual

Pipe

Size

(Inches)

1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A

1 514 353 284 243 215 195 179 167 157 148 131 119 109 102

1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209

1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313

2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602

2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960

3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700

4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460

10 20 30 40 50 60 70 80 90 100 125 150 175 200

Length of Pipe in Straight Feet

Check inlet gas supply

NOTICE

 WARNING

The gas piping must be sized for the proper ﬂ ow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

3. On Models 400 - 500 loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. On Models 600 - 850 remove the 1/8" (3 mm) pipe plug on the inlet ﬂ ange to the valve and install a suitable 1/8" (3 mm) ﬁ tting (ﬁ eld supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the set screw is loosened or the 1/8" (3 mm) ﬁ tting is installed (depending on model) as shown in FIG.’s 7-5 and 7-6 on page 51.

CSA or UL listed ﬂ exible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to ﬁ re at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust gas valve outlet pressure. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

4. Slowly turn on the gas supply at the ﬁ eld installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.

7. Observe the gas supply pressure as the burner ﬁ res at 100% of rated input. Percent of burner input will be displayed on the control panel.

8. Ensure inlet pressure is within speciﬁ ed range. Minimum and maximum gas supply pressures are speciﬁ ed in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualiﬁ ed installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. On Models 400 - 500 re-tighten the set screw inside the pressure tap. On Models 600 - 850 remove the 1/8" (3 mm) ﬁ eld supplied ﬁ tting and reinstall the pipe plug removed in Step 3.

Page 51

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and ﬂ ame characteristics.

Figure 7-5 Inlet Gas Supply Check - Model 400 - 500

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open ﬂ ame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Gas pressure

The gas pressure must remain between 4 inches w.c. (.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum for Natural gas and between 8 inches w.c. (1.9 kPa) minimum and 14 inches w.c. (3.2 kPa) maximum for LP gas during standby (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet (3 m) from the FTXL boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a ﬂ anged connection to the venturi and blower.

 WARNING

Failure to follow all precautions could result in ﬁ re, explosion, or death!

Figure 7-6 Inlet Gas Supply Check - Models 600 - 850

 WARNING

Page 52

8 Field wiring

Installation & Operation Manual

 WARNING

NOTICE

 CAUTION

Figure 8-1 Line Voltage Field Wiring Connections

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Line voltage connections

1. Connect 120 VAC power wiring to the line voltage terminal

strip in the junction box, as shown in FIG. 8-1.

2. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code (see FIG. 8-1).

3. When connecting a domestic hot water (DHW) pump,

connect the wiring to the line voltage terminal strip as shown in FIG. 8-1.

4. To activate a system pump, wire as shown in FIG. 8-1. Dry

contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 8-2.

2. Continue to route the wires through the plastic bushings to the left of the low voltage connection board.

3. Connect low voltage wiring to the low voltage connection board as shown in FIG. 8-3 on page 55 of this manual and the boiler wiring diagram. Make certain the wires will stay well away from the top of the heat exchanger.

Figure 8-2 Routing Field Wiring

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Thermostat

1. Connect the room thermostats or end switches (isolated contact only) to heat/loop demand 1, 2, or 3, as shown in FIG. 8-3.

2. Install the thermostat on the inside wall away from inﬂ uences of drafts, hot or cold water pipes, lighting ﬁ xtures, television, sunlight, or ﬁ replaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to match

total electrical power requirements of connected devices. See device manufacturers’ speciﬁ cations and thermostat instructions for details.

Page 53

8 Field wiring (continued)

Installation & Operation Manual

Outdoor temperature sensor

1. Mount the sensor on an exterior wall, shielded from direct sunlight or ﬂ ow of heat or cooling from other sources.

2. Route sensor wires through a knockout at the rear of the boiler (see FIG. 8-2).

3. Connect the outdoor temperature sensor (FIG. 8-3) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the FTXL. If ﬁ xed temperature operation is required, do not install outdoor sensor.

DHW (Domestic Hot Water) thermostat

Connect storage indirect water heater (DHW) thermostat (FIG. 8-3) to the DHW thermostat terminals on the connection board. If a tank sensor is connected (see DHW Tank Sensor below) the tank thermostat is ignored.

DHW tank sensor

By installing a tank sensor, the SMART SYSTEM control can perform the tank thermostat function. The SMART SYSTEM control automatically detects the presence of this sensor, and generates a DHW call for heat when the tank temperature drops 6°F (3°C) below the tank set point, and ﬁ nishes the call for heat when the tank temperature reaches the tank set point.

The tank sensor included with the Lochinvar Squire® indirect DHW tanks (TST20015) is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals on the low voltage connection board (FIG. 8-3).

 WARNING

If TST20015 is not compatible with the indirect tank, a tank thermostat can be used to control the boiler. The tank thermostat should be installed per the manufacturer’s instructions and wired to the DHW Thermostat terminals on the low voltage connection board (FIG. 8-3).

Failure to use the correct sensor may result in the tank temperature being either above or below the set point.

Low gas pressure switch

1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts (FIG. 8-3).

2. If both a high and low gas pressure switch is used, connect their respective contacts in series, and connect them to the terminals on the connection board (FIG. 8-3).

Variable speed system pump

If a variable speed pump is used in the primary loop, and a 0-10V signal is available from the pump speed control, this signal can be used by the SMART SYSTEM control to anticipate changes in the building heat load. By connecting this 0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler (or cascade) can modulate up and down as the primary ﬂ ow increases and decreases.

Boiler pump speed output

This 0 - 10V output is available to control the speed of a variable speed boiler pump. The SMART SYSTEM control will vary the speed of this pump in order to maintain a minimum T across the heat exchanger, as well as prevent high limit lockouts when the ﬂ ow in the primary loop is extremely low. NOTE: This feature is to be used with Primary / Secondary piping systems only. A system supply sensor MUST be installed. Connect this output to the 0 - 10V input on the boiler pump speed control.

Rate output

This output provides a 0 - 10V signal that is proportional to the ﬁ ring rate of the boiler. This may be used by a BMS system to monitor the actual rate of the boiler.

