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

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.

H

NTI # 85422

2

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

3

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

4

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.

5

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.

(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED: When the

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

6

DESCRIPTION

FTG 600

FTG 800

FTG 1200

FTG 1400

FTG 2000

FTG 2200

FTG 2400

Gas Connection
(inches, NPT)

1

1-1/4

1-1/2

Water Inlet
(inches, groove-joint)

3

Water Outlet
(inches, groove-joint)

2

3

Exhaust Vent
Connection (inches)

6

8

Air-inlet Connection
(inches)

6

8

Overall Height
(inches)

68-1/2

64-3/8

Overall Width
(inches)

33-7/8

Overall Depth
(inches)

38-3/8

54

70

Approximate Weight
with water (lb.)

930

1500

2140

Water Content
(gallons)

17

34

51

Electrical Rating

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

(Note 1)

(Note 2)

(Note 3)

Notes:

1

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

2

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

3

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

97

96

96.2

96

96.1

95.7

95.3

Thermal
Efficiency (%)2

96

95

96.1

96

96

95.6

95.2

Notes:

1

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

2

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

7

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 by 10%

de-rate by 10%

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:

1

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].

2

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.

8

Clearances

Dimensions - inches

Front

Top

Sides

Rear

3

Flue Pipe

Minimum

24 1

12 4 12

1

Recommended

36

24

24

2

24

1

Notes:

1

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.

2

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

3

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.

9

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

2

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

2

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.

10

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.

11

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.

12

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

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:

1

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.

2

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.

3

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.

4

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.

13

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.

14

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:

1

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

2

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

3

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

95

90

85

80

75

70

65

60

55

FTG 1200-2400

NG/LP

8

150

145

140

135

130

125

120

115

110

105

Notes:

1

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

2

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.

3

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).

15

Description

Vent

Size

Supplier P/N

Figure

Vent Material

Compatibility

Termination

Roof

Wall

IPEX Low Profile (Wall)

7

4”

196986 (NTI P/N 84358)

4-4(c)

PVC/CPVC

7

-



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)

8

4”

(ICWT462 & ICTC0446)

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

InnoFlue®

Polypropylene

-



InnoFlue® Concentric
(Roof)

8

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:

1

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

2

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

more details.

3

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

4

Piping MUST be secured to the vent terminal during installation.

5

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

6

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).

7

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.

8

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

ICTC0446.

9

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

10

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

16

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

17

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.

18

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

19

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.

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



20

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-

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.

21

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

22

Clearances to Air-Inlet Termination

Canada 1

USA 2

Min. Distance

Min. Distance

A

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

B

Above roof line - Concentric Vent

6, 11, 13

24 in.

610 mm

24 in.

610 mm

C

To exhaust vent from any other boiler

36 in.

915 mm

12 in.

305 mm

Clearances to Exhaust Vent Termination

Min. Distance

Min. Distance

A

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

D

Minimum vertical separation above air inlet 9

18 in.

457 mm

18 in.

457 mm

E

Minimum horizontal separation from air inlet 3

4 in.

102 mm

4 in.

102 mm

F

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

36 in.

915 mm

12 in.

305 mm

G

To combustion air inlet of any other appliance

36 in.

915 mm

12 in.

305 mm

H

Non-mechanical air supply inlet to building

36 in.

915 mm

12 in.

305 mm

I

Mechanical air supply inlet to building 4

6 ft.

1.83 m

3 ft.

915 mm

J

Soffit, overhang, eave or parapet

24 in.

610 mm

24 in.

610 mm

K

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

6 ft.

1.83 m

6 ft.

1.83 m

L

Outside corner 10

- - -

-

M

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

36 in.

915 mm

36 in.

915 mm

N

Service regulator / vent outlet

36 in.

915 mm

36 in.

915 mm

P

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

36 in.

915 mm

36 in.

915 mm

Q

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

7 ft.

2.13 m

7 ft.

2.13 m

R

Above a public walkway

X X X

X

S

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

X X X

X

T

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

24 in.

610 mm

24 in.

610 mm

U

Above, under or near exterior stairs

X X X

X

V

Into a canopy or carport

X 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

23

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

Concentric Vent
Termination

Q

Two-Pipe
Termination

F

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

G

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)

24

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.

25

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.

26

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

27

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.

28

Figure 7-1 Gas Line Connection (Typical)

Apply propane gas compatible pipe sealing compound to the male-end of all treaded
connections before assembly. Support boiler gas line connection during assembly of
gas piping to prevent damage to internal boiler components. Failure to follow these
instructions may result in fire, property damage, serious injury or death.

Test all gas piping, internal and external to the boiler, for leaks. Failure to follow
these instructions may result in fire, property damage, serious injury or death.

Drip Leg / Sediment Trap

(field supplied)

Union

(field supplied)

Manual Gas Shutoff Valve

(Factory Supplied)

Should overheating occur or
the gas supply fails to shutoff,
close the Manual Gas Shutoff

Valve to the boiler.

Gas Supply Line

Must be externally supported.

DO NOT support with boiler

gas line connection.

Installation & Operation Manual│ FTG

29

FTG │Installation & Operation Manual

8.0 LIGHTING THE BOILER

Before Start-up refer to Mandatory Pre-commissioning Procedure for Plastic Venting
in Section 4.0. Failure to follow these instructions can result in explosions, injury or death.

Prior to turning the gas supply on and lighting the boiler, ensure all aspects of the

installation are complete and in conformance with the instructions provided in this
manual, including the Vent/Air-inlet, Condensate Drain, and System Water Piping. Failure to precisely follow
these instructions will cause a fire or explosion resulting in property damage, serious injury or death.

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.

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.

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

Do not store or use gasoline or other flammable vapors & liquids in the vicinity of this or
any other boiler. Failure to follow instructions could result in explosion causing property
damage, serious injury or death.

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

Should overheating occur or the gas supply fails to shutoff, close the Manual Gas Shutoff
Valve to the boiler. Failure to follow instructions could result in explosion causing
property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

OPERATING INSTRUCTIONS_

TO TURN OFF GAS TO THE BOILER_

30

Installation & Operation Manual│ FTG

 Ensure the boiler is wired in accordance with this manual.
 Ensure the gas shutoff valve is turned on, and that the gas system has been fully tested for leaks.
 Ensure the system is completely filled with water, and that ALL the air is purged out.
 Ensure the Vent and Air-inlet piping is completely installed in accordance with this manual.

Initial Start-Up

1. Turn on power to the boiler and turn-up the Thermostat(s). The boiler should run through a purge, and

combustion should occur. (The control system has a built-in ignition retry, allowing the system to try at least
two times, before locking-out.)

2. With the unit operating at full capacity, verify that the gas line pressure is 4-10.5 inches w.c. for Natural gas,

and 8-13 inches w.c. for Propane (see Section 9.0 for details).

3. Using an appropriate Oxygen (O2) or Carbon Dioxide (CO2) analyzer, take a sample of the flue gas. The

sample must fall within the acceptable ranges for CO2 (see Section 9.0 for details).

4. Perform at least three ignitions in succession to ensure proper operation.

5. After the three successive ignitions, unplug the flame sensor and allow the unit to cycle again. The flame

safety system will allow the unit to go through 2 ignition cycles before going to “Lockout 110 – Ignition
failure occurred”. Once you have confirmed this behavior, reinstall the wire on the flame sensor, clear the
lockout and reconfirm proper ignition.

located in the burner plate); this device is used for spark ignition and produces 20,000 Volts potential which
would result in an EXTREME ELECTRICAL SHOCK possibly causing serious injury or death.

burner is rough or erratic. Failure to follow these instructions may result in serious injury or death.

