NTI FTG 600, FTG 1400, FTG 2000, FTG 2200, FTG 2400 Installation And Operation Manual

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FTG Firetube Giant Boiler

Models: FTG 600 through FTG 2400 Version Date: 2017-08-14

INSTALLATION AND OPERATION MANUAL

TABLE OF CONTENTS

HAZARD SYMBOLS AND DEFINITIONS

Danger Sign: Indicates a hazardous situation which, if not avoided, will result in serious injury or death.

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

Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in property damage.

Notice Sign: Indicates a hazardous situation which, if not avoided, could result in property damage.

This Boiler must be installed by a licensed and trained Heating Technician or the Warranty is Void. Failure to properly install this

unit may result in property damage, serious injury to occupants, or possibly death.

NTI # 85422

Installation & Operation Manual │ FTG

Read Before Proceeding

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

A) This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

B) BEFORE OPERATING smell all around the boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any boiler.

• Do not touch any electric switch.

• Do not use any phone in your building.

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

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

C) Use only your hand to turn the gas “shutoff” valve. Never use tools. If the handle will not turn by hand,

do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D) Do not use this boiler if any part has been under water. Immediately call a qualified service technician

to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS_

1. STOP! Read the safety information above very carefully.

2. Set the thermostat to lowest setting. Turn off all electric power to the boiler.

3. This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

4. Turn the manual gas valve to the OFF position. Remove front access panel.

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

STOP! Follow “B” in the safety information above. If you do not smell gas, go to the next step.

6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas.

7. Replace the front access panel.

8. Set thermostat to highest setting. Turn on all electric power to the boiler.

9. Ignition sequence is automatic. Combustion will occur after a brief fan purge.

10. If ignition does not occur, follow the instructions “To Turn Off Gas To Boiler” and call your service

technician or gas supplier.

TO TURN OFF GAS TO THE BOILER_

1. STOP! Read the safety information above very carefully.

2. Turn off all electric power to the boiler.

3. Turn the manual gas valve to the OFF position.

Crystalline Silica - Certain components confined in the combustion chamber may contain this potential carcinogen. Improper installation, adjustment, alteration, service or

maintenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to Section 15.0 for information on handling instructions and recommended personal protective equipment. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

Void Warranty - This Boiler must have water flowing through it whenever the burner is

on or it will damage the unit and void the warranty. Failure to follow these instructions

may result in serious injury or death.

FTG │Installation & Operation Manual

1.0 INTRODUCTION General Installation Requirements

The installation of your NTI FTG gas boiler must conform to the requirements of this manual, your local authority, and the National Fuel Gas Code ANSI Z223.1 and or CAN/CGA B149 Installation Codes. Where

required by the Authority, the installation must conform to the standard for “Controls and Safety Devices for

Automatically Fired Boilers ANSI/ASME CSD-1.” This document pertains to the correct installation and operation of NTI FTG boiler models FTG 600, FTG 800,

FTG 1200, FTG 1400, FTG 2000, FTG 2200 and FTG 2400. The instructions detailed in this document supersede any and all previous instructions provided by NTI, written or otherwise. Each unit is provided with the following:

1. Installation and Operation Manual,

2. Appendix A – Controller and Touchscreen Display Instructions,

3. FTG Users’ Manual, and

4. Natural Gas to LP Conversion Kit* * The conversion kit is required to convert the boiler so it will safely operate with Propane Gas.

Read and understand this entire document prior to proceeding with the installation of the

FTG boiler. Failure to follow the instructions outlined in this document will result in

property damage, serious injury or death.

User Responsibilities

This boiler must be installed and serviced by a qualified installer or service technician. This boiler must be serviced and inspected annually when operating in normal residential applications. Demanding applications or extreme conditions (i.e. when operating with LP-Propane) may require more frequent service and inspection. As the User/Owner of this equipment, you are responsible for ensuring the maintenance is performed at the required intervals (see Section 15.0 – Annual Maintenance and Inspection).

Failure to have the boiler properly serviced and inspected on a regular basis by a qualified

service technician may result in property damage, serious injury or death.

Failure to keep the Vent and Combustion Air Intake clear of ice, snow, and other debris

may result in property damage, serious injury, or death.

Installer Responsibilities

As the installing technician it is your responsibility to ensure the installation is performed in accordance with this instruction manual as well as any applicable local or National installation codes. It is also your responsibility to inform the User/Owner of their obligation with respect to the above description under “User Responsibilities.” Failure to follow this warning could result in fire, serious injury, or death.

Installation & Operation Manual │ FTG

ATTENTION: LIQUEFIED PETROLEUM (LP) PROPANE

Liquefied Petroleum (LP) propane gas is heavier than air; therefore, it is imperative that your boiler is not installed in a pit or similar location that will permit heavier than air gas to collect. Local Codes may require boilers fueled with LP gas be provided with an approved means of removing unburned gases from the room. Check your local codes for this requirement.

Natural Gas to LP Conversion Kit

Model

Kit Part Number

LP-Orifice

FTG 600-1400

85418-1

N/A

FTG 2000-2400

85758-1

N/A

FTG boilers are factory set to operate with Natural Gas; BEFORE OPERATING WITH PROPANE, the boiler must be converted using the appropriate Natural Gas to

LP Conversion Kit – see below; each kit comes with conversion instructions. Failure to properly convert the unit to safely operate with Propane will cause severe boiler failure, resulting in property damage, serious injury or death.

Exhaust Vent / Air-Inlet Piping

The FTG is certified as a “Category IV” boiler, and requires a “Special Venting System” designed for pressurized venting. The exhaust gases must be piped directly to the outdoors using the vent materials and rules outlined in these instructions. Failure to follow these instructions will result in serious injury or death.

IN THE STATE OF MASSACHUSETTS ONLY

(a) For all horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or

in part for residential purposes, including those owned and operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall

horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed and on each additional level of the dwelling, building or structure served by the equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an

attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision cannot be met at the time of completion of

installation, the owner shall have a period of 30 days to comply with the above requirements; provided, however, that during said 30 day period a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance

with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building

at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating boiler or equipment. The sign shall read, in print size no less than onehalf (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS” (plate included with boiler).

4. INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall

not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current

edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate

from the dwelling, building or structure used in whole or in part for residential purposes.

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED:

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment

installation instructions; and

2. The “special venting system” shall be Product Approved by the Board, and the instructions for that system shall

include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

all venting instructions, all parts list for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

FTG │Installation & Operation Manual

Installation & Operation Manual│ FTG

DESCRIPTION

FTG 600

FTG 800

FTG 1200

FTG 1400

FTG 2000

FTG 2200

FTG 2400

Gas Connection (inches, NPT)

1-1/4

1-1/2

Water Inlet (inches, groove-joint)

Water Outlet (inches, groove-joint)

Exhaust Vent Connection (inches)

Air-inlet Connection (inches)

Overall Height (inches)

68-1/2

64-3/8

Overall Width (inches)

33-7/8

Overall Depth (inches)

38-3/8

Approximate Weight with water (lb.)