ModBus/BACnet

When an optional ModBus or BACnet interface module is installed, the RS-485 cable is connected to these terminals. Use shielded, 2-wire twisted pair cable. If desired, the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus or BACnet interface module.

Louver proving switch

1. When the operation of the louvers needs to be veriﬁ ed before the boiler ﬁ res, remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch (FIG. 8-3).

High gas pressure switch

1. If a switch is provided to detect excessive gas pressure, remove the jumper wire from the terminals on the connection board, and then connect them to its normally closed contacts (FIG. 8-3).

Flow switch

1. A ﬂ ow switch is used to guarantee ﬂ ow through the boiler before allowing it to ﬁ re. The ﬂ ow switch must be installed at the boiler outlet.

2. Remove the jumper wire from the terminals on the connection board and connect these terminals to the normally open contacts on the ﬂ ow switch (FIG. 8-3).

System supply sensor

1. By installing the system supply sensor into the supply of the primary loop, the temperature of the system supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler ﬁ ring rate to maintain the system supply temperature to the set point (if outlet sensor control is currently selected).

Page 54

8 Field wiring

See the FTXL Service Manual for instructions on how to

use the inlet sensor as the controlling sensor. When the inlet sensor is programmed as the controlling sensor, it is vital that the SYSTEM SUPPLY sensor be installed. DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN.

2. The TST2032 sensor provided with the boiler must be used for the system sensor.

3. Connect these terminals to the system supply sensor (FIG. 8-3).

Boiler management system

1. An external control may be connected to control either the ﬁ ring rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the heat/loop demand 1 terminals. Otherwise, the SMART SYSTEM control will be enabled by the 0-10V signal.

2. Make sure the (-) terminal is connected to the (-) or common output terminal of the external control, and the (+) terminal is connected to the 0 - 10 VDC or (+) terminal of the external control. Make sure that the (-) voltage is not below ground.

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the boiler is down.

DHW recirculation sensor

The FTXL is able to control a DHW recirculation pump. To

operate this feature, a TST2032 temperature sensor must be installed in the circulation loop return. Connect this sensor to the DHW recirculation sensor terminals on the Low Voltage Connection Board.

DHW recirculation pump

When the DHW recirculation sensor (as described above) is connected, the FTXL SMART SYSTEM control will output 24VAC to control a DHW recirculation pump relay (ﬁ eld supplied). Connect the coil of the DHW recirculation pump relay to the 24VAC recirculation pump relay coil terminals on the Low Voltage Connection Board.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See page 62 “Conﬁ guration of the Cascade” for a detailed explanation of this procedure.

Installation & Operation Manual

Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop (FIG.’s 6-5 through 6-10). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG. 8-3). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.

If outdoor air reset is desired, the outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 8-3). If the outdoor air sensor is connected, the Leader control will calculate the water temperature set point based on the programmed reset curve parameters. If the outdoor air sensor is not connected, the Leader control will maintain the ﬁ xed water temperature set point that is programmed into the control.

If a Thermostat or Zone Control enable output is available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the heat/loop demands 1-3 (FIG. 8-3). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the heat/loop demand input. This will initiate a call for heat on the Cascade.

Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards (FIG. 8-3). If more than two boilers are on the Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible.

When the Member 1 boiler is programmed as an alternate leader this allows the Member 1 boiler to automatically assume control of the Cascade should it lose communication with the Leader boiler. When programmed to YES, it is recommended that the Member 1 boiler have its own set of external sensors installed (such as the system supply sensor), to maintain the same level of temperature control as with the Leader boiler. Voltage signals (such as 0 - 10V system pump speed input) can be connected to both boilers.

 WARNING

When communication is re-established with the Leader boiler, Member 1 will automatically relinquish control of the Cascade to the Leader boiler.

Do not connect the sensors connected to the Leader boiler to the Member 1 boiler. The actual water temperatures will be higher than expected, which could lead to property damage, personal injury, or death.

Page 55

8 Field wiring (continued)

Figure 8-3 Low Voltage Field Wiring Connections

Installation & Operation Manual

Page 56

9 Condensate disposal

Installation & Operation Manual

Condensate drain

1. The FTXL is a high efﬁ ciency appliance that produces condensate.

2. The condensate trap is sized for a 1" PVC outlet connection pipe.

3. Plug the wiring connection from the condensate trap into the connector located on the back of the unit.

4. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing ﬁ lter. Condensate from the FTXL will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing ﬁ lter if required by local codes.

A Neutralizer Kit (FIG. 9-1) is available from the factory

(KIT3087 for Models 400 - 500 and KIT3046 for Models 600 - 850). KIT3046 must be placed on a surface that is a minimum of 3 inches lower than the condensate trap with ﬁ eld supplied piping (vacuum break) installed between the condensate trap and the neutralizer kit.

5. Do not expose condensate line to freezing temperatures.

NOTICE

6. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overﬂ ow switch to prevent property damage from condensate spillage. The switch should be wired in series with the blocked drain switch inside the boiler (see FIG. 10-1 on page 58).

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certiﬁ ed PVC or CPVC pipe, ﬁ ttings, and cement. Do not use copper or black iron pipe, or ﬁ ttings.

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch (25 mm).

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.

Figure 9-1 Condensate Disposal

KIT3046 shown for illustration purposes.

Page 57

10 Start-up

Installation & Operation Manual

Check/control water chemistry

 CAUTION

Hardness less than 7 grains

1. Consult local water treatment companies for hard water areas (above 7 grains hardness).

Chlorine concentration less than 200 ppm

1. Do not ﬁ ll boiler or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the boiler to directly heat swimming pool or spa water.

Test/replace freeze protection ﬂ uid

1. For systems using freeze protection ﬂ uids, follow ﬂ uid manufacturer’s instructions.

2. Freeze protection ﬂ uid must be replaced periodically due to degradation of inhibitors over time. Follow all ﬂ uid manufacturer’s instructions.

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

Freeze protection (when used)

1. Determine freeze protection ﬂ uid quantity using

system water content, following ﬂ uid manufacturer’s instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.