Re-lighting Unit

1. Stop and read these instructions very carefully.

2. Set the thermostat to the lowest setting, and then turn off all power to the boiler.

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

Do not try to light the burner by hand.

4. Turn the gas shutoff valve to the off position, and then remove the front cover.

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

“Stop” and follow “B” above (see FOR YOUR SAFETY, READ BEFORE OPERATING). If you do
not detect any gas proceed to the next step.

6. Turn the gas shutoff valve to the on position, wait an addition five (5) minutes and check for gas.

7. Replace the front cover.

8. Set the thermostat to the highest setting, and then turn on all power to the boiler.

9. Ignition sequence is automatic, combustion will occur after a brief fan purge. Ignition will retry once.

10. If ignition does not occur, “Turn off the gas and electricity to the boiler” and contact a qualified service

technician, or gas supplier.

Turning Off the Boiler

1. Set the thermostat to the lowest setting, and then turn off all power to the boiler.

2. Turn the gas shutoff valve to the off position.

The initial lighting of the boiler must be performed by a licensed Gas Technician.
Failure to follow instructions may result in property damage, serious injury or death.

Allow primers/cements to cure for 8 hours prior to Start-up. If curing time is less than 8
hours, first perform Steps 2 through 6 of Mandatory Pre-commissioning Procedure for
Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosion,
serious injury or death.

The flame probe is located in the burner plate; it has a single white/semi-transparent wire
connected to it. DO NOT remove the orange spark cable from the ignition electrode (also

If the unit fails to light consistently and smoothly, contact NTI for technical assistance at
1-800-688-2575. Never allow the boiler to operate if the ignition or operation of the

31

Gas

Line Pressure (inches w.c.)

Offset Pressure

(inches w.c. / [Pa])

4

CO2 (%)

1,2,3

Max. CO

(ppm)

Nominal/

Desired

Min.

Max.

Min.

Max.

Natural

7 4 10.5

-0.01 to 0 / [-3 to -1]

8.7

9.5

175

Propane

11 8 13

-0.04 to -0.03 / [-10 to -8]

10

10.8

175

Notes:

1

Combustion calibration must only be performed with the burner operating at maximum modulation rate.

2

Combustion values listed are for burner operation at maximum modulation rate; CO2 and CO values will be lower at

minimum modulation rate.

3

When tested at minimum modulation rate, the CO2 must be 0.5-1.0% lower than CO2 at maximum modulation rate.

4

The Offset Pressure for models FTG 2000-2400 converted to Propane, must be checked, and if necessary adjusted, in

accordance with the procedure detailed in Figure 9-2.

FTG │Installation & Operation Manual

9.0 GAS VALVE AND BURNER SET-UP

Set-up of the FTG gas valve must be performed by a licensed Gas Technician. Failure to
perform the set-up correctly may result in incorrect operation, component failure,

Gas Line Pressure

The boiler gas valve is equipped with a line pressure test port; see Figure 9-1. Use the following procedure to
measure the gas line pressure to the boiler to ensure if falls within the range given in Table 9-1:

1. Turn the supply of gas to the boiler off.

2. For models FTG 600-1400, use a 3/16 in. hex wrench to remove the plug from the inlet flange of the gas

valve, and install a 1/8 NPT x hose barb adapter suitable for connecting the tubing of the gas pressure
manometer being used to measure gas line pressure. Models FTG 2000-2400 encorporate a bleed screw on
the inlet flange of the gas valve, open it approximately 1-1/2 turns. See Line Pressure Test Port in Figures
9-1(a) and 9-1(b).

3. Slide the gas pressure manometer tubing over the hose bard adapter located on the inlet flange of the gas

valve (bleed screw fitting for models FTG 2000-2400); connect the other end of the tubing to the gas
pressure manometer. Ensure both ends of the tubing make a tight connection.

4. Open the supply of gas to the boiler and check for gas leaks.

5. Observe the line pressure under static conditions and compare it to Table 9-1. The pressure will be greatest

under static conditions.

6. With all other gas appliances in the application running, operate the burner to the maximum firing rate (see

Table 9-2) and compare the observed line pressure with Table 9-1. The pressure will be lowest during the
maximum flow of gas.

7. Adjust the gas line pressure to ensure the parameters in Table 9-1 are attained under all conditions (see

NOTICE below). If possible, adjust the line pressure to the "Nominal/Desired" value listed in Table 9-1,
while the unit is operating at the maximum modulation rate, see Table 9-2.

8. Continue observing the gas line pressure until the completion of the combustion analyses, in case

adjustments need to be made.

9. Upon completion of the line pressure testing, turn the gas supply off, and then reinstall the Line Pressure

Test Port plug, applying appropriate thread sealant to the threads prior to installing. For models FTG 2000­2400, close the bleed screw. Turn gas on and check for leaks.

Table 9-1 Line Pressure and Combustion Parameters

property damage, serious injury or death.

The line pressure is a function of the gas supply and is affected solely by field provided
parameters such as line size and regulator settings. Under no circumstances can the boiler
gas valve influence or be used to adjust the gas line pressure.

Failure to properly re-install the Line Pressure Test Port plug (FTG 600-1400), or close
the Line Pressure Test Port bleed screw (FTG 2000-2400) will cause severe leakage of
gas, resulting in a fire or explosion causing property damage, serious injury or death.

32

Model

Min. Modulation

Rate (RPM)

Max. Modulation

Rate (RPM)

Model

Min. Modulation

Rate (RPM)

Max. Modulation

Rate (RPM)

FTG 600

1150

5600

FTG 2000

1050

7100

FTG 800

1150

7450

FTG 2200

1050

7200

FTG 1200

1050

8100

FTG 2400

1050

8000

FTG 1400

1050

7800

Throttle/Input Adjustment Screw

Increase gas
Turn Counter Clockwise

Decrease gas
Turn Clockwise

Installation & Operation Manual │ FTG

Table 9-2 Minimum and Maximum Modulation Rates

Carbon Monoxide - Never leave the unit operating while producing Carbon Monoxide

(CO) concentrations in excess of 175ppm. Failure to follow this warning may result in
serious injury or death.

Manifold Pressure – DO NOT adjust or measure the Manifold Pressure of boiler models
FTG 600-1400; the correct manifold pressure is factory set. Field adjustment could
result in improper burner operation resulting in fire, explosion, property damage or death.

Adjustments to the Throttle/Input Adjustment Screw may only be made by a qualified
gas technician, while using a calibrated combustion analyzer capable of measuring CO2
and CO. Adjustments may only be performed if the gas line pressure is maintained above
minimum levels throughout the duration of the test, see Table 9-1. Failure to follow these
instructions may result in serious injury or death.

Flue Gas Analysis and Adjustment

Throttle / Input Screw Adjustments – The boiler is equipped with a Throttle/Input Adjustment Screw, located

at the Gas Valve; see Figures 9-1(a) & 9-1(b); it is used to adjust the flow of gas leaving the Gas Valve
entering the Venturi and then the combustion air stream. Turn the Throttle Screw in (clockwise) to reduce
the flow of gas, make combustion leaner, and reduce the concentration of CO2 in the flue gases. Turn the
Throttle screw out (counterclockwise) to increase the concentration of CO2 and flow of gas in the combustion
air stream. Typical adjustment required is 0-1/8 of a turn in or out from the factory setting. See Figure 9-1
for Throttle screw location and Table 9-1 for appropriate CO2 levels.