930

1500

2140

Water Content (gallons)

Electrical Rating

120V / 1Ph / 60Hz / less than 12A

(Note 1)

(Note 2)

(Note 3)

Notes:

FTG 2000 electrical rating is 120V / 1Ph / 60Hz / less than 16A.

FTG 2200 electrical rating is 208V / 3Ph / 60Hz / less than 16A.

FTG 2400 electrical rating is 240V / 3Ph / 60Hz / less than 16A.

DESCRIPTION

FTG 600

FTG 800

FTG 1200

FTG 1400

FTG 2000

FTG 2200

FTG 2400

CSA Input Modulation (MBH)1

80 - 600

80 - 800

120-1200

140-1400

235-2000

235-2200

235-2350

DOE Heating Capacity (MBH)

1,2

576

760

1153

1344

1920

2103

2237

Net I=B=R Rating (MBH)

1,2

500

660

1003

1169

1670

1829

1945

Combustion Efficiency (%)2

96.2

96.1

95.7

95.3

Thermal Efficiency (%)2

96.1

95.6

95.2

Notes:

Listed Input and Output ratings are at Sea Level. Numbers will be lower with altitudes greater than 2000 feet.

Based on standard test procedures prescribed by the U.S. Department of Energy. Ratings have been confirmed by AHRI.

2.0 SPECIFICATIONS

Table 2-1 General Specifications

Table 2-2 Boiler Performance Specifications

Elevations

2001 ft [610 m]

3000 ft [914 m]

4000 ft [1219 m]

4500 ft [1372 m]

5000 ft [1524 m]

In Canada 1

de-rate by 10%

de-rate % may vary

In USA 2

de-rate by 12%

de-rate by 16%

de-rate by 18%

de-rate by 20%

Notes:

Canada: Altitudes between 2000 & 4500 ft. [610 &1372 m], de-rate by 10%. Consult local authorities for de-rating for

altitudes above 4500ft [1372 m].

USA: De-rate capacity by 4% for every 1000 ft [305 m], if altitude is above 2000 ft [610 m].

FTG │Installation & Operation Manual

High Altitude Operation

The FTG is designed to operate at its maximum listed capacity in installations located at 0-2000 ft above Sea Level. Since the density of air decreases as elevation increases, maximum specified capacity should be de-rated for elevations above 2000 ft [610 m] in accordance with Table 2-3.

Table 2-3 De-rate % for High Altitudes

Combustion – At elevations above 2000 feet, the combustion of the boiler must be

checked with a calibrated combustion analyzer to ensure safe and reliable operation. It is

the Installers responsibility to check the combustion and to adjust the combustion

in accordance with Section 9.0. Failure to follow these instructions may result in

property damage, serious injury, or death.

Clearances

Dimensions - inches

Front

Top

Sides

Rear

Flue Pipe

Minimum

24 1

12 4 12

Recommended

Notes:

6 in. if surface is removable allowing a minimum of 24 in. clearance (i.e. closet installation). See Ventilation Air

Opening dimensions in Figure 3-1.

Recommend allowing 24” clearance on at least one side for servicing, clearance on opposite side can be as little as 4”.

Notice: the rear of the boiler must be accessible for installation and service.

Installation & Operation Manual │ FTG

3.0 BOILER LOCATION

In all cases, the FTG boiler must be installed indoors in a dry location where the ambient temperature must be maintained above freezing and below 100F [38C]. All boiler components must be protected from dripping, spraying water, or rain during operation and servicing. Consider the proximity of system piping, gas and electrical supply, condensate disposal drain, and proximity to vent termination when determining the best boiler location.

Floor Mounting

The FTG boiler can be mounted directly on combustible flooring, with the exception of carpeting. Installing the boiler on carpeting is not permissible. Ensure the boiler is mounted above any anticipated flood level. Units include factory supplied/field installed leveling legs. Once the unit is removed from the pallet, thread the leveling legs into the allocated threaded inserts in the bottom of the unit.

Boiler Area Ventilation Air Openings

If boiler area clearances are less than the recommended clearances specified in Table 3-1, the boiler area must be ventilated. EXCEPTION: if the boiler area/room has a volume of 365 ft3 or greater (275 ft3 for models FTG 600-800; 320 ft3 for models FTG 1200-1400), ventilation of the boiler room is not required. Each ventilation air opening must meet the minimum requirements of 1 in2 per 1000 Btu/hr., but not less than 100 in2. The lower ventilation opening must be located within 6 in. of the floor while the upper opening must be located 6 in. from the top of the space.

Closet Installations

For closet installations it is necessary to provide two ventilation air openings as shown in Figure 3-1, each providing a minimum area equal to 1 in2 per 1000 Btu/hr., but not less than 100 in2 and within 6 in. of the top and bottom of the closet door. See Table 3-1 for minimum clearances.

Alcove Installations

Alcove installations have the same minimum clearances as closet installations, except the front must be completely open to the room at a distance no greater than 18 in. [457 mm] from the front of the boiler and the room is at least three (3) times the size of the alcove. Provided these conditions are met, the boiler requires no extra ventilation air openings to the space. See Table 3-1 for minimum clearances.

Residential Garage Installations

When installed in a residential garage, mount the boiler a minimum of 18 in. [457 mm] above the floor. Locate or protect the boiler so it cannot be damaged by a moving vehicle. Check with your local authorities for other possible regulations pertaining to the installation of a boiler in a garage.

Table 3-1 Minimum Clearances for Installation and Service

Water or flood damaged components must be replaced immediately with new factory-

approved components as failure to do so may result in fire, serious injury, or death.

If the "Boiler Area" does not meet the recommended clearances listed in Table 3-1, and if the boiler area has a volume less than 365 ft3, it is considered a Closet or Alcove. In US/Canada, PVC vent pipe and fittings shall not be used within the closet or alcove; only approved CPVC, Polypropylene or Stainless Steel vent pipe and fittings can be used. See Table 4-4 for a list of approved materials. Under all circumstances, the minimum clearances listed in Table 3-1 must be provided.

Figure 3-1 Closet Installation, Minimum Clearances

Ventilation Air Openings are not required if the boiler area meets the Recommended Clearances listed in Table 3-1.