2. Local codes may require a backﬂ ow preventer or actual

disconnect from city water supply.

3. When using freeze protection ﬂ uid with automatic ﬁ ll,

install a water meter to monitor water makeup. Freeze protection ﬂ uid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water ﬁ ll pressure for a commercial system is 12 psi (82.7 kPa).

b. Pressure will rise when boiler is turned on and

system water temperature increases.

4. At initial ﬁ ll and during boiler startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

 WARNING

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve. Route the

hose to an area where water can drain and be seen.

b. Close the boiler or system isolation valve between

the purge valve and ﬁ ll connection to the system.

c. Close zone isolation valves. d. Open quick-ﬁ ll valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Allow

water to run through the zone, pushing out the air. Run until no noticeable air ﬂ ow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-ﬁ ll water valve and purge valve and

remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-ﬁ ll pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in the system, open

the manual air vents in the system one at a time, beginning with the lowest ﬂ oor. Close the vent when water squirts out. Repeat with remaining vents.

4. The freeze protection set points may be lowered when freeze protection ﬂ uid is used (see the FTXL Service Manual).

Fill and test water system

1. Fill system only after ensuring the water meets the

requirements of this manual.

2. Close manual and automatic air vents and boiler drain

valve.

2. Open automatic air vent (diaphragm-type or bladdertype expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest ﬂ oor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Reﬁ ll to correct pressure.

Page 58

10 Start-up

Installation & Operation Manual

Check for gas leaks

 WARNING

Figure 10-1 Condensate Trap

Before starting the boiler, and during initial operation, smell near the ﬂ oor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no ﬁ eld adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

 WARNING

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to each

of the heat/loop demand terminals on the connection board.

2. Connect a voltmeter across these two incoming wires.

Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does appear under any condition, check and

correct the external wiring. (This is a common problem when using 3-wire zone valves.)

TO FLOOR DRAIN OR NEUTRALIZER KIT 1” PVC / CPVC CONNECTION

FROM CONDENSATE VENT ON BOILER

FROM CONDENSATE DRAIN ON BOILER

5. Once the external thermostat circuit wiring is checked and

corrected if necessary, reconnect the external thermostat circuit wires to the connection board. Allow the boiler to cycle.

Inspect condensate system

Inspect/check condensate lines and ﬁ ttings

1. Inspect the condensate drain line, condensate PVC

ﬁ ttings and condensate trap.

Page 59

10 Start-up (continued)

Final checks before starting the boiler

Installation & Operation Manual

 Check vent piping and air piping

 Read the FTXL Service Manual to familiarize yourself with

SMART SYSTEM control module operation. Read this manual, page 60 for proper steps to start boiler.

 Verify the boiler and system are full of water and all system

components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 57

and 58 have been completed.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 10-2, page 60.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is boiler water temperature above 200°F (93°C)?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

 WARNING

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 48 of this manual (connecting gas supply piping).

 WARNING

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

 WARNING

Venting system must be sealed gastight to prevent ﬂ ue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no ﬁ eld adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?

If none of the above corrects the problem, refer to the Troubleshooting Section of the FTXL Service Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 57 and 58 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

 WARNING

Check ﬂ ame and combustion

1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.

2. Remove the brass plug from the combustion measurement port inside the ﬂ ue collector. NOTE: Combustion measurements will be made at this point.

3. Turn the main power on to the boiler by placing the “On/Off” switch in the ON position.

Page 60

10 Start-up

Figure 10-2 Operating Instructions

Installation & Operation Manual

Page 61

10 Start-up (continued)

Installation & Operation Manual

Check ﬂ ame and combustion (continued)

4. Place the boiler into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 69).

5. Locate the pinhole button above the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode. In Service Mode the boiler will ﬁ re at ignition speed and will then modulate up to full ﬁ re.

6. Insert the probe from a combustion analyzer into the combustion measurement port (see FIG. 10-3). There is a stop underneath the combustion measurement port to prevent the probe from collecting condensate at the bottom of the ﬂ ue collector.

7. Once the boiler has modulated up to full ﬁ re, measure the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the speciﬁ ed range,

reference the Troubleshooting Section of the FTXL Service Manual for possible causes and corrective actions.

Figure 10-3 Combustion Measurement Port

Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be based on one of three sensors; the inlet, outlet, or system supply sensor. The SMART SYSTEM control is programmed at the factory to control the temperature of the outlet sensor. The control will automatically switch to the system supply sensor once it is connected. If it is desired to base the temperature control on the inlet sensor, the appropriate parameter must be changed in the control. See the FTXL Service Manual for a detailed explanation of this procedure.

Verify space heat circulator mode

The Space Heating Mode controls both the system pump (if connected), and the boiler pump. When the SMART SYSTEM control receives a space heating call for heat, it turns on the system pump. If the set point is not met, or the system sensor is not connected, it also turns on the boiler pump. After the space heating call for heat ends, the system pump continues to run for a short period of time. The system pump can be programmed to run continuously, except during outdoor shutdown. Other settings may affect the operation of the boiler and system pumps, as explained on the following pages. If the boiler pump was running, it continues to run for a short period of time as well. These pump delays are factory set to 30 seconds. If different delays are desired, the appropriate parameters in the control must be changed. See the FTXL Service Manual for a detailed explanation of this procedure.

Table 10A Flue Products Chart

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

8. Once the combustion analysis is complete, test the

safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down and registers an alarm. Turn the manual shutoff switch to the ON position and reset the control.

9. Turn the main power off to the boiler and replace the

plug in the ﬂ ue sample port.

10. Place the boiler back into normal operation.

 WARNING

You must replace the plug in the ﬂ ue sample port to prevent ﬂ ue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

Adjust set point temperature(s)

NOTICE

The NAVIGATION dial may be used during normal operation to adjust the space heating and tank set point temperatures.

1. From the Status Screen press the NAVIGATION dial.

2. Turn the NAVIGATION dial counterclockwise to select

the appropriate set point.