Combustion Calibration - To calibrate burner operation, perform the following procedure using a calibrated

combustion analyzer capable of measuring CO2 and CO from Natural and Propane Gas burning boilers:

1. Operate the unit at the maximum modulation rate, see Table 9-2.

2. Ensure the gas line pressure is maintained within tolerance, see Table 9-1.

3. While at the maximum modulation rate, measure the CO2 and CO; adjust as necessary, using the Throttle

Screw, to be within the limits listed in Table 9-1.

4. Operate the unit at the minimum modulation rate (see Table 9-2). Ensure the combustion remains

smooth and CO2 and CO values are lower than the values obtained during maximum modulation, as per
notes in Table 9-1. If not, do not adjust further, contact NTI for assistance.

5. For FTG 2000-2400 models converted to LP, perform the Gas Valve Offset Check/Adjustment procedure

detailed in Figure 9-2.

Each FTG boiler is factory set to operate with Natural Gas, for boilers field converted to operate with Propane
Gas, a flue gas analysis and adjustment is mandatory. See Natural to LP Conversion Instructions included with
the boiler.

Failure to perform the flue gas analysis and adjustment detailed in this section may result

in erratic and unreliable burner operation, leading to reduced efficiency, increased fuel
consumption, reduced component life, heat exchanger combustion deposits, and general unsafe operation.
Failure to follow these instructions may result in serious injury or death.

Analysis – Perform flue gas analysis, and adjust throttle/input screw as required until CO2 and CO levels are

within acceptable limits.

33

Figure 9-1(a) Gas Valve Assembly (FTG 600-1400)

DO NOT Adjust

Gas Valve

Manifold Pressure Test Port

(located on gas valve outlet
flange)

Throttle / Input Adjustment
Screw (use 3 mm hex wrench)

Line Pressure Test Port

(located on gas valve inlet
flange)

Venturi

Combustion Blower

Air Filter

Cap (remove to access Throttle

Adjustment Screw)

Low Gas Pres. Switch
(auto-reset)

High Gas Pres. Switch
(manual reset)

Front-Top Cover (must be removed

to access Gas Valve components)

FTG │Installation & Operation Manual

34

Figure 9-1(b) Gas Valve Assembly (FTG 2000-2400)

Pressure Tappings for
Measuring Offset

(Refer to Offset
Adjustment Procedure –
Figure 9-2)

Gas Valve

Offset Adjustment Screw

(Refer to Offset Adjustment
Procedure – Figure 9-2)

Throttle Adjustment Screw

Line Pressure Test Port

(located on gas valve inlet
flange)

Venturi

Combustion Blower

Air Filter

Low Gas Pres. Switch
(auto-reset)

High Gas Pres. Switch
(manual reset)

Front-Top Cover (must be removed

to access Gas Valve components)

Installation & Operation Manual │ FTG

35

Figure 9-2 Gas Valve Offset Check/Adjustment (FTG 2000-2400)

The Gas Valve Offset Pressure is factory set for Natural Gas; only applications
operating with Propane need to have the Gas Valve Offset Pressure field adjusted.

Improperly adjusted Gas Valve Offset Pressure will result in unpredictable burner
operating characteristics, which may lead to burner malfunction causing property
damage, serious injury or death.

Offset Adjustment Screw – used
to set offset and combustion at min.
modulation rate; see Figure 9-1(b)

Differential Pressure
Manometer – min. graduation

of 0.01 in. w.c (1 Pa)

Offset Adjustment Procedure:

1) Differential Pressure Manometer –

obtain a meter capable of measuring
differential pressure (“+” and “-“ ports)
with a minimum graduation of 0.01
inches w.c. (or 1 Pa).

2) Installation – with the burner off,
remove the caps from the pressure
tappings. Connect the Feedback
Pressure Tapping to the Positive (+) port
of the manometer; connect the Manifold
Pressure Tapping to the Negative (-)
port of the manometer. Verify that the
manometer is reading zero – zero the
meter if necessary.

3) Calibrate Combustion – operate burner
to maximum modulation rate (seeTable
9-2), ensuring gas line pressure is
maintained above 4 inches w.c.; set
combustion according to Table 9-1 using
the Throttle Screw – record CO2 value.

4) Set Offset – operate burner to minimum
modulation rate (see Table 9-2); set
offset pressure according to Table 9-1
using the Offset Adjustment Screw.

NOTICE: Since the Manifold Pressure

Tapping is connected to the Negative (-)
port of the manometer, a negative Offset
Pressure will read positive; e.g., to
achieve an offset pressure of -0.03,
manometer will read +0.03.

5) Verify Combustion – with the burner
remaining in operation at the minimum
modulation rate, measure combustion
and compare to readings obtained
during maximum modulation – CO2 must
be 0.5 to 1.0% lower at minimum
modulation. If readings are out of
tolerance – CONTACT NTI FOR
ASSISTANCE.

6) Complete Test – shutdown the burner,
remove the manometer tubing and
reinstall the factory caps on Offset
Pressure Tappings.

Positive (+)

Negative (-)

Feedback

Pressure

Manifold

Pressure

Throttle Adjustment Screw –

used to calibrate combustion at max.
modulation rate; see Figure 9-1(b)

FTG │Installation & Operation Manual

36

Table 10-1 Boiler System Cleansers and Corrosion Inhibitors

Application

Fernox Product

NTI Part #

Description

Boiler Water Treatment

F1 Protector

83448

Corrosion inhibitor.

Cleanser for new and old systems

F3 Cleaner

83449

Removes flux, grease and carbon residue.

Cleanser for Retrofits

DS-40 System Cleaner

83450

Removes heavy lime scale and sludge deposits.

 PH – between 6.6 and 8.5.

 Iron – less than 0.5mg/l.

 Chloride – less than 125mg/l.

 Copper – less than 0.1mg/l.

 Conductivity – less than 400µS/cm (at 25ºC); [TDS < 200ppm or Total Hardness < 11.6grains/USgal.]

Installation & Operation Manual│ FTG

10.0 BOILER AND HEATING SYSTEM PIPING

The fire tube design of the FTG heat exchanger results in minimal head loss, however it must be considered
when sizing system piping and circulators. Furthermore, the low mass of the FTG heat exchanger requires a
minimum flow rate anytime the burner is operating. To maintain the efficient and reliable operation of the heat
exchanger, and to avoid heat exchanger failure, it is critical to ensure the rules and guidelines in this section are
followed.

Failure to follow the instructions provided in this section will void the NTI warranty and
may result in property damage, fire, serious injury or death.

Boiler System Preparation

Prior to connecting plumbing to the boiler, flush the entire system to ensure it is free of sediment, flux, solder,
scale, debris or other impurities that may be harmful to the system and boiler. During the assembly of the
heating system, it is important to keep the inside of the piping free of any debris including construction and
copper dust, sand and dirt.

For retrofits, all system piping, including radiators, must be cleansed of build-up including sludge and scale. All
systems, old and new, must be cleansed to remove flux, grease and carbon residue; NTI recommends cleaning
the boiler system with “Fernox F3 Cleaner”. For retrofit applications with heavy lime scale and sludge deposits,
a heavier duty cleaner may be required; NTI recommends the use of “Fernox DS-40 System Cleaner”. For
information on performing the cleaning, follow the instructions included with the applicable Fernox Cleaner.
See Table 10-1 for a list of recommended boiler system cleaning and treatment products.

Failure to rid the heating system of the contaminants listed above will void your NTI
warranty and may result in premature heat exchanger failure and property damage.

Boiler Water

Pressure - FTG boilers are intended solely for use in pressurized closed-loop heating systems operating with a

minimum pressure of 12 PSI at the boiler outlet. To obtain the minimum system design pressure, follow the
piping diagrams illustrated in this section.