Top ventilation opening Max. 6” below ceiling / top

Removable surface / closet door

Ventilation air opening 1in2 per 1000 Btu/hr, min. 100in

Bottom ventilation opening Max. 6” above floor / bottom

Sides = 4”

Top = 12”

Exhaust Vent Pipe Clearances as per Special Vent System

manufacturer’s instructions

Front = 6”

(if removable)

Rear = 12”

Ventilation air opening 1in2 per 1000 Btu/hr, min. 100in

FTG │Installation & Operation Manual

Closet/Alcove installations in US and Canada require approved CPVC, Polypropylene or Stainless Steel vent and air-inlet pipe and fittings (see Table 4-4); PVC is not permitted.

Failure to follow these instructions may result in damage or serious injury.

Products to Avoid

Contaminated Sources to Avoid

Antistatic fabric softeners, bleaches, detergents, cleaners

Laundry facilities

Perchloroethylene (PCE), hydrocarbon based cleaners

Dry cleaning facilities

Chemical fertilizer, herbicides/pesticides, dust, methane gas

Farms or areas with livestock and manure

Paint or varnish removers, cements or glues, sawdust

Wood working or furniture refinishing shops

Water chlorination chemicals (chloride, fluoride)

Swimming pools, hot tubs

Solvents, cutting oils, fiberglass, cleaning solvents

Auto body or metal working shops

Refrigerant charge with CFC or HCFC

Refrigerant repair shops

Permanent wave solutions

Beauty shops

Fixer, hydrochloric acid (muriatic acid), bromide, iodine

Photo labs, chemical / plastics processing plants

Cement powder, crack fill dust, cellulose, fiber based insulation

Concrete plant or construction site

Installation & Operation Manual │ FTG

4.0 GENERAL VENTING

The FTG boiler is certified as a “Category IV” boiler requiring a “Special Venting System” designed for pressurized venting. The Exhaust Vent must be piped to the outdoors, using the vent materials and rules outlined in this section. Under no conditions may this unit vent gases into a masonry chimney, unless it is vacant, and utilizes the approved venting material and rules described in this section.

Vent and Air-inlet are to be piped separately. The FTG boiler cannot share a common vent or air-inlet with multiple boilers. Failure to comply will result in serious injury or

Direct Vent Installation (Best Practice)

When installed as a Direct Vent boiler the combustion air-inlet must also be piped directly to the outdoors using the methods described in this section and in accordance with the National Fuel Gas Code, ANSI Z223.1 (U.S.) or CSA B149.1 (Canada) and local requirements.

Installation Using Indoor Combustion Air

When the installation uses Indoor Combustion Air (i.e. piping is not directly connecting the appliance air-inlet fitting to the outdoors), provisions for combustion and ventilation air, in accordance with section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (U.S.), or Clause 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1 (Canada), or applicable provisions of the local building codes, must be adhered to.

Combustion Air-inlet Contamination

Be careful not to locate the air-inlet termination in an area where contaminants can be drawn in and used for combustion. Combustion air containing dust, debris or air-borne contaminants will drastically increase the required maintenance and may cause a corrosive reaction in the Heat Exchanger which could result in premature failure, fire, serious injury, or death. See Table 4-1 for a list of areas to avoid when terminating air-inlet piping:

Table 4-1 Corrosive Products and Contaminant Sources

death.

The boiler shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

Make up air requirements for the operation of exhaust fans, kitchen ventilation systems,

clothes dryers, and fireplaces shall be considered in determining the adequacy of a space

to provide combustion air requirements. Failure to ensure adequate make up air to all

appliances may result in personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this

or any other boiler. Failure to follow instructions may result in serious injury or death.

It is BEST PRACTICE to pipe the combustion air-inlet directly to the outdoors (Direct

Vent installation) to avoid contamination often contained in indoor air.

Model No.

Vent Pipe Size

CPVC Transition Vent Pipe Length

Full Insertion Depth

FTG 600-800

6”

Minimum 6.5” (factory supplied)

2-7/8”

FTG 1200-2400

8”

Minimum 9”

2-7/8”

FTG │Installation & Operation Manual

Flammable Solvents and Plastic Piping

Due to the extremely flammable characteristics of most glues, cements, solvents and primers used in the process of joining plastic vent and air-inlet pipe, explosive solvent vapors must be evacuated from the vent and air-inlet prior to start-up. Avoid using excess cement or primer that may lead to pooling inside the pipe assembly. Freshly assembled piping assembly should be allowed to cure for a minimum of 8 hours before applying power to the gas fired boiler. Refer to Mandatory Pre-commissioning Procedure for Plastic Venting in this section.

to reduce these risks. Failure to follow these instructions can cause explosions, property damage, injury or death.

Mandatory Pre-commissioning Procedure for Plastic Venting (PVC or CPVC)

1) Working with the power turned off to the boiler, completely install the vent and air intake system, securely

cementing joints together. If possible, allow primers/cements to cure for 8 hours before firing the burner. If curing time is less than 8 hours, proceed with Steps 2 through 6.

2) Maintain the boiler gas supply shut-off valve in the off position.

3) Remove the cable from the Spark Ignition Electrode and Ignition Transformer.

4) Turn power on to the boiler and apply a heat demand.

5) Allow for a complete trial for ignition, consisting of pre and post purge of the combustion blower, until an

ignition lockout occurs.

6) Turn power off and reconnect the cable to the Spark Ignition Electrode and Ignition Transformer.

Near Boiler Vent/Air-inlet Piping

Exhaust-vent Connector – the FTG exhaust-vent connector is designed to accept single-wall FasNSeal®

Stainless Steel (SS) Special Gas Venting. To use other types of venting, the appropriate adaptor must be inserted into the boiler exhaust-vent connector; see Table 4-4 for a list of approved venting materials and Table 4-3 for a list of approved boiler exhaust-vent adaptors.

Air-inlet Connector (FTG 600-800) – the FTG 600 & 800 employ a universal air-inlet connector that accepts

DuraVent’s 6 in. PolyPro

PVC/CPVC/ABS pipe, without the need for additional adapters. The universal connector incorporates three seals, one for 6 in. PVC/CPVC/ABS pipe (6.625 in. OD), one for 6 in. PolyPro® PP pipe (5.94 in. OD) and one for 6 in. FasNSeal® SS pipe (6 in. OD).

Air-inlet Connector (FTG 1200-2400) – the FTG 1200 through 2400 employ an 8 in. rubber coupling that

directly accepts most 8 in. diameter air-inlet pipe material.

PVC Exhaust Venting – When exhaust venting with PVC, insert a length of CPVC Pipe (see Table 4-2) into the

PVC/CPVC exhaust-vent adapter (see Table 4-3); cement the other end of the CPVC Transition Pipe to the PVC exhaust venting using a field supplied PVC or CPVC coupling; see Figure 4-1(a). Where PVC cements to CPVC, be sure to use an approved transition cement, see Table 4-4.