3. Press the NAVIGATION dial to adjust the temperature. Rotate the NAVIGATION dial to change the setting.

4. Once the desired temperature is displayed, press the RIGHT SELECT [SAVE] key.

5. If necessary repeat Steps 3 and 4 to make adjustments to additional set points.

6. Press the RIGHT SELECT [HOME[ key to upload the changes.

7. If the RIGHT SELECT [SAVE] key is not pressed, the new settings will be discarded.

Please note that the brackets ([]) denote screen status.

Page 62

10 Start-up

Set domestic hot water (DHW) operation

Verify DHW mode

Installation & Operation Manual

There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum ﬁ ring rate may be limited in this mode if desired.

In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop. When a DHW demand begins, the control will turn on the DHW pump output, and raise the system temperature set point to the DHW boiler set point (if higher). The boiler pump will be turned on. The system pump may be forced on, forced off, or not changed, depending on the System Pump Mode selected (reference the FTXL Service Manual for details). In this mode, any low temperature zones (such as radiant heating) may need additional controls to limit the water temperature sent to those zones.

Set DHW boiler target temperature

When in the DHW Mode, the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point. This set point is set at the factory to 180°F. If a different set point is desired, the appropriate parameter in the control must be changed. See the FTXL Service Manual for a detailed explanation of this procedure.

Set maximum DHW fan speed

If the rated input of the indirect tank is less than the maximum output of the boiler, change the maximum DHW fan speed setting to limit the boiler output accordingly. See the FTXL Service Manual for a detailed explanation of this procedure.

Set clock

NOTICE

The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the boiler is installed, and anytime the boiler has been powered off for more than 4 hours. Use the following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

2. The display changes to read [PASSWORD], with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

Please note that the brackets ([]) denote screen status.

7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial.

9. Turn the NAVIGATION dial to adjust the date. Press the NAVIGATION dial.

10. Turn the NAVIGATION dial to adjust the year. Press the RIGHT SELECT [SAVE] key.

11. Press the RIGHT SELECT [HOME] key.

NOTICE

The clock is automatically updated whenever a PC is connected and the Win_Pro-Installer program is started.

Conﬁ guration of the cascade

NOTICE

When installed in a Cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters.

Press the [MENU] key for at least ﬁ ve (5) seconds. Input the Installer code as described in the FTXL Service Manual. Once the control parameters have been accessed, use the NAVIGATION DIAL to select the Control Mode parameters. Press the NAVIGATION DIAL to access these parameters.

Rotate the NAVIGATION dial to select the parameter “Cascade Address”. Press the NAVIGATION dial to access this parameter. Each appliance in the Cascade system must be programmed with its own address. The boiler designated as the Leader will have an address of 0. The remaining boilers in the Cascade will be Members and have addresses from 1 - 7. Rotate the NAVIGATION dial to select the appropriate address. Press the RIGHT SELECT [SAVE] key.

Press the RIGHT SELECT [HOME] key to upload the address into the control. Repeat this procedure for all boilers in the Cascade, designating the Leader control and the Member controls.

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Please note that the brackets ([]) denote screen status.

Page 63

Installation & Operation Manual

11 Operating information

General

How the boiler operates

The FTXL uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes ﬂ ue products out of the boiler through the heat exchanger and ﬂ ue piping. The control module regulates blower speed to control the boiler ﬁ ring rate. The gas valve senses the amount of air ﬂ owing into the boiler and allows only the right amount of gas to ﬂ ow.

How the control module operates

The SMART SYSTEM control module receives inputs from boiler sensors and external devices. The control module activates and controls the blower and gas valves to regulate heat input and switches the boiler, Domestic Hot Water (DHW), DHW recirculation, and system pumps on and off as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature, boiler inlet water temperature, system temperature, a 0 - 10V signal, Modbus, or BACnet, depending on the parameter settings.

Control inputs and outputs

Room thermostat

There are three (3) heat/loop demand connections available on this control. These inputs tell the boiler to provide water for space heating. Each demand connection has its own set point and outdoor air reset curve. When multiple demands have a call for heat the control will give priority to the demand with the highest set point.

Example: Assume that both heat/loop demand 1 and heat/ loop demand 2 have a call for heat. Demand 1 has a set point of 110°F. Demand 2 has a set point of 140°F. The boiler will regulate the system temperature to 140°F until Demand 2 has been satisﬁ ed. Once Demand 2 has been satisﬁ ed the boiler will provide 110°F water to the system.

 CAUTION

SMART SYSTEM Multi-temp loop control

The FTXL boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. This device controls the temperatures of up to three (3) separate loops, based on the settings for the three (3) heat/ loop demands (reference Lochinvar kit RLY30086).

0 - 10V input (set point or power)

The FTXL can be controlled by a Building Management System (BMS) using a 0 - 10 VDC signal. The control can be conﬁ gured by the installer to use this signal to either control set point or ﬁ ring rate.

The FTXL can also be programmed to accept a call for heat from a 0 - 10V signal, reference the FTXL Service Manual for a detailed explanation of this procedure.

When multiple temperature loops are used, mixing valves are required for the protection of any low temperature loops.

DHW priority

The SMART SYSTEM control allows the connection of a DHW thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the DHW thermostat input is ignored. When a boiler is programmed for DHW Normal Mode, the maximum ﬁ ring rate can be limited to match the input rating of the indirect tank coil.

DHW / space heating (SH) cycling

If a DHW call for heat is received while a space heating call is in progress, and the DHW is in Normal Mode, the control will start the DHW pump and shut the boiler pump off. The system pump will remain on. For stand-alone boilers, if the space heating call is still active while the DHW call is in operation, the control will wait for 30 minutes (time adjustable by installer) then it will switch back to the space heating demand. There is a timer to switch from space heating to DHW and a timer to switch from DHW to space heating. The control will switch back and forth until one of the heat demands end. This function does not apply to cascade systems.

Programmable controlling sensor

The control module is programmed to use the outlet sensor as the control sensor by default. If a system supply sensor is connected, the control automatically uses it as the control sensor. For stand-alone boilers, the control sensor can be changed by the installer to the inlet sensor. If the inlet sensor is chosen as the controlling sensor, it is recommended that the system supply sensor be installed in the system supply in order to provide the best control of the inlet temperature.