Oxygen Elimination - This boiler may only be installed in a pressurized closed-loop heating system, free of air

and other impurities. To avoid the presence of oxygen, ensure all of the air is removed from the system
during commissioning via strategically placed, adequately sized air-removal devices; located throughout the
heating system. See figures in this section detailing the location of the primary air-removal device required
for the boiler. Immediately repair any leaks in the system plumbing to avoid the addition of make-up water;
make-up water provides a source of oxygen and minerals that may lead to heat exchanger failure. Failure to
follow these instructions will result in poor performance, unnecessary wear of system components and
premature failure.

The FTG is not approved for operation in an “open system”, thus it cannot be used for
direct potable water heating or process heating of any kind.

Water Chemistry – The installer of the FTG boiler must consider the condition of the water in the heating

system. Ensure the condition of the boiler water falls within the following parameters:

37

FTG │Installation & Operation Manual

Treatment - Boiler water that falls outside of the conditions listed above must be treated with a corrosion

inhibitor. For information on performing the treatment, follow the instructions included with the corrosion
inhibitor. See Table 10-1 for a list of recommended boiler system cleaners and corrosion inhibitors.

To maintain protection, the level of corrosion inhibitor must be monitored periodically
for the correct concentration.

Anti-freeze - For systems requiring freeze protection, use only inhibited propylene glycol, specially formulated

for hydronic heating systems; use of other types of antifreeze may be harmful to the system and will void the
warranty. Note: the use of glycol may reduce the usable output capacity of the boiler, thus requiring the unit
to be “down-fired” by limiting the maximum operating capacity and/or the maximum water temperature.

DO NOT use inhibited glycol with non-compatible boiler inhibitors. Non-compatible
inhibitors may counteract each other rendering them ineffective.

Near Boiler Piping

Pressure Relief Valve – A Pressure Relief Valve is factory supplied with each unit, and must be field installed

in the vertical position, with the outlet facing horizontally and piped towards the floor away from where it
could be harmful; see Figure 10-1. NOTICE: FTG boilers have a maximum allowable operating pressure of
160 PSI.

If installed in the incorrect orientation (horizontally with outlet pointing down) the relief
valve may not function properly resulting in property damage or personal injury.

Ensure the discharge of the pressure relief is piped to a location where exiting steam or
hot water will not cause property damage or serious injury.

Pressure & Temperature Gauge – FTG units come with a factory supplied Pressure & Temperature Gauge.

The gauge must be installed in the boiler outlet fitting, as illustrated in Figure 10-1.

Auto Air Vent – An automatic air vent is factory installed on the boiler; see Figure 10-1. Open the auto air

vent’s vent-cap to promote the removal of air during commissioning of the boiler and to avoid

malfunctioning of the LWCO. Once the air is removed from the system, close the vent-cap to prevent water
from leaking onto the boiler.

Low Water Cutoff (LWCO) – FTG boilers are provided with a factory installed LWCO switch which

incorporates a Test Button and Power and Low Water indicator lights. Perform the following Operational
Test Procedure before placing the boiler in service, and ensure Maintenance is carried out with the following
schedule.

Do not run the boiler unattended until the following procedure is completed. Failure to
follow procedure may lead to unsafe boiler operation resulting in fire, property damage
and loss of life.

Operational Test Procedure (LWCO)

1. Before introducing water to the boiler, turn the power on; both the green “POWER” LED and amber “LOW

WATER” LED should illuminate. Generate a burner demand; the burner should not fire and “Lockout 67

ILK OFF” should appear on the screen. Contact NTI for assistance if this does not happen.

2. Fill the boiler with water; the “LOW WATER” LED should turn off. Press the TEST / RESET button on the

LWCO and clear the Lockout from the display board – burner should now fire.

3. With the burner firing, press the TEST / RESET button to simulate a low water condition; the amber “LOW

WATER” LED should illuminate and the burner should turn off.

Maintenance (LWCO)

 Every Year – perform Step 3 from the Operational Test Procedure.
 Every 5-years – Remove the LWCO and clean all surfaces in contact with water.

38

Figure 10-1 Near Boiler Piping

ATTENTION: Boiler piping can be adapted to ANSI pipe thread, flange, or other style piping

connection, immediately upon exiting the boiler. With the exception of the boiler inlet and outlet fittings,
Grooved Joint style piping connections are NOT required.

Low Water Cutoff

(factory installed)

Pressure Relief Valve

(factory supplied)

Pressure/Temperature Gauge

(factory supplied)

Groove Joint Coupling

(factory supplied)

3 in. Groove Joint Coupling

(factory supplied)

Isolation Valve

(Typical)

Y-Strainer

(recommended)

Boiler Drain / Back­flush Valve (typical)

Relief Valve Outlet –

Directed Downward (typical)

To System

From System

Isolation Valve

(Typical)

Boiler Drain / Back­flush Valve (typical)

Auto Air Vent

(factory supplied)

Installation & Operation Manual│ FTG

39

Table 10-2 Minimum Flow Rate Requirements

Model

Flow (US gpm)

Model

Flow (US gpm)

FTG 600

19

FTG 2000

63

FTG 800

25

FTG 2200

69

FTG 1200

38

FTG 2400

74

FTG 1400

44

Model

Temp.

Rise (ºF)

Boiler Flow

Rate (GPM)

Boiler Head

Loss (ft.)

Minimum

Pipe Size

Model

Temp.

Rise (ºF)

Boiler Flow

Rate (GPM)

Boiler Head

Loss (ft.)

Minimum

Pipe Size

FTG

600

20

56

6.7

2-1/2 in.

FTG

2000

20

192

11.2

4 in.

25

45

4.2

2 in. 25

154

7.2

3 in.

35

32

2.1

2 in. 35

110

4

3 in.

FTG

800

20

74

12

2-1/2 in.

FTG

2200

20

210

13.2

4 in.

25

59

7.6

2-1/2 in.

25

168

8.3

4 in.

35

42

3.8

2 in. 35

120

4.5

3 in.

FTG

1200

20

115

7.8

3 in.

FTG

2400

20

224

15

4 in.

25

92

5.4

2-1/2 in.

25

179

9.7

4 in.

35

66

3.5

2-1/2 in.

35

128

5

3 in.

FTG

1400

20

134

10

3 in.

25

108

6.9

3 in.

35

77

4.5

2-1/2 in.

FTG │Installation & Operation Manual

Boiler System Plumbing

FTG boilers use a low mass heat exchanger that requires a minimum rate of forced water circulation any time the
burner is operating (See Table 10-2 for minimum flow rate requirements). To ensure the minimum flow rate is
attained, carefully follow the plumbing instructions in this section.

Failure to ensure the minimum water flow rate through the boiler when the burner is
operating will result in “short-cycling”, reduced performance and operating efficiency,
and may also cause overheating and premature failure which will void the warranty.
Failure to follow instructions may result in fire, property damage, serious injury or death.

Circulating Pumps – FTG boilers are equipped with three sets of pump contacts:

1. DHW PUMP - operates during a Domestic Hot Water demand (DHW).

2. CH PUMP - operates during a Central Heat demand (CH).

3. BOILER PUMP - operates during any demand.

Ensure circulating pumps are oriented as per the manufacturers’ instructions. Wiring of these circulators will
depend on the system configuration selected; see Figures 10-3 and 10-4. For wiring details see Section 12.0.

Circulators responsible for forcing water flow through the boiler must be sized to
account for the head loss of the boiler and boiler piping at the required flow rate; see
Table 10-3 and Figure 10-2.