Table 4-2 CPVC Vent Pipe Transition Piece (used when venting with PVC)

Flammable Cements and Primers – It is the installers’ responsibility to familiarize

themselves with the hazards associated with explosive solvents and to take all precautions

Do not apply power to the boiler prior to Step 4 in the Mandatory Pre-commissioning

Procedure for Plastic Venting.

Spark Ignition Circuit - Maintain a safe distance (2 in. minimum) from the spark ignition

circuit to avoid injury from electrical shock.

Failure to use the appropriate exhaust-vent adaptor for the type of venting being used,

will lead to flue gas leakage possibly resulting in property damage, Carbon Monoxide

poisoning or death.

Polypropylene (PP) or FasNSeal® Stainless Steel (SS) pipe, as well as 6 in.

Material

Vent Brand

FTG 600-800

FTG 1200-2400

Inlet

Exhaust

Inlet

Exhaust

Stainless

Steel

FasNSeal®

(DuraVent)

(See Note 1)

(See Note 2)

(See Note 3)

(See Note 4)

Z-Vent®

(Z-Flex)

Secure Seal® SS

(Security Chimneys)

SS6PVCU

SS6FFNSAU

SS8FFNSAU

Corr/Guard®

(Metal-Fab)

TBD

Saf-T Vent®

(Heatfab / Selkirk)

VIC

(ICC Chimney)

SWKL-Vt

(Jeremias)

Poly-

propylene

PolyPro®

(DuraVent)

(See Note 1)

FSA-06M-6PPF

FSA-08M-8PPF

Z-Dens®

(Z-Flex)

2ZDCPVCG6

2ZDZV6

2ZDZV8

InnoFlue®

(Centrotherm)

ISAAL0606

ISSA0606

ISSA0808

PVC/

CPVC

N/A

(See Note 1)

FSA-6FNSM-6PVCF

(factory supplied)

FSA-8FNSM-8PVCF

Notes:

The FTG 600-800 combustion air-inlet connector is designed to directly accept 6 in. PVC/CPVC, PolyPro®, FasNSeal®

or Z-Vent® Special Gas Venting; no separate adapter is required.

The FTG 600-800 exhaust vent outlet connector is designed to directly accept 6 in. FasNSeal® or Z-Vent® Special Gas

Venting; no separate adapter is required.

The FTG 1200-2400 use an 8 in. rubber adapter as the combustion air-inlet connector; no special adapter is required to

adapt to the respective brand of combustion air-inlet piping.

The FTG 1200-2400 exhaust vent outlet connector is designed to directly accept 8 in. FasNSeal® or Z-Vent® Special Gas

Venting; no separate adapter is required.

Installation & Operation Manual │ FTG

When assembling the venting, follow the instructions provided with the Special Venting

System. Take care not to damage gaskets when inserting pipe into fittings, bevel cut ends

of piping to avoid damaging or dislodging the sealing gasket during installation. For

Table 4-3 Exhaust-vent and Air-inlet Adapters

PVC/CPVC bevel by approximately 1/8 in.

Gasket Seating - Improper gasket seating can cause leakage and eventual failure of the

sealing gasket. Ensure the vent pipe is properly beveled, prior to installation, and that the

pipe is fully inserted into the exhaust-vent adapter. Failure to follow these instructions

may result in serious injury or death.

DO NOT insert PVC pipe directly into the PVC/CPVC exhaust-vent adapter; the

clamping force of the gear clamp can deform the PVC pipe. Failure to follow these

instructions may result in gasket failure and/or the dislodging of the exhaust pipe from the

exhaust-vent adapter, resulting in property damage, serious injury or death.

Exhaust venting must be supported to reduce strain on piping joints. Failure to follow

these instructions may result in result in damage, serious injury or death.

In Canada, the first 3 ft (915 mm) of vent piping must be readily accessible for inspection.

Figure 4-1(a) Near Boiler Venting (PVC)

Figure 4-1(b) Near Boiler Venting (CPVC)

Figure 4-1(c) Near Boiler Venting (PP)

Figure 4-1(d) Near Boiler Venting (SS)

Adapter to CPVC (see Table 4-3)

PVC Air-inlet Pipe*

CPVC Exhaust-vent

Air-inlet

Exhaust

Adapter to PP

(field supplied – see Table 4-3)

PP Air-inlet Pipe

(PolyPro® illustrated)

Air-inlet

Exhaust

PP Exhaust-vent

(PolyPro® illustrated)

SS Air-inlet Pipe

(FasNSeal® illustrated)

Air-inlet

Exhaust

SS Exhaust-vent

(FasNSeal® illustrated)

CPVC Transition Pipe (see Table 4-2)

Adapter to CPVC

(see Table 4-3)

**CPVC Transition Pipe

is mandatory when

venting with PVC

PVC Coupling

PVC Air-inlet Pipe*

PVC Exhaust-vent

Air-inlet

Exhaust

FTG │Installation & Operation Manual



Air-inlet - check with applicable local codes for acceptable pipe material.

Items 1

Materials

2, 3

Venting System Standards

All Vent and Air-Inlet materials installed on gas fired appliances in CAN/US must meet the Standards listed in this Table. Failure to comply could result in fire, serious injury or death.

United States

Canada 4

Vent Piping

and Fittings

PVC - DWV

ANSI/ASTM D2265

All venting material in

Canada must be

ULC S636 approved.

PVC Schedule 40

ANSI/ASTM D1785

CPVC Schedule 40

ANSI/ASTM F441

Stainless Steel (SS)

UL-1738

Polypropylene (PP)

ULC S636

Pipe Cement PVC

ANSI/ASTM D2564

CPVC

ANSI/ASTM F493

Primers

PVC / CPVC

ANSI/ASTM F656

Notes:

Refer to Table 4-5 for Allowable Vent and Air-inlet Pipe Sizes and Lengths.

PVC venting (exhaust and air-inlet) is not permitted within the Closet/alcove of a Closet/alcove installation.

The Air-inlet does not require high temperature pipe material. Check applicable local codes for acceptable materials.

Model No.

Fuel

Pipe Dia.

(in.)

Length

(ft.)

Number of Elbows (90’s or 45’s) and Equivalent Feet

1 2 3 4 5 6 7 8 9

FTG 600-800

NG 6 150

145

140

135

130

125

120

115

110

105

LP 6 100

FTG 1200-2400

NG/LP

150

145

140

135

130

125

120

115

110

105

Notes:

Minimum length of each the exhaust vent and combustion air-inlet piping is 5 feet equivalent.

For models FTG 600-800, the last 6 ft. of exhaust vent piping (vent termination) can be reduced to 4 or 5 in. diameter

vent pipe.

For models FTG 1200-2400, the last 6 ft. of exhaust vent piping (vent termination) can be reduced to 6 or 7 in. diameter

vent pipe.