Anti-cycling

After the burner turns off, the control will delay the next burner cycle for a set time period (time is adjustable by the installer). The time delay will be bypassed if the inlet water temperature drops too far during the delay.

Boiler and system pump control

The boiler pump will run whenever the burner is ﬁ ring, unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank. The boiler pump will run during Freeze Protection Mode as well. It will continue to run for a short time after the burner turns off or the Freeze Protection Mode ends.

The system pump will run whenever there is a space heating call for heat, or the boiler goes into Freeze Protection Mode. It may be programmed to run during a DHW call for heat when the DHW is programmed for Zone Mode. It will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode. The system pump can be programmed to run continuously if desired, except during outdoor shutdown and/ or a DHW call for heat.

DHW recirculation pump control

When a DHW recirculation loop is used, the FTXL boiler can control the recirculation pump. To activate this function, simply install the DHW recirculation sensor into the return water from the DHW circulation loop. The control will turn on the DHW recirculation pump when the return water drops 10°F (5.5°C) below the DHW tank set point, and will turn back off when the return water rises to within 5°F (2.5°C) of the DHW tank set point. The control will turn the DHW recirculation pump off whenever DHW night setback is active.

Page 64

11 Operating information

Installation & Operation Manual

Temperature control

Modulation

The FTXL is capable of modulating its ﬁ ring rate from a minimum of 10% to a maximum of 100%. The ﬁ ring rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, ramp delay (if enabled), and various other temperature limitations.

Ramp delay

For systems with lower ﬂ ow, the SMART SYSTEM can limit the ﬁ ring rate (when enabled) when a space heating call for heat starts, when the set point is controlled by the BMS, or when switching from a DHW call for heat to a space heating call for heat. There are six (6) limits that can be programmed, as well as six (6) time intervals corresponding to each limit. The sixth limit will also limit the ﬁ ring rate for the rest of the call for heat.

Gradient limiting

If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the ﬁ ring rate to its lowest setting.

Outdoor air reset

If an outdoor air sensor is connected, the control module will calculate the set points of the three (3) space heating demands based on the programmed reset curves. The installer can change the slope of the reset curves by several adjustable parameters. The user can limit the maximum set points for each demand using the space heating set points.

Boost function

If outdoor air reset is active, and any space heating demand has been active continuously for a set period of time (time adjustable by installer) and there has been no DHW demands, the control can increase the set point of that demand by a ﬁ xed number of degrees (adjustable by installer). This process will continue until the space heating demand ends, the set point reaches the programmed set point or a maximum of 20 increases has occurred. Once the system heat demand is satisﬁ ed, the set point will revert to the value determined by the reset curve.

Night setback

The controller may be programmed to reduce the space heating and DHW set points during certain times each week. Seven different start and stop times may be programmed for the space heating setback and seven start and stop times for the DHW setback.

Vacation mode

Vacation Mode is used to lower the Space Heat (SH) and/ or DHW set points much like night setback. The set points will remain lowered until Vacation Mode is disabled. Night setback will not function when Vacation Mode is enabled.

Flame current support

To prevent nuisance shutdowns when the boiler is ﬁ ring at minimum rates, the control will increase the ﬁ ring rate when the ﬂ ame signal drops too low.

Protection features

Outlet temperature, ﬂ ue temperature, and temperature rise limiting

The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds 185°F, the unit will reduce the fan speed. If the outlet water temperature exceeds 195°F (90°C) the control will shut the unit down until it cools off.

The control module monitors the ﬂ ue temperature by a sensor located in the ﬂ ue exhaust. If the ﬂ ue temperature exceeds 215°F (102°C) the control will reduce the maximum fan speed. If the ﬂ ue temperature exceeds 240°F (115°C) the control will shut the unit down. The unit will restart automatically once the ﬂ ue temperature drops 25°F (14°C) and the minimum off time has expired.

The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 70°F (39°C) the control will reduce the maximum fan speed. If the temperature difference exceeds 80°F (44°C) the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 70°F (39°C) and the minimum off time has expired.

Freeze protection

DO NOT install the boiler in a room likely to freeze. The following integral feature of the SMART SYSTEM control

module provides some protection for the boiler only -- not for the system.

• The SMART SYSTEM control module provides freeze-up protection as follows when the boiler water temperature drops below 45°F (7°C):

• Below 45°F (7°C), the boiler and system pumps operate constantly.

• Below 37°F (3°C), the boiler turns on.

• Boiler and pumps turn off if boiler water temperature rises above 45°F (7°C).

• Lower temperatures may be programmed for systems with anti-freeze solutions.

NOTICE

 CAUTION

Low voltage blocking

The blower and gas valve require a minimum amount of voltage in order to operate properly. If an ignition attempt is made when the line voltage is temporarily low (such as during a brownout), the control could enter a manual reset lockout. To prevent this, the control monitors the voltage and blocks any heat demands until the voltage returns to an acceptable level.

When system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust.

This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.

Page 65

Installation & Operation Manual

11 Operating information (continued)

Monitor external limits

Connections are provided on the connection board for a ﬂ ow switch and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever either of these external limits open.

Run-time and alarm outputs

The boiler provides dry contacts for indicating when the boiler is running, and when it is unable to operate.

Run-time and cycle counting

The control uses two timers to monitor the total hours of burner operation. One timer monitors the time the boiler is in the Space Heating Mode. The other timer monitors the time the boiler is ﬁ ring in the DHW Mode.

The control uses two (2) ignition counters to monitor the amount of boiler cycles. The ﬁ rst counter counts all ignitions of the control. The second counter counts only ignition attempts that have failed.

Service reminder

The control can be programmed for service reminder notiﬁ cation. This notiﬁ cation will become active when either a set time frame has expired, or a set amount of running hours or cycles has expired (all adjustable by the installer). The display will show a Maintenance Required screen. The installer’s name and phone number can be programmed into the control. This information will appear on the Maintenance Required screen. The service reminder notiﬁ cation can be reset or disabled by the installer.