Table 10-3 Boiler Piping Size Requirements

40

Figure 10-2(a) FTG 600-800 Head Loss Curve

Figure 10-2(b) FTG 1200-1400 Head Loss Curve

Figure 10-2(c) FTG 2000-2400 Head Loss Curve

Installation & Operation Manual│ FTG

FTG │Installation & Operation Manual

41

Air Removal – The boiler and system plumbing layout must be configured to promote the removal of air from

the water. Air vents and bleeders must be strategically placed throughout the system to aid in purging the air
from the system during commissioning of the boiler. The system must also employ the use of a strategically
located air removal device, such as an air-scoop or micro-bubbler, designed to remove the air from the water
as it flows through the system.

Follow the installation instructions included with the air removal device when placing it
in the system; air removal devices generally work better when placed higher in the
system. Always locate air removal devices in areas of the system that have a guaranteed
positive pressure, e.g., in close proximity to the water fill and expansion tank.

Expansion Tank – The expansion tank must be sized in accordance with the water volume of the system as well

as the firing rate of the appliance. It is important to locate the expansion tank, and make-up water fill, on the
inlet side of any circulator in the system, as doing so will guarantee the lowest pressure in the system will be
at least equal to the tank and make-up water pressure. See examples in Figures 10-3 and 10-4.

Ensure the expansion tank cannot become isolated from the boiler anytime the system is
operating. The installation of flow checks, motorized valves or other shutoff devices
(other than for the purpose of servicing) are not permitted between the outlet of the boiler
and the expansion tank; see Figures 10-3 and 10-4. Failure to follow these instructions
may result in discharge of the Pressure Relief Valve resulting in property damage or
personal injury.

Indirect Water Heater (IWH) – When installed as per Figure 10-4, the indirect water heater is in series with the

boiler during a demand for DHW. Therefore, its head loss, along with the head loss of the boiler and
associated piping, must be considered when sizing the circulator.

Figures 10-3 and 10-4 illustrate typical piping systems. These piping schematics do not
illustrate all of the required concepts and components required to have a proper
installation. Concepts not shown include: prevention of thermal-siphoning (heat traps),
isolation valves, drain and purge valves, etc. It is the responsibility of the installing
contractor and system designer to determine which system best meets the need of the
installation and to consider all aspects of a proper system design. Contractor
modifications to these instructions may be required, based upon existing piping and
system design; consult NTI for required assistance (1-800-688-2575).

42

Figure 10-3 Plumbing Schematic – Single Central Heating Circulator

Figure illustrates the basic plumbing requirements for an FTG boiler installation with a
single Central Heating circulator, and an Indirect Water Heater. Refer to Figure 10-1
for boiler fitting identification.

Installation & Operation Manual│ FTG

43

Figure 10-4 Plumbing Schematic – Multiple Central Heating Circulators

Figure illustrates the basic plumbing requirements for an FTG boiler installation with a
multiple Central Heating circulators, and an Indirect Water Heater. Refer to Figure 10­1 for boiler fitting identification.

FTG │Installation & Operation Manual

44

# of

Units

Model

FTG 600

FTG 800

FTG 1200

FTG 1400

FTG 2000

FTG 2200

FTG 2400

2

3 in.

4 in.

4 in.

4 in.

5 in.

5 in.

5 in.

3

4 in.

4 in.

5 in.

5 in.

6 in.

6 in.

6 in.

4

4 in.

4 in.

5 in.

5 in.

6 in.

6 in.

8 in.

5

4 in.

5 in.

6 in.

6 in.

8 in.

8 in.

8 in.

6

5 in.

5 in.

6 in.

6 in.

8 in.

8 in.

8 in.

7

5 in.

5 in.

6 in.

8 in.

8 in.

8 in.

8 in.

8

5 in.

6 in.

8 in.

8 in.

8 in.

8 in.

8 in.

Note: Minimum pipe size based on assumed temperature rise of 25ºF at maximum firing rate.

Installation & Operation Manual│ FTG

11.0 LEAD LAG INSTRUCTIONS
Multiple Boiler Applications

The FTG controller has the internal capacity to stage or Lead-Lag up to 8 boilers configured in a cascade. This
Lead-Lag capability allows a designated “Master” boiler to communicate with and effectively control each
boiler in a multiple boiler system. This function is accomplished by “Daisy Chaining” a 3-wire cable between
each of the boilers and enabling the Master parameter in the boiler of your choice. The boiler with the Master
parameter enabled becomes the single point of contact for Central Heating, Domestic Hot Water and Outdoor
Reset settings and control wiring. Use the instructions detailed in this section to set-up and install the cascade
boiler system; reference Appendix A – Controller and Touchscreen Display Instructions for details on more
advanced settings and for assistance with navigating the touchscreen display.

Lead Lag Instructions - Common

Plumbing – install as many as 8 FTG boilers in parallel in a primary/secondary plumbing configuration as

illustrated in Figure 11-1. Size common piping as per Table 11-1.

Boiler Pump – each boiler must have its own circulator (see Figure 11-1) which is controlled by its BOILER

PUMP output; see Field Wiring Figure 12-2 and Table 12-1. The Boiler Pump must be sized according to

Table 10-3.

Communication Wiring – using 3-wire cable, daisy-chain terminals LL DATA +, LL DATA – and COMMUN.

COM of each boiler in parallel; see Field Wiring Table 12-2 and Figure 12-3.

System Sensor (Optional) – install a system sensor (NTI P/N: 84010) on the outlet (supply) pipe feeding the

heating system, see Figure 11-1. Wire the system sensor to the SYSTEM SENSOR terminals of the Master
Boiler; see Field Wiring Table 12-2 and Figure 12-3. The system sensor automatically becomes the
modulation sensor for the boiler system, i.e. the control attempts to achieve setpoint temperature at the
location of the sensor. If a system sensor is NOT used, at the Master boiler set the applicable sensor input to
Unconfigured as follows:

Configure – Sensor Configuration – S10 (J10-7) sensor

Outdoor Sensor (Optional) – wire the outdoor sensor to the OUTDOOR SENSOR terminals of any one of the

boilers in the cascade; see Field Wiring Table 12-2 and Figure 12-3. Note: only one outdoor sensor is needed
for the multiple boiler system.

Modbus Address – assign a unique MB2 Modbus Address to each boiler in the cascade. Access the MB2

Modbus Address setting via the System Identification & Access menu as follows:

Configure – System Identification & Access – MB2 Modbus Address

Master Enable – choose one (and only one) boiler in the cascade to be the Master, this boiler will receive all

control wiring and will be used for setting control parameters (see steps below). On this one boiler, set
Master enable equal to Enabled via the Lead Lag Master Configuration menu, accessed as follows:

Configure – Lead Lag Master Configuration – Master enable

Table 11-1 Minimum Pipe Sizes for Multiple Boiler Applications

45

Figure 11-1 Multiple Boiler Cascade – Plumbing Configuration

Figure illustrates the basic plumbing requirements for multiple FTG boilers installed in
cascade configuration. Refer to Figure 10-1 for boiler fitting identification.

FTG │Installation & Operation Manual

46

Installation & Operation Manual│ FTG

Lead Lag Instructions – Central Heating

Central Heat Demand Switch (Room Thermostat) – connect to R (24VAC) and CH2 (LL) of the Master

Boiler; see Field Wiring Table 12-2 and Figure 12-3. Switch must be an isolated end switch (dry contact).