Installation & Operation Manual │ FTG

Exhaust-vent/Air-inlet Pipe Material

Table 4-4 Approved Vent and Air-Inlet Pipe Material

The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in the exhaust venting system is prohibited. Failure to follow these

Vent/Air-inlet Pipe Length Determination Use Table 4-5 to determine the maximum pipe length that can be used. The table calculates 90º elbows, and 45º

elbows at 5 equivalent feet each.

Table 4-5 Allowable Vent and Air-inlet Pipe Size and Lengths

instructions may result in property damage, personal injury or death. Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. Failure

to follow these instructions may result in property damage, personal injury or death.

Termination Options – Direct Vent Installation

The venting system of the FTG boiler may be terminated using field supplied piping to construct a “Two-Pipe” termination, see Figures 4-2, 4-4(a) and 4-5(a); alternatively the venting may be terminated using a factory kit selected from Table 4-6.

Venting Options - Due to potential moisture loading (build-up) along the exterior wall,

sidewall venting may not be the preferred venting option; see Figures 4-2(a), 4-2(c), 4-3(a) and 4-5.

When sidewall venting, it is recommended to reduce the diameter of the exhaust vent at

the termination, to increase exhaust gas velocity, further directing it away from the

building. The final 6 ft. of exhaust vent can be reduced to a diameter of 4 in. for models

FTG 600-800, and 6 in. for models FTG 1200-2400; see Figures 4-2(a) and 4-2(c).

Description

Vent

Size

Supplier P/N

Figure

Vent Material

Compatibility

Termination

Roof

Wall

IPEX Low Profile (Wall)

4”

196986 (NTI P/N 84358)

4-4(c)

PVC/CPVC



IPEX Concentric (Wall/Roof)

5,6,7

4”

196021 (NTI P/N 84355),

197021

4-3(a), 4-4(b),

4-5(b)



PolyPro® Twin Pipe (Wall)

4”

4PPS-HTPL

4-4(c)

PolyPro®

Polypropylene



PolyPro® Concentric (Wall)

4”

4PPS-HK

4-3(b), 4-4(d)

PolyPro® Concentric (Roof)

4”

4PPS-VK

4-3(a), 4-5(c)



InnoFlue® Concentric (Wall)

4”

(ICWT462 & ICTC0446)

4-3(b), 4-4(d)

InnoFlue®

Polypropylene



InnoFlue® Concentric (Roof)

4”

(ICRT4679 & ICTC0446)

4-3(a), 4-5(c)



Z-DENS® Horizontal Kit Low Profile (Wall)

4”

2ZDHKLP4

4-4(c)

Z-DENS®

Polypropylene



Z-DENS® Concentric (Wall)

4”

2ZDHK4

4-3(b), 4-4(d)

Z-DENS® Concentric (Roof)

4”

2ZDVK4

4-3(a), 4-5(c)



Z-VENT® Termination Hood – Exhaust (Wall)

4-5”

2SVSHTX04, 2SVSHTX05

Z-VENT®

Stainless Steel



SS Miter Cut – Exhaust (Wall)

4-8”

SS4MCU – SS8MCU

Secure Seal®

Stainless Steel



Saf-T Vent® Mitered Termination – Exhaust (Wall)

4-8”

9490, 9590, 9690, 9790 &

9890

Saf-T Vent®

Stainless Steel



ICC Miter Cut – Exhaust (Wall)

5-8”

HM-5MC – HM-8MC

ICC Chimney

Stainless Steel



Notes:

Instructions included with termination kits contain detailed assembly and installation instructions.

Concentric kits can be shortened to fit the requirements of the installation; see instructions included with the kit for

more details.

Clearance requirements in this manual supersede those of the instructions included with the vent terminal.

Piping MUST be secured to the vent terminal during installation.

IPEX Concentric Terminal MUST be cemented together and to the vent pipes during installation.

Vent Screens provided with boiler may be used with the IPEX Concentric Vent Kits; otherwise use IPEX vent screens

(4 in. vent screen P/N 196052 – each sold separately).

IPEX Low Profile and Concentric kits (excluding P/N 197021) are constructed out of ULC S636 approved PVC;

check with your local authority for the acceptance of PVC as a venting material prior to use.

Centrotherm Concentric termination kits must use the applicable “Twin pipe to concentric adapter,” part number

ICTC0446.

4 & 5 in. Vent Termination Kits may only be used with models FTG 600-800.

7 & 8 in. Vent Termination Kits may only be used with models FTG 1200-2400.

FTG │Installation & Operation Manual

The vent for this appliance shall not terminate over public walkways; or near soffit vents

or crawl space vents or other area where condensate of vapor could create a nuisance or

hazard or cause property damage; or where condensate or vapor could cause damage or

could be detrimental to the operation of regulators, relief valves, or other equipment.

Optional Termination Kits – Direct Vent Installation Kits certified with the FTG boiler are listed in Table 4-6 and are available from the respective vent pipe

manufacturer. For more information on each kit, contact the kit manufacturer.

Table 4-6 Optional Vent Termination Kits

Figure 4-2(a) Two-pipe (Sidewall)

Figure 4-2(b) Two-pipe (Roof)

Figure 4-2(c) Two-pipe (Rooftop / Sidewall)

Combustion Air-inlet

– pointing down, min. 12in. above snow level

Exhaust – pointing up, min. 18in. above combustion air-inlet

Combustion Air-inlet

– pointing down, min. 12in. above snow level

Exhaust – pointing out, min. 18in. above combustion air-inlet

Combustion Air-inlet

– pointing down, min. 12in. above snow level

Exhaust – pointing up, min. 12in. above snow level

Combustion Air-inlet

– pointing down, min. 12in. above snow level

Exhaust – pointing out, min. 12in. above snow level

Installation & Operation Manual │ FTG

Figure 4-3(a) Concentric (Roof)

Figure 4-3(b) Concentric (Sidewall)

Refer to vent-teminal

manufacturer instructions

for correctly connecting

to vent-terminal

Combustion Air-inlet

– drawn from bottom of bell shape, min. 12in. above snow level

Exhaust –

exits the top

Exhaust

Air-inlet

Combustion Air-inlet

– drawn from bottom or circumference, min. 12in. above snow level

Exhaust –

exits the center

Exhaust

Air-inlet

Refer to vent-teminal

manufacturer instructions

for correctly connecting

to vent-terminal

FTG │Installation & Operation Manual

Concentric and Low Profile Vent Termination Kits are only available in sizes up to 4 in.;

therefore they are not an option for models FTG 1200-2400.

Sidewall Termination Details – Direct Vent Installation

Figure 4-4(a)

Figure 4-4(b)

Two-Pipe Termination (Sidewall)

IPEX Concentric Termination (Sidewall)

Refer to documentation included with termination kit for complete installation instructions.

Figure 4-4(c)

Figure 4-4(d)

Low Profile Termination (Sidewall)

PolyPro / InnoFlue Termination (Sidewall)

Refer to documentation included with termination kit for complete installation instructions.