Error logging

The control will hold in memory the last 10 lockouts. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences will be held in memory.

Boiler temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water temperature and regulates boiler ﬁ ring and ﬁ ring rate to achieve a target temperature. The target temperature can be set between 32°F (0°C) and 190°F (88°C).

• Target temperature is ﬁ xed when the outdoor sensor is not installed.

• Target temperature is calculated as described on this page under “Outdoor Reset Operation” and “Target Temperature Boost” when the outdoor sensor is connected.

High limit operations

The FTXL is equipped with adjustable automatic reset and manual reset high limits. The automatic reset high limit has a maximum set point of 200°F and the manual reset high limit has a maximum set point of 210°F.

When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 190°F, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at 210°F.

High limit test procedure

NOTICE

1. Turn ON the main power to the boiler by placing the ON/OFF switch in the ON position.

2. From the Status Screen, press the NAVIGATION dial to access the Set Points Screen.

3. Press the LEFT SELECT (LIMITS) key.

4. Select the manual reset high limit (MRHL) by rotating the NAVIGATION dial counterclockwise, then press the NAVIGATION dial.

5. Decrease the set point of the MRHL to below the current outlet temperature (or to its minimum setting, whichever is higher) by turning the NAVIGATION dial counterclockwise.

6. Press the RIGHT SELECT [SAVE] key.

7. Press the RIGHT SELECT [HOME] key. The new parameter will upload to the control.

8. If the current outlet temperature is above the new MRHL set point, the MRHL will function causing boiler lockout. If this occurs, skip to Step 11.

9. If the current outlet temperature is below the new MRHL set point, locate the pinhole (SERVICE button) below the RESET button on the display board. Insert a thin probe (such as a paper clip) into the hole and press the button continuously for ﬁ ve (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will ﬁ re at ignition speed and will then modulate up to full ﬁ re.

10. Once the outlet temperature rises up to the MRHL set point, the MRHL will function, causing the boiler to shut down and lock out.

11. Repeat Steps 2 through 7 to adjust the MRHL to its normal setting.

Please note that the brackets ([]) denote screen status.

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11 Operating information

Installation & Operation Manual

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger. If the ﬂ ow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low ﬂ ow conditions.

2. In addition, an electronic low water cutoff control is provided.

Outdoor reset operation, if used

Target temperature with outdoor reset

This feature improves the system’s efﬁ ciency as the outdoor temperature warms up.

See the FTXL Service Manual to change the settings.

Reset curve

The reset curves look at outdoor air temperature and adjust the set points.

Cascade

When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. Member 1 can be conﬁ gured to take over control of the Cascade should the Leader stop communicating with the Members. The Leader control can be programmed to use Lead/Lag or Efﬁ ciency Optimization control methods.

Sequence of the cascade

To equalize the run time of all boilers on the Cascade, the ﬁ ring sequence will automatically be changed at set intervals.

For the ﬁ rst 24 hours, the sequence will be changed once every hour. The switching on/off sequence will be as follows:

TIME SWITCHING ON SEQUENCE

Start L-M1-M2-M3-M4-M5-M6-M7

1 hour M1-M2-M3-M4-M5-M6-M7-L

2 hours M2-M3-M4-M5-M6-M7-L-M1

After the ﬁ rst 24 hours, the sequence will change every night at 2:00 a.m. If a boiler locks out or is used to heat an indirect DHW tank, it will automatically be given the lowest priority until 2:00 a.m.

DHW, Night Setback, and Ramp Delay operation with cascade

For normal mode DHW operation any boiler(s) in the Cascade can be selected to provide heat for a DHW call. Select a boiler to be designated as the DHW boiler. Connect the DHW thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device. When the boiler receives a DHW call, the Leader control will take that boiler out of the Cascade sequence. If another boiler is available, the Leader will start it up to take its place.

The DHW boiler will adjust its set point to the programmed DHW boiler set point and will adjust its ﬁ ring rate to maintain this. Once the DHW call has been satisﬁ ed, the Leader control will place that boiler back into the Cascade sequence.

Once the Leader boiler receives a call for heat from a room thermostat, BMS, Modbus, or BACnet the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve parameters. See the FTXL Service Manual to program the reset curve. If outdoor air reset is not desired, do not connect the outdoor air sensor. A ﬁ xed temperature set point can be programmed into the control. See page 61 of this manual to program the set point.

If the water temperature at the system supply sensor is less than the set point + the turn-off offset - the off-on differential, then the control will initiate a call for heat on the Cascade (see the FTXL Service Manual for an explanation of the offset and differential). The Leader will energize the lead boiler on the Cascade. For a new startup this will be the Leader boiler.

Switching of the boiler between DHW operation and SH operation when there is a call for both does not occur in Cascade Mode.

When DHW is programmed for Zone Mode, connect the DHW thermostat or tank sensor to the Leader boiler. When a DHW call is received, the Leader will modulate the entire Cascade to bring the system supply temperature up to the DHW boiler set point (if higher).

Night Setback operation of the boilers within the Cascade is available. Programming of the Night Setback will be done through the Leader boiler. Refer to the FTXL Service manual for information regarding Night Setback.

Ramp Delay operation of the boilers as described in the FTXL Service Manual is available when the boilers are part of a Cascade system.

Page 67

Installation & Operation Manual

11 Operating information (continued)

Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the gas pressure switch(es) must be closed.

2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW). The ﬂ ow switch and/or LWCO must close.

3. The control turns on power to the louver relay. The louver proving switch, and blocked drain switch must close.

4. The control starts the prepurge cycle by initiating the blower.

5. The control starts the trial for ignition by ﬁ ring the spark electrode and opening the gas valve.

6. If ﬂ ame is not detected after the sparking ends, the control will perform a postpurge, then start another prepurge cycle and try to light the burner again. On the 500 and larger models, the control will lock out if this second attempt also fails. On the 400 model, the control will perform a total of 4 attempts before locking out.