Central Heat Setpoint – at the Master boiler only, set the CH setpoint via the Lead Lag Master Configuration

menu, accessed as follows:

Configure – Lead Lag Master Configuration – CH setpoint

Outdoor Reset Settings – at the Master boiler only, set the Outdoor reset parameters via the Lead Lag Master

Configuration menu, accessed as follows:

Configure – Lead Lag Master Configuration – Advanced Settings – Outdoor reset

CH Pump – one boiler in the cascade can be chosen to operate the Central Heating pump via its CH PUMP

output; see Field Wiring Figure 12-2 and Table 12-1. From the respective boiler display, check the box next
to Use for Lead Lag Master demands for the CH Pump to ensure proper pump behavior. Menu access to the
CH Pump parameters is as follows:

Configure – Pump Configuration – Central Heat pump – Use for Lead Lag Master demands

Lead Lag Instructions – Domestic Hot Water

Tank Thermostat – connect to terminals DHW of the Master Boiler; see Field Wiring Table 12-2 and Figure

12-3. Switch must be an isolated end switch (dry contact).

DHW Setpoint – at the Master boiler only, set the DHW setpoint via the Lead Lag Master Configuration menu,

accessed as follows:

Configure – Lead Lag Master Configuration – DHW setpoint

DHW switch (Lead Lag) – at the Master boiler only, set DHW switch equal to DHW (S6) sensor shorted via the

Lead Lag Master Configuration menu, accessed as follows:

Configure – Lead Lag Master Configuration – Advanced Settings – Domestic Hot Water – DHW switch

DHW enable (Local) – at the Master boiler only, set DHW enable equal to Disabled via the Domestic Hot

Water Configuration menu, accessed as follows:

Configure – Domestic Hot Water Configuration – DHW enable

DHW Pump – one boiler in the cascade can be chosen to operate the DHW pump via its DHW PUMP output;

see Field Wiring Table 12-1 and Figure 12-2. From the respective boiler display, check the box next to Use
for Lead Lag Master demands for the DHW Pump to ensure proper pump behavior. Menu access to the
DHW Pump parameters is as follows:

Configure – Pump Configuration – DHW pump – Use for Lead Lag Master demands

Tank Sensor – when operating in a cascade system, the boiler controls do not support the
use of a tank sensor; a tank thermostat (switch) must be used.

47

FTG │Installation & Operation Manual

12.0 FIELD WIRING

All wiring must be in accordance with the Canadian Electrical code, CSA C22.2 and any applicable local codes.
Ensure that the wiring complies with this manual. The boiler must be electrically grounded in accordance with
the National Electrical Code ANSI/NFPA 70, local codes, and/or the Canadian Electrical Code CSA C22.1.

Power Supply – The required power supply varies between boiler models; connect a power supply matching the

description provided below for the respective boiler model:

 FTG 600-1400 – 120V / 1Ph / 60Hz, fused (or protected via a circuit breaker) to a maximum of 15 Amps.
 FTG 2000 – 120V / 1Ph / 60Hz, fused (or protected via a circuit breaker) to a maximum of 20 Amps.
 FTG 2200 – 208V / 3Ph / 60Hz, fused (or protected via a circuit breaker) to a minimum of 15 Amps.
 FTG 2400 – 240V / 3Ph / 60Hz, fused (or protected via a circuit breaker) to a minimum of 15 Amps.

Failure to connect the correct power supply, fused as specified, may result in component
failure, serious injury or death.

Avoid Shocks - To Avoid Electrical Shock, turn off electrical power to the boiler prior to
opening any electrical box within the unit. Ensure the power remains off while any
wiring connections are being made. Failure to follow these instructions may result in
component failure, serious injury or death.

Wire Protection - When passing any wiring through the cabinet of the boiler, the
installer must use wire grommets, or strain reliefs, suitable for securing the wiring and
preventing chafing. Failure to follow instructions may result in component failure,

Line Voltage Connections

Line voltage field wiring enters the back of the boiler through strain reliefs (field supplied), then routes
internally via a chase-way on the right-hand side of the boiler, to the line voltage junction box located at the
front of the boiler on the right-hand side. Remove the Front and Top-Front panels to access the junction box and
chase-way; see Figure 12-1. Secure field wiring to the chase-way using the factory supplied wire supports.
Terminate line voltage field wiring in accordance with instructions provided in Figure 12-2 and Table 12-1.

FTG 2200-2400 – the 3-phase power supply connects at a factory installed disconnect switch at the back of the

boiler; see Figure 12-1. From the disconnect, the 3-phase wiring is factory routed internally to a Fuse Block
where it is distributed to the combustion blower and 120V transformer; see Figure 12-2. NOTICE: 120V is
factory wired to the Line Voltage Junction Box.

Pump Relays – The FTG incorporates three non-powered isolation relay contacts for switching high capacity

pumps. Contact Secondary Maximum rating is 1.5HP @ 120V, 3.0HP @ 240V, or 30A. Refer to Figure 12-2
for Field Wiring requirements.

Low Voltage Connections

Low voltage field wiring enters the back of the boiler through grommets (factory supplied), then routes
internally, via a chase-way on the left-hand side of the boiler, to the low voltage junction box located at the front
of the boiler on the left-hand side. Remove the Front and Top-Front panels to access the junction box and chase­way; see Figure 12-1. Secure field wiring to the chase-way using the factory supplied wire supports. Terminate
low voltage field wiring in accordance with instructions provided in Figure 12-3 and Table 12-2.

serious injury or death.
Labeling - Label all wires prior to disconnecting them when servicing controls. Wiring

errors can cause improper and dangerous operation. Failure to follow instructions may
result in property damage or personal injury.

Continuity - Before connecting the line voltage wiring, perform a continuity check
between all wires and ground to make sure that there are no electrical leaks that could
blow a fuse or damage electrical components.

48

Figure 12-1 Wiring Terminal Access

Field wiring enters the back of the boiler through
strain reliefs/grommets, then is routed internally
via chase-ways to the junction boxes located at
the front of the boiler. Secure internal field wiring
to the chase-way using the factory supplied wire
supports. Field wiring entering the junction boxes
must pass through the factory supplied grommets.

Line Voltage Wiring

Strain Reliefs

(field supplied)

Low Voltage

Wiring Grommets

(factory supplied)

Access Cover – for

securing stain reliefs

Power Disconnect Switch

(FTG 2200/2400 illustrated)

- For FTG 2200/2400, remove cover and

connect 4-wire 3Ph power supply to switch,
as per Figure 12-2

- For FTG 600-2000, route 120V power supply

through strain reliefs, and terminate at the
line voltage Junction Box, as per Figure 12-2

Ethernet Connection

(optional kit required)

Condensate

Pump Receptacle

Field Wiring Chase-

way to Junction Box

(line voltage)

Junction Box Cover

(line voltage)

Junction Box

(line voltage)

Junction Box

(low voltage)

Junction Box Cover

(low voltage)

Field Wiring Chase-

way to Junction Box

(low voltage)

Control Panel

Installation & Operation Manual│ FTG

49

Figure 12-2 Line Voltage Field Wiring

Connection

Location

Description

L1 (120VAC)

1

Location for connecting line wire of 120V power supply.

NOTICE: 120V

power supply is factory
wired for models FTG
2200 & 2400.

L2 (Neutral)

2

Location for connecting neutral wire of 120V power supply.

GROUND

3

Location for connecting earth ground.

Non-Powered

(Dry Contacts)

DHW PUMP

(PUMP A)

4

DHW Pump Relay – Normally Open Dry Contact for DHW circulator; contact closes
during a demand for DHW. Maximum rating is 1.5HP @ 120V, 3.0HP @ 240V, or
30A.

5

BOILER

PUMP

(PUMP B)

6

Boiler Pump Relay – Normally Open Dry Contact for Boiler circulator; contact closes
during all demands. Maximum rating is 1.5HP @ 120V, 3.0HP @ 240V, or 30A.