Min. 12”

above grade or snow level

Exhaust

Air-inlet

Exhaust

Air-inlet around

perimeter

Min. 12”

above grade or snow level

Exhaust center

Air-inlet bottom

Exhaust

Air-inlet

Gas Vent Directly Below

Keep Free of Obstructions

Refer to documentation included with termination kit for complete installation instructions.

Exhaust

Air-inlet

Min. 12”

above grade or snow level

Vertical

Min. 18”

Horizontal 4-12” or greater than 36”

Exhaust

Air-inlet

Vent Screen

Vent pipe piece to retain vent screen

Gas Vent Directly Below

Keep Free of Obstructions

Exhaust

Air-inlet

Min. 12”

above grade or snow level

Air-inlet around perimeter (1-2” from wall)

Exhaust through center

Vent Screen

Vent pipe piece to retain vent screen

Installation & Operation Manual │ FTG

FTG │Installation & Operation Manual

Roof Termination Details – Direct Vent Installation

Figure 4-5(a)

Figure 4-5(b)

Two-Pipe Termination (Roof)

IPEX Concentric Termination (Roof)

Figure 4-5(c)

Figure 4-5(d)

PolyPro / InnoFlue Termination (Roof)

Exhaust only Termination (Roof)

Min. 12”

above grade or snow level

Vent Screen

Vent pipe piece to retain vent screen

Exhaust

Air-inlet

Vertical

Min. 18”

Horizontal

4-12” or greater

than 36”

Flashing

Min. 12”

above grade or snow level

Vent Screen

Vent pipe piece to retain vent screen

Exhaust center

Air-inlet around

perimeter

Flashing

Refer to documentation included with termination kit for complete installation instructions.

Min. 12”

above grade

or snow level

Flashing

Exhaust

Air-inlet

Figure illustrates two options for exhaust termination only; neither vent pipe illustrated is for combustion air-inlet.

Min. 12”

above grade or snow level

Flashing

Vent pipe piece to retain vent screen

Vent Screen

Exhaust Option 1

Exhaust Option 2



Installation & Operation Manual │ FTG

Venting Rules and Guidelines

1. Prevailing Winds: Ensure the vent is located where it will not be exposed to normal prevailing winds.

2. Combustion Air-inlet Contamination: Air for combustion must be drawn from an area free of dust and

contaminants. Combustion air containing chemicals such as chloride, fluoride, bromine or iodine or dust and debris will cause corrosion damage of the heat exchanger voiding your NTI warranty. Refer to Table 4-1 for a list of corrosive products and contaminants sources to avoid.

3. Vertical Separation: The exhaust must be a minimum of 18 in. above the air inlet, and the air inlet must

always be a minimum of 12 in. plus snow allowance above any surface that will support snow. (Two feet plus snow allowance is highly recommended). Consult your weather office for the maximum typical snowfall for your region. Example: New Brunswick Canada - typical maximum snowfall is 19 in., thus the inlet must be (12”+19”) = 31 in. above grade and exhaust must be (31”+18”) = 49” above grade.

4. Horizontal Separation: The horizontal distance between the inlet and exhaust must be a minimum of 4”

[102 mm] center to center.

5. Wall Flashing: Under normal operating conditions this boiler will produce a plume of white gases, and

should be taken into consideration when selecting an adequate location. A 36 in. diameter stainless, plastic, or vinyl shield can be used to flash the exterior of the residence.

6. Flue Gas Hazard: Position the vent termination where vapors cannot make accidental contact with people

and pets or damage nearby shrubs and plants.

7. Elbow Extensions: Elbows on outside of wall must be no more than ½ in. away from the wall.

8. Vent Sloping: All indoor exhaust piping must be on a slope back to the boiler a minimum of ¼ in. per

linear foot of vent. For applications where excessive condensation is possible ½ in. per linear foot is recommended.

9. Vent Supports: Where required Vent and Air-inlet piping shall be secured to the wall for more rigidity. All

interior vent pipe shall be supported a minimum of every 36 in.

10. Roof Exhaust: In all roof applications the discharge must point away from the pitch of the roof.

11. Roof Flashing: Install adequate flashing where the pipe enters the roof, to prevent water leakage.

12. Rain Cap: Install and seal a rain cap over existing chimney openings, in vacant chimney applications.

13. Venting Below Grade: For installations that exit the wall below grade refer to Figure 4-6.

14. Vent Screens: Install factory supplied vent screens on the outside of the last fitting for both the inlet and

exhaust vent terminations. Install the screen into the female opening of the fitting, then cut a small piece of pipe to sandwich the screen into the elbow. NOTE: ensure the small piece of cut pipe, does not extend past the end of the fitting. Two screens are provided in the package. See Figures 4-4 and 4-5.

15. Condensate Hazard: Do not locate vent over public walkways, driveways or parking lots. Condensate

could drip and freeze resulting in a slip hazard or damage to vehicles and machinery.

16. Warning Plate: For Sidewall Venting, install the warning plate “Gas Vent Directly Below”, directly above

(within 4 ft. vertically) the location of the air-inlet pipe, so it is visible from at least 8 ft away. See Figure 4-

17. Wall Thickness: Direct vent terminations are designed to work with any standard wall thickness.

Installation guidelines for min/max wall thickness are as follows: Min. = 1 in., Max. = 60 in...

18. Venting Options: Due to potential moisture loading (build-up) along the exterior wall, sidewall venting

may not be the preferred venting option. Refer to Figures 4-2(a), 4-2(c), 4-3(a) and 4-5 for roof top venting options.

Figure 4-6 Venting Below Grade

For installations that exit the wall below grade:

1. Excavate site to a point below where the pipes

are to exit as shown.

2. Ensure the wall is fully sealed where the pipes

penetrate.

3. The Vent/Air-inlet piping MUST be secured to

the side of the building above grade, as shown, to provide rigidity.

4. Ensure that the Vent/Air-inlet clearances are

maintained, see Section 5.0 for details.

Figure 4-7 Outdoor Venting

Vent piping outside the building is permitted under the following conditions:

1. The maximum length outside the building is 20 ft.

Note that outdoor length must be included in the overall vent length calculation.

2. All normal termination clearances are maintained.

3. The pipe is supported every 24 in...

4. The exhaust and inlet are sloped back to the boiler

½ in. elevation for every linear foot.

Figure 4-8 Existing Chimney Chase Way

It is permissible to use an existing chimney as a chase way to run the Vent/Air-inlet piping as long as:

1. The chimney is not being used by any other

boiler.

2. Flue gases do not enter the vacant chimney.

3. Only FTG certified venting materials are used,

see Table 4-4.