Page 68

11 Operating information

Sequence of operation (continued)

OPERATION DISPLAY

7. If ﬂ ame is detected, it holds the ﬁ ring rate steady for a few seconds to let the ﬂ ame stabilize, then it begins to modulate the ﬁ ring rate based on a set point or some other command (such as a 0-10V BMS signal).

8. If the space heating call for heat is active, and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on ﬁ rst, then the boiler pump will turn off (boiler and DHW pump operation brieﬂ y overlap to ensure ﬂ ow is maintained through the unit). This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead. The control will then modulate to maintain the outlet temperature to the DHW boiler set point.

Installation & Operation Manual

9. If the boiler is not part of a Cascade, and both the space heating and DHW calls for heat remain active long enough, the boiler will switch back and forth between the two heating modes until one of them is satisﬁ ed.

10. Once both calls for heat are satisﬁ ed, the control will turn off the burner. The blower will continue to run during the postpurge period.

11. Any pumps that are running will continue to run for their respective pump delay times before turning off, unless programmed to remain on continuously. A 60 second anti-cycle period will start, which will delay any new call for heat until it times out.

12. In Standby, ready to start a new cycle.

Page 69

Installation & Operation Manual

11 Operating information (continued)

FTXL control module

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.

Figure 11-1 Control Panel

USB

DRIVE

CONNECTION

LEFT

SELECT KEY

NAVIGATION

DIAL

IMG01093

RESET

SWITCH

RIGHT

SELECT KE

The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in the center):

MENU = Left SELECT Key SETPOINTS = NAVIGATION Dial - Pressing Down SHDN = Right SELECT Key

Access modes

User

The user can adjust space heating and tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is ﬂ ashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 62).

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the parameter listings; press again to return

Installer

Most parameters are available only to the installer, accessible by entering the installer password, see the FTXL Service Manual.

to the menu listings. Remember to press the RIGHT SELECT [HOME] key when ﬁ nished programming in order to save the changes made.

Saving parameters (reference the Parameter Table in the FTXL

Service Manual)

NOTICE

Please note that the brackets ([]) denote screen status.

See the FTXL Service Manual for a detailed description of parameters and access modes.

Page 70

11 Operating information

Figure 11-2 Status Display Screen

Installation & Operation Manual

(BOILER

STATUS)

(CALL FOR

HEAT)

(OPERATIONAL INFORMATION)

(LEFT SELECT

KEY)

(RIGHT SELECT KEY)

(NAVIGATION DIAL)

Status Display Screens

NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.

Section Display Description

STANDBY

START The unit has begun a burn cycle and is checking all safety circuits.

The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.

(Boiler Status

Bar)

(Call for Heat

Indicators)

PREPURGE The unit has initiated a prepurge period on a call for heat.

IGNITION The unit has begun a spark period to ignite the main burner.

The unit has ﬁ red and is running at the displayed percentage.

The call for heat has been satisﬁ ed and the unit runs the fan for an

POSTPURGE

SHUTDOWN The unit has been placed in the OFF position.

SETPOINT MET The controlled temperature has exceeded its set point and its offset.

BLOCKED

additional postpurge period to clear the combustion chamber and vent system of residual ﬂ ue products.

The unit has detected a condition that has temporarily interrupted the current call for heat.

Room Thermostat 1 has a call for heat.

Room Thermostat 2 has a call for heat.

Room Thermostat 3 has a call for heat.

The tank thermostat or sensor has a call for heat.

Indicates which room thermostat demand has priority.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

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Installation & Operation Manual

11 Operating information (continued)

Status Display Screens (cont’d)

NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.

Section Display Description

a. SYSTEM TEMP b. TANK TEMP c. OUTDOOR TEMP

DETAILS SCREEN 1

DETAILS SCREEN 2

d. INLET TEMP e. OUTLET TEMP f. DHW RECIRC TEMP - The temperature read by the DHW recirculation sensor (if connected).

a. DELTA T b. FLUE TEMP c. FLAME CURRENT d. FAN SPEED e. LOOP 1 TEMP - The temperature of Loop 1 reported by the MTLC control. f. LOOP 2 TEMP - The temperature of Loop 2 reported by the MTLC control. g. LOOP 3 TEMP - The temperature of Loop 3 reported by the MTLC control.

(Operational

Information)

I/O SCREEN

BMS SCREEN

HISTORY SCREEN

LAST 10 FAULTS

a. GAS PRESS SW - The state of the gas pressure switch. b. FLOW SW - The state of the ﬂ ow switch. c. LOUVER RELAY - The state of the louver relay output. d. LOUVER SW - The state of the louver proving switch. e. BLOCKED DRAIN - The state of the blocked drain switch. f. GAS VALVE - The state of the gas valve output.

a. 0 - 10V BMS IN b. 0 - 10V RATE OUT c. BMS ADDRESS d. BMS CONTROL? e. SYS PUMP SPEED f. BLR PUMP OUT

a. SH RUN TIME - Total time running for Space Heat (SH). b. SH CYCLES - Total Space Heat (SH) demand cycles. c. DHW RUN TIME - Total time running for DHW. d. DHW CYCLES - Total DHW demand cycles. e. POWER TIME - Total time powered ON. f. IGNITIONS - Total number of successful ignitions. g. IGN ATTEMPTS - Total number of ignition attempts.

a. FAULT NO. b. FAULT c. DATE d. TIME

Page 72

11 Operating information

Status Display Screens (cont’d)

NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.

Section Display Description

Installation & Operation Manual

(Operational

Information

cont.)

(LEFT SELECT

key function)

(NAVIGATION

dial function)

(RIGHT SELECT

key function)

a. CASCADE STATUS

CASCADE STATUS

NIGHT SETBACK

USB Press the LEFT SELECT key to access the USB and Installer menu.

MODIFY

SHDN Press the RIGHT SELECT key to turn the boiler OFF.

ON Press the RIGHT SELECT key to turn the boiler ON.

NO Press the RIGHT SELECT key to cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

b. CASCADE POWER c. PRESENT

a. TRIGGER 1 - Next Space Heat (SH) night setback trigger. b. TRIGGER 2 - Next DHW night setback trigger.