7

CH PUMP
(PUMP C)

8

CH Pump Relay – Normally Open Dry Contact for Central Heating circulator;
contact closes during a demand for CH. Maximum rating is 1.5HP @ 120V, 3.0HP @
240V, or 30A.

9

LINE VOLTAGE

JUNCTION BOX

3PH DISCONNECT SWITCH

(FTG 2200/2400 ONLY)

Located at the back of the

boiler; see Figure 12-1

FTG │Installation & Operation Manual

50

Figure 12-3 Low Voltage Field Wiring

Installation & Operation Manual│ FTG

51

Connection

Location

Description

COM

(24VAC)

1

24VAC Common – Neutral for the 24VAC power supply from the boiler. COM can be used
in conjunction with terminal R to provide a power source for a digital thermostat.

R (24VAC)

2

24VAC Hot - Power supply for inputs EXT. LIMIT, CH1, and CH2 (LL).

3

EXT. LIMIT

4

External Limit – Input requiring 24VAC from R-terminal to permit the burner to operate.
Comes factory equipped with a jumper to the R-terminal. For installations requiring the use of
an additional safety switch, such as a Flow Switch or auxiliary temperature limit, remove the
factory installed jumper and install the normally open isolated contacts of the field supplied
additional limit.

AUX.

PROOF

5

Auxiliary Proof – Comes factory equipped with a jumper. For applications using Indoor
Combustion Air, remove jumper and replace with field supplied end switch incorporated with
motorized damper/louver control.

6

CH1

7

Central Heat Demand (Local) – Input requiring 24VAC from R-terminal to initiate a “local”
CH call. Switch is made using an isolated end switch (dry contact) via thermostat, zone
controller or other device. Typically used as the lone heat input or as the high temperature
input in dual CH temperature systems.

CH2 (LL)

8

Central Heat Demand (Lead-Lag) – Input requiring 24VAC from R-terminal to initiate a
“lead-lag” CH call. Switch is made using an isolated end switch (dry contact) via thermostat,

zone controller or other device. Typically used as a lead-lag input for cascaded boilers or as the
low temperature input in dual CH temperature systems.

ALARM

9

Normally Open Alarm Contacts – Contacts close during a lockout or other alarm condition.
May be connected to a BMS, maximum capacity of 0.63Amps at 24VAC.

10

OUTDOOR

SENSOR

11

Outdoor Temperature Sensor – A wall mountable OD Sensor is included with each boiler.

When connected to terminals 11 and 12, the control will indicate the outdoor temperature and
adjust the boiler temperature set point during a Central Heat demand.

12

DHW
13

DHW Tank Demand – Input requiring closure of terminals 13 and 14 to initiate a demand for

DHW. Switch made via isolated end switch (dry contact) from a thermostat (aquastat) located
in an Indirect Water Heater, or optional Tank Sensor (P/N 84632), see Appendix A.
(NOTICE: tank sensor cannot be used for cascade boiler arrangements).

14

SYSTEM

SENSOR

15

System Water Temperature – An optional strap-on System Sensor is available from NTI

(P/N 84010). When connected to terminals 15 and 16, the control will indicate a “CH” or
“Lead-Lag” temperature, which can be used for direct modulation of system temperature. By

default, the System Sensor becomes the Modulation Sensor for a Lead Lag demand.

16

4 -20mA

(– / +)

17

External Modulation Control – Using a 4-20mA signal, an external control can be used to
directly modulate the burner firing rate or adjust the active set point. This can be useful for
applications using external staging controls or BAS.

18

LL DATA+

19

Lead-Lag – Connects internally to the controller’s MB2, Modbus communication port.
Terminals 19, 20 and 23 (COMMUN. COM) can be "daisy-chained" to multiple boilers (up to
8 in total) for the purpose of staging.

LL DATA-

20

BMS D+

21

Building Management System (BMS) – Connects internally to the display’s COM2, Modbus
communication port. Terminals 21, 22 and 23 (COMMUN. COM) can be connected to a
Gateway for communication to a BMS or other device.

BMS D-

22

COMMUN.

COM

23

Communication Common – Common port for LL and BMS Communication wiring, as well

as the TOD input.

TOD

24

Time of Day (Night Time Setback) – Input requiring closure of terminals 24 and 23
(COMMUN. COM) to initiate TOD setback settings. Switch is made using an isolated end
switch (dry contact) using a timer, BAS or other device.

FTG │Installation & Operation Manual

52

Figure 13-1 FTG Connection Diagram

Installation & Operation Manual│ FTG

13.0 WIRING SCHEMATICS

53

Figure 13-2 FTG Ladder-Logic Diagram

FTG │Installation & Operation Manual

54

Installation & Operation Manual│ FTG

14.0 INSTALLATION CHECKLIST
Installation

 1. If operating on Propane Gas, convert boiler using the applicable Natural Gas to LP Conversion

Instructions.

 2. Locate the boiler in accordance with Section 3.0 of this manual.
 3. Install the Vent/Air-inlet piping in accordance with Sections 4.0 and 5.0 of this manual. Ensure all

joints are secured and cemented properly. Perform the Mandatory Pre-commissioning Procedure for
Plastic Venting in Section 4.0.

 4. Connect the condensate trap and drain in accordance with Section 6.0 of this manual.
 5. Connect the gas supply in accordance with Section 7.0 of this manual.
 6. Install the plumbing in accordance with this manual. Flush/cleanse the internals of the heating system.

Treat system water with Fernox F1 Protector when needed.

 7. Connect field wiring in accordance with Section 12.0 of this manual.
 8. Advise home/building owner of their responsibilities with respect to maintaining the boiler.

The building owner is responsible for keeping the Vent/Air-inlet termination free of snow,
ice, or other potential blockages and for scheduling boiler routine maintenance as

described in the next section. Failure to properly maintain the boiler may result in serious injury or death.

Start-up

Allow primers/cements to cure for 8 hours prior to Start-up. If curing time is less than 8
hours, first perform Steps 2 through 6 of Mandatory Pre-commissioning Procedure for
Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosion,

 1. Turn gas shut-off valve to the ON position.
 2. Turn Power on to the boiler.
 3. Set Controller to the desired settings.
 4. Turn thermostat up, Ignition will occur.

Operational Checklist

 1. System is free of gas leaks.
 2. System is free of water leaks.
 3. Water pressure is maintained above 15 PSI.
 4. All air is purged from the heating system piping.
 5. Ensure proper water flow rate; unit must not kettle, bang, hiss or flash the water to steam.
 6. Ensure gas line pressure is in accordance with Section 9.0.
 7. System is free of combustion leaks.
 8. Unit must operate smoothly.
 9. Ensure the flue gas combustion readings are within the tolerances listed in Table 9-1.
 10. Each ignition must be smooth.
 11. Verify that all condensate lines are clean and drain freely.

Before Leaving

 1. Seal the Line Pressure Test Port fitting on the inlet flange of the gas valve;, test for leaks. See Section 9.0.
 2. Install flue gas test port plug and test for leaks, see Section 9.0.
 3. Allow the boiler to complete at least one heating cycle, or to operate for at least 15 minutes.
 4. Always verify proper operation after servicing.

Instructions to Installing Contractor

 1. Ensure that the customer receives the Warranty Documentation included with the installation manual.
 2. Leave the manual with the customer so they know when to call for annual maintenance and inspection.

serious injury or death.

This boiler must have water flowing through it whenever the burner is firing. Failure to
comply may damage the unit, void the warranty, and cause serious injury or death.