4. Vent lengths are within the maximums specified.

5. The top of the chimney is capped and the

Vent/Air-inlet pipes are flashed to prevent leakage into the vacant chimney.

Exhaust

Air-inlet

Wall Brackets

Supports every 24 in. [610 mm]

12 in. [305 mm] plus snow

allowance above grade

Air-Inlet

Maximum of 20 ft. [6.1 m] is permitted for piping outside a building.

Exhaust Vent

Gas Vent Directly Below

Keep Free of Obstructions

Air-Inlet

Existing Chimney (used as a chase way)

Chimney Cap

Exhaust Vent

Exhaust Vent Min. 18 in. above airinlet

Air-Inlet Min. 12 in. above roof and snow level

FTG │Installation & Operation Manual

Clearances to Air-Inlet Termination

Canada 1

USA 2

Min. Distance

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

Above roof line - Concentric Vent

6, 11, 13

24 in.

610 mm

24 in.

610 mm

To exhaust vent from any other boiler

36 in.

915 mm

12 in.

305 mm

Clearances to Exhaust Vent Termination

Min. Distance

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

Minimum vertical separation above air inlet 9

18 in.

457 mm

18 in.

457 mm

Minimum horizontal separation from air inlet 3

4 in.

102 mm

4 in.

102 mm

Window or door that may be opened, or other building opening

36 in.

915 mm

12 in.

305 mm

To combustion air inlet of any other appliance

36 in.

915 mm

12 in.

305 mm

Non-mechanical air supply inlet to building

36 in.

915 mm

12 in.

305 mm

Mechanical air supply inlet to building 4

6 ft.

1.83 m

3 ft.

915 mm

Soffit, overhang, eave or parapet

24 in.

610 mm

24 in.

610 mm

Soffit vent or vent opening in an overhang, eave or parapet

6 ft.

1.83 m

6 ft.

1.83 m

Outside corner 10

- - -

Inside corner of an L-shaped structure (including walls and fences)

36 in.

915 mm

36 in.

915 mm

Service regulator / vent outlet

36 in.

915 mm

36 in.

915 mm

Each side of center line above or below meter / regulator assembly 5

36 in.

915 mm

36 in.

915 mm

Above a paved sidewalk, driveway, or parking lot on public property if adjacent 12

7 ft.

2.13 m

7 ft.

2.13 m

Above a public walkway

X X X

Above a sidewalk or paved driveway that is located between two single family dwellings and services both dwellings

X X X

Under a concrete veranda, porch, deck, or balcony 7

24 in.

610 mm

24 in.

610 mm

Above, under or near exterior stairs

X X X

Into a canopy or carport

X X X

Notes:

1 - Canadian installations must comply with the current CSA B149.1 Natural Gas and Propane Installation Code and local

building codes. 2 - US installations must comply with current ANSI Z223.1/ NFPA 54 National Fuel Gas Code and local building codes. 3 - Horizontal separation center-to-center (c.c.) 4”-12” (102-305 mm).

4 - For US installations, an exhaust vent must be 3 ft above a mechanical air supply inlet if within 10 ft. [3 m] horizontally. 5 - Horizontal clearance must be observed up to a height of 15 ft. [4.6 m] above/below the meter, regulator, or relief devices. 6 - Concentric Vent must protrude from the roof precisely 24” [610 mm] measuring from the terminal end-cap vanes. 7 - Permitted if veranda, porch, deck, or balcony is made of concrete and a minimum of two sides are fully open beneath. 8 - 24” is the recommended snow level allowance above grade/roofline or any surface that will support snow, debris, or ice

(i.e. for roof venting clearances - roofline and snow level). If living in a snowfall region, consult your local weather

office for the maximum typical snowfall for your area.

9 - Note that the vent must maintain a minimum vertical distance above the air-inlet. Example: Vent height = 18” (457

mm) above air inlet + 12” (305 mm) for air inlet above grade/roof line and snow level = 30” (762 mm) above grade and

snow level.

10 - Clearances to an outside corner to be in accordance with local installation codes. 11 - In Canada, concentric vent materials are subject to approval by local inspectors. See Termination Kits in Section 4.0.

12 - Above public walkways, driveways or parking lots if adjacent to it and condensate cannot drip, freeze, or create a hazard. 13 - Contact the manufacturer for special exemptions relating to multiple boiler installations using concentric vents.

Installation & Operation Manual│ FTG

5.0 VENT/AIR-INLET TERMINATION CLEARANCES

instructions detailed in this section are a combination of FTG specific and National Gas Code restrictions. Compliance alone does not insure a satisfactory installation as good common sense must also be applied. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Table 5-1 Termination Clearances Quick Reference Table (See Figures 5-1 and 5-2)

The quick reference table below is to be read in conjunction with the numbered notes as indicated, Figures 5-1 and 5-2, and the Venting Rules and Guidelines in Section 4.0. The

G – Letter represents a specific Termination Position. Refer to Table 5-1 for corresponding termination clearances.

Concentric Vent Termination

Two-Pipe Termination

Clearance “Q” Adjacent to Public Walkway or Driveway Minimum 7ft. [2.13 m]

Clearances “F” and “G” Canada – Minimum 3 ft. [915 mm] The US – Minimum 1 ft. [305 mm]

FTG │Installation & Operation Manual

Figure 5-1 Termination Clearance Quick Reference Diagram (See Table 5-1)

Illustrations of Termination Clearances

Figure 5-2 Sidewall Termination (See Table 5-1)

Installation & Operation Manual│ FTG

Removing an Existing Boiler from Common Venting System

Upon removal of an existing boiler, the following steps shall be followed for each boiler remaining in the common venting system; prior to commencing this procedure, shutdown all boilers remaining in the common venting system.

Steps to Removing an Existing Boiler:

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

2. Visually inspect the venting system for proper size and horizontal pitch. Verify that there is no blockage,

restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close fireplace dampers, all building doors and windows and all doors between the

space in which the boilers remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any boiler 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.

4. Place in operation the boiler being inspected. Follow the applicable lighting instructions. Adjust thermostat

so boiler will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each boiler remaining connected to the common venting system properly

vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning boiler to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms to

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 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

Extra precaution must be taken to adequately support the weight of the Vent/Air-inlet piping in applications using roof-top terminations. Failure to follow these instructions may result in venting or boiler component failure resulting in flue gas spillage leading to property damage, serious injury or death.

Under no circumstances may an existing chimney or chase-way be used to vent or provide combustion inlet air to an FTG boiler. Failure to follow these instructions will result in fire, property damage, serious injury or death.

Do not install the FTG boiler into a common venting system with any other boiler. Failure to comply with this warning will cause flue gas spillage and leech carbon monoxide emissions into the surrounding air resulting in serious injury or death.

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining boilers connected to it. Instructions have been provided on how to remove the existing boiler and how to resize the remaining venting system. Failure to follow these instructions may result in property damage, serious injury or death.