Pressing the NAVIGATION dial will allow the installer to change the text.

HOME

Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes.

Page 73

Installation & Operation Manual

12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and ﬁ ll with fresh water

• Check for leaks (water, gas, ﬂ ue, condensate)

• Verify ﬂ ue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and ﬂ ame sense electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and

ANNUAL START-UP

performance veriﬁ cation per Section 10.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high ﬁ re)

• Clean the heat exchanger if ﬂ ue temperature is more than 54°F (30°C) above return water temperature.

Owner maintenance

(see the FTXL User’s Information Manual for

instructions)

• Check boiler area

Daily

• Check pressure/temperature gauge

• Check vent piping

• Check air piping

Monthly

Periodically

• Check air and vent termination screens

• Check relief valve

• Check condensate drain system

• Check air vents

• Test low water cutoff

• Reset button (low water cutoff)

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

• Clean the blower wheel

Every

6 months

End

of season

months

• Check boiler piping (gas and water) for leaks

• Operate relief valve

• Shut boiler down (unless boiler used for domestic hot water)

Page 74

12 Maintenance

Installation & Operation Manual

 WARNING

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

The boiler should be inspected annually only by a qualiﬁ ed service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efﬁ ciency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other ﬂ ammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual and the FTXL Service Manual.

Inspect boiler interior

1. Lift the top bezel (prop the bezel up for service) and inspect the interior of the boiler.

2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.

Clean condensate trap

Figure 12-1 Condensate Trap

FROM CONDENSATE VENT ON BOILER

FROM CONDENSATE

TO FLOOR DRAIN OR NEUTRALIZER KIT 1” PVC / CPVC CONNECTION

DRAIN ON BOILER

Check all piping for leaks

 WARNING

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

1. Inspect the condensate drain line, vent line, condensate PVC ﬁ ttings, and condensate trap.

Flush condensate trap with water

1. Remove the four (4) screws securing the top cover to the condensate trap and remove the cover (FIG. 12-1).

2. Locate the plastic ball inside the ﬂ oat tube. Verify there

is nothing under the ball causing it to not seat properly.

3. Fill with fresh water until the water begins to pour out of

the drain.

4. Replace the top cover and the screws removed in Step 1.

Page 75

12 Maintenance (continued)

Installation & Operation Manual

Flue vent system and air piping

1. Visually inspect the entire ﬂ ue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

 WARNING

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and

operational.

2. Check the cold ﬁ ll pressure for the system. Verify it is

correct (must be a minimum of 12 psi (82.7 kPa)).

3. Watch the system pressure as the boiler heats up (during

testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect automatic air vents and air separators. Remove

air vent caps and brieﬂ y press push valve to ﬂ ush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in

and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks and air eliminators.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify ﬂ ow.

Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - Hydronic Piping before proceeding further.

 WARNING

2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the ﬂ ow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water ﬂ ows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

Page 76

12 Maintenance

Installation & Operation Manual

Inspect ignition and ﬂ ame sense electrodes

1. Remove the ignition and ﬂ ame sense electrodes from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/ﬂ ame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/ﬂ ame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

Figure 12-2 Burner Assembly - Model 400 - 850

FAN TOP PLATE

GASKET

BURNER

GASKET

HEX TOP PLATE

FIBER BOARD

HEAT EXCHANGER

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of the FTXL Service Manual. Adjust settings if necessary. See Section 1 of the FTXL Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests speciﬁ ed in

Section 10 - Start-up.

2. Verify cold ﬁ ll pressure is correct and that operating

pressure does not go too high.

Check burner ﬂ ame

1. Inspect ﬂ ame through observation window.

2. If the ﬂ ame is unsatisfactory at either high ﬁ re or low ﬁ re,

turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2.

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG. 12-2).

IMG01072

Page 77

12 Maintenance (continued)

Installation & Operation Manual

Check ﬂ ame signal

1. At high ﬁ re the ﬂ ame signal shown on the display should be at least 10 microamps.

2. A lower ﬂ ame signal may indicate a fouled or damaged ﬂ ame sense electrode. If cleaning the ﬂ ame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the ﬂ ame sense electrode.

3. See Section 3 - Troubleshooting in the FTXL Service Manual for other procedures to deal with low ﬂ ame signal.

Review with owner

1. Review the FTXL User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule speciﬁ ed in the FTXL User’s Information Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

7. Disconnect the condensate hose from the condensate trap and route to drain.

8. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.

9. Using a clean cloth dampened with warm water, wipe out the combustion chamber. Rinse out debris with a low pressure water supply.

10. Allow the heat exchanger to thoroughly dry.

11. Reinstall the condensate hose, heat exchanger top plate, burner, fan plate, fan, venturi, and bezel (FIG. 12-2).

12. Perform a combustion analysis by following the instructions in Section 10 - Start-up - Check Flame and Combustion, on pages 59 and 61 of this manual.

13. Resume operation.

Cleaning boiler heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup.

• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention ﬂ uid in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it has been ﬁ ring.

3. Remove the bezel from the unit.

4. Remove the screw securing the fan and venturi from the

fan plate and set aside.

5. Remove the nuts securing the fan plate and burner from

the heat exchanger plate and set aside (FIG. 12-2).

6. Loosen the heat exchanger bolts to remove the heat

exchanger top plate (FIG. 12-2).

 WARNING

The boiler contains ceramic ﬁ ber materials. Use care when handling these materials per instructions in the FTXL Service Manual. Failure to comply could result in severe personal injury.

Page 78

13 Diagrams

Figure 13-1 Wiring Diagram

Installation & Operation Manual

Page 79

13 Diagrams (continued)

Figure 13-2 Ladder Diagram

Installation & Operation Manual

Page 80

Revision Notes: Revision A (ECO #C15743) initial release. Revision B (ECO #C16066) reﬂ ects updates made to the room air kit on

page 19 along with updates made to the wiring and ladder diagrams. Revision C (ECO C17014) reﬂ ects the standardization of pressure drop

information on pages 49 and 50 as well as the the addition of the system supply sensor note on page 53. .

FTXL-I-O Rev C

01/15