Allowing the boiler to operate with a dirty combustion chamber will adversely affect its
operation and void the warranty. Failure to clean the heat exchanger on a frequency that
matches the need of the application may result in fire, property damage, or death.

FTG │Installation & Operation Manual

55

15.0 ANNUAL MAINTENANCE AND INSPECTION

This unit must be inspected at the beginning of every heating season by a Qualified Technician.

Annual Inspection Checklist

 1. Lighting is smooth and consistent, and the combustion fan is noise & vibration free.
 2. The condensate drain flows freely, and is cleaned of sediment.
 3. Pressure Relief Valve and air vents are not weeping.
 4. Low water cut off is tested (remove and clean a minimum of once every 5 years, see Section 10.0)
 5. Examine all venting for evidence of leaks. Ensure vent screens are cleaned and clear of debris.
 6. Check the burner plate for signs of leaking.
 7. The combustion chamber must be cleaned (cleaning frequency based on need for application – see below)
 8. Keep boiler area clear/free from combustible materials, gasoline, and other flammable vapors and liquids.
 9. Ensure there is nothing obstructing the flow of combustion and ventilation air.
 10. Listen for water flow noises indicating a drop in boiler water flow rate.

Important - The hydronic system may need to be flushed to eliminate hard water scale
(Use Fernox DS-40 Descaler, NTI PN: 83450).

 11. Verify proper operation after servicing.

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

Combustion Chamber Cleaning Procedure

The combustion chamber must be cleaned after the first year of operation, with subsequent cleanings scheduled
based on the condition of the combustion chamber at the time of the first cleaning. Units operating with LP Gas
or in an industrial environment may require more frequent cleanings.

Crystalline Silica - Read carefully the warnings and handling instructions pertaining to
Refractory Ceramic Fibers before commencing any service work in the combustion
chamber. Take all necessary precautions and use recommended personal protective
equipment as required.

Cleaning Instructions (contact NTI for a more detailed procedure)

1. Power Down – Remove the demand for heat, allow the post-purge cycle to finish, turn gas and power supply

off. Ensure the combustion chamber has cooled before proceeding.

2. Remove Display Assembly – Working inside the cabinet, disconnect tubing and wiring from the display

assembly, remove the display assembly as a whole, leaving the junction boxes attached to the boiler cabinet.

3. Remove Blower, Venturi & Transfer-tube as an Assembly – Disconnect wiring from the Blower, unbolt

the gas-line and remove tubing from the Venturi, and then disconnect the Transfer-tube for the Burner Door.
Remove the Blower, Venturi and Transfer-tube as an assembly. Be careful not to damage or misplace any of
the gaskets – replace if damaged.

4. Remove Burner from the Burner Door; be careful not to damage the gasket – replace if damaged. Inspect

burner for signs of damage – do not re-use a damaged burner.

5. Remove Burner Door – Disconnect wiring from the ignition and flame sensing electrodes, remove the 12

nuts/bolts securing the door to the heat exchanger. Remove the Burner Door, being careful not to damage the
combination gasket/insulation on the inside of the door – replace if damaged.

6. Remove Rear Combustion Chamber Door (if necessary) – From the rear of the boiler, remove the screws

securing the middle access panel to the back of the boiler cabinet. Remove the 12 nuts/bolts securing the rear
door to the heat exchanger and remove the door; be careful not to damage the combination gasket/insulation
on the inside of the door – replace if damaged.

7. Inspect Combustion Chamber – Assess the level of debris inside combustion chamber and at the entrance

to the flue passageways; future cleanings should be scheduled based on this assessment.

8. Clean Combustion Chamber – Vacuum any loose debris or dust, then use a garden hose with a trigger

nozzle to direct pressurized water through the heat exchanger tubes; the water will exit via the condensate
drain on the back. Continue process until the tubes are clear and the water runs clean. Use dry rags or plastic
to protect electrical components from being damaged by dripping or spraying water.

56

Reduce the Risk of Exposure

Precautions and Recommended Personal Protective Equipment

Avoid contact with skin and eyes

 Wear long-sleeved clothing, gloves, and safety goggles or glasses.

Avoid breathing in silica dust

 Wear a respirator with an N95-rated filter efficiency or better. 1
 Use water to reduce airborne dust levels when cleaning the combustion chamber.
 Do not dry sweep silica dust. Pre-wet or use a vacuum with a high efficiency filter.

Avoid transferring contamination

 When installing or removing RFCs, place the material in a sealable plastic bag.
 Remove contaminated clothing after use. Store in sealable container until cleaned.
 Wash contaminated clothing separately from other laundry.

First Aid Measures

If irritation persists after implementing first aid measures consult a physician.

 Skin - Wash with soap and water.
 Eyes - Do not rub eyes; flush with water immediately.
 Inhalation – Breathe in fresh air; drink water, sneeze or cough to clear irritated

passage ways.

1

Respirator recommendations based on CCOHS and OSHA requirements at the time this document was written. Consult

your local regulatory authority regarding current requirements for respirators, personal protective equipment, handling,
and disposal of RCFs.

For more information on Refractory Ceramic Fibers, the risks, recommended handling procedures and acceptable disposal
practices contact the organization(s) listed below:

Canada (CCOHS): Telephone directory listing under

Government Blue Pages Canada—Health and Safety—
Canadian Centre for Occupational Health and Safety; or
website http://www.ccohs.ca.

United States (OSHA): Telephone directory listing under
United States Government—Department of Labor—
Occupational Safety and Health Administration; or website
http://www.osha.gov.

Installation & Operation Manual │ FTG

9. Condensate Trap – Disassemble the condensate trap and thoroughly clean it; then reassemble and securely

connect it to the boiler condensate drain, see Section 6.0.

10. Reassemble – Assembly is in the reverse order as disassembly. Inspect all gaskets and insulation prior to

assembly – replace if damaged.

11. Perform the Start-up and Operational Checklist – See Section 14.0.

Replace gaskets and insulation that show any signs of damage – DO NOT RE-USE.
Failure to follow these instructions may result in fire, property damage or death.

Refractory Ceramic Fibers (RFC)

Personal Protective Equipment Recommended - Read the following warnings and
handling instructions carefully before commencing any service work in the combustion
chamber. The insulating material on the inside of the burner plate contains Refractory
Ceramic Fibers and should not be handled without personal protective equipment.

Potential Carcinogen - Use of Refractory Ceramic Fibers in high temperature

applications (above 1000oC) can result in the formation of Crystalline Silica
(cristobalite), a respirable silica dust. Repeated airborne exposure to crystalline silica dust may result in chronic
lung infections, acute respiratory illness, or death. Crystalline silica is listed as a (potential) occupational
carcinogen by the following regulatory organizations: International Agency for Research on Cancer (IARC),
Canadian Centre for Occupational Health and Safety (CCOHS), Occupational Safety and Health Administration
(OSHA), and National Institute for Occupational Safety and Health (NIOSH). Failure to comply with handling
instructions in Table 15-1 may result in serious injury or death.

maintenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to
Table 15-1 for handling instruction 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).

Table 15-1 Handling Instructions for Refractory Ceramic Fibers (RCF)

Crystalline Silica - Certain components confined in the combustion chamber may

contain this potential carcinogen. Improper installation, adjustment, alteration, service or

57

Applicable
Models

Desciption

Location

Component(s) Fused

FTG 600-2400

Ignition Transformer
(120V, 7A)

Right side of control panel

Ignition Transformer

FTG 600-1400

24V Transformer
(24V, 3A – Circuit Breaker)

24V Transformer (on control
panel)

All 24V Components:

- Control board

- Touchscreen display

- Gas Valve

- Limit switches