FTG │Installation & Operation Manual

6.0 CONDENSATE DRAIN

The FTG boiler produces liquid condensate in the heat exchanger and venting system as a product of combustion. Steps must be taken to ensure condensate does not collect in the venting system; therefore, all exhaust piping must slope back to the boiler a minimum ¼ in. per linear foot of vent. Condensate must be drained from the unit into a household drain.

Check with your municipality, or local gas company to determine if the disposal of combustion condensate is permitted in your area (e.g. in the State of Massachusetts the

The following are important notes that must be taken into consideration when constructing the condensate drain system (see Condensate Trap Installation Instructions for further details):

 DO NOT install condensate lines outside. A frozen or blocked drain will cause the condensate to back-up

and leak. This may result in damage to boiler components resulting in a no heat condition; property damage may also occur.

 NEVER use copper, steel, or galvanized piping in the construction of the condensate system (condensate is

very corrosive and will corrode most metals).

 When a condensate pump is used or required, select a pump that is designed for residential furnaces.

Condensate Trap Installation Instructions (see Figure 6-1)

(Note: the Condensate Trap is factory supplied with the boiler and must be field installed)

1. Identify Condensate Trap & Accessories Provided with the Boiler – A Condensate Trap, Gear Clamp

and Support Bracket (c/w screws) are factory supplied with each FTG boiler, and are needed for properly securing the Condensate Trap to the boiler (see Figure 6-1).

2. Attach to Boiler Condensate Drain – As illustrated in Figure 6-1(a), slide the Condensate Trap inlet fitting

over the Boiler Condensate Drain; use the factory supplied Gear Clamp to secure the Condensate Trap in place (ensure that the Condensate Trap cannot be pulled off). With the factory supplied screws, fasten the Support Bracket into place while trapping the top of the Condensate Trap between the Support Bracket and boiler, thus ensuring the Condensate Trap stays in the vertical position.

3. Prime Condensate Trap – Fill the Condensate Trap with water to prevent flue gases from escaping during

initial firing of the burner.

4. Outlet to Drain – Direct condensate from the outlet of the Condensate Trap to a household drain,

condensate pump or neutralizer (check with your local authority regarding the disposal of condensate). If necessary connect suitable tubing to the outlet of the Condensate Trap and route it to drain, being careful NOT to route it higher than the Condensate Trap outlet (see Figure 6-1).

condensate must be neutralized prior to entering a drain).

All tubing, drains and surfaces that come in contact with condensate draining from the boiler, must be constructed out of corrosion resistant material; copper, steel and galvanized are not acceptable materials for draining condensate. Failure to abide by this caution will result in property damage.

The Condensate Trap must be periodically disassembled and cleaned as part of a regular maintenance plan. Failure to clean the trap regularly can cause condensate drain blockage leading to boiler malfunction, property damage and even personal injury.

Carefully follow the above instructions and the accompanying figure – check to ensure the Condensate Trap is secure and that no strain is placed on it. Failure to install the condensate trap properly will result in flue gas spillage and leeching of carbon monoxide emissions into the surroundings resulting in serious injury or death.

Figure 6-1(a) Condensate Drain Trap – Exploded View

Figure 6-1(b) Condensate Drain Trap - Assembled

Condensate Trap

(factory supplied)

Gear Clamp

(factory supplied)

Boiler Condensate Drain

Support Bracket

(factory supplied)

Tighten Gear Clamp

securing Condensate Trap

to Boiler Condensate Drain.

Direct condensate to a vented drain, ensure

no strain is applied to the Condensate Trap

and Boiler Condensate Drain.

Prime Condensate Trap with water before firing boiler

Position the Condensate Trap inside the Support Bracket, then fasten the bracket to the boiler.

Installation & Operation Manual│ FTG

FTG │Installation & Operation Manual

7.0 INSTALLING GAS PIPING

FTG boilers are factory set to operate with Natural Gas; BEFORE OPERATING WITH PROPANE, the boiler’s gas valve must be adjusted in accordance with the

applicable Natural Gas to LP Conversion Instructions. Failure to properly convert the unit to safely operate with Propane will cause severe boiler failure, resulting in property damage, serious injury or death.

Liquefied Petroleum (LP) propane gas is heavier than air. Do not install the boiler in a pit or similar location that will permit heavier than air gas to collect. Check with Local Codes as they may require boilers fueled with LP gas to be provided with an approved means of removing unburned gases from the room. Failure to follow these instructions

Installation

Refer to the current National Fuel Gas Code ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 installation codes, and local codes for gas piping requirements and sizing. Pipe size running to the unit depends on:

 Length of pipe.  Number of fittings.  Type of gas.  Maximum input requirement of all gas boilers in the residence.

Ensure that:

 The gas line connection to the boiler does not apply any weight to the gas valve. NTI recommends using

approved flexible gas piping (if acceptable by local codes) to connect the boiler to the gas supply (see Figure 7-1 for details).

 You plan the installation so the piping does not interfere with the vent pipe, or the removal of the valve,

burner, and serviceable components.

 The Boiler is installed such that the gas ignition system components are protected from water (dripping,

spraying, rain etc.) during installation and servicing.

 The gas piping is large enough for all the gas appliances in the home. No appreciable drop in line pressure

should occur when any unit (or combination of units) lights or runs. Use common gas-line sizing practices.

 Always use a pipe-threading compound that is resistant to Propane (LP) gas solvent action. Apply sparingly

to all male threads, starting at two threads from the end. Over doping or applying dope to the female end, can result in a blocked gas line.

 DO NOT TIGHTEN FITTINGS WITHOUT SUPPORTING THE INTERNAL GAS LINE CONNECTION

WITHIN THE BOILER as damage to the boiler’s internal gas carrying components could occur.

 Install a manual “Equipment Shut-Off Valve” as shown in Figure 7-1. Valve must be listed by a nationally

recognized testing laboratory.

 The gas line piping can safely be removed from the boiler for servicing, by strategically placing the gas line

shutoff and union; see example in Figure 7-1.

 All gas piping, including gas components in the boiler, are checked for leaks using a “Bubble Test”, prior to

operating the boiler.

may result in serious injury or death.

Strain on the gas valve and fittings may result in vibration, premature component failure and leakage and may result in a fire, explosion, property damage, serious injury or death.

Do not use an open flame to test for gas leaks. Failure to follow these instructions may result in fire, property damage, serious injury or death.

When performing a pressure test on the gas line piping, be sure the boiler is disconnected or isolated if the test pressure is expected to exceed 1/2 PSI (14 in. w.c.), as damage to the gas valve could occur resulting in fire, property damage, serious injury or death.

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NTI FTG 600, FTG 1400, FTG 2000, FTG 2200, FTG 2400 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

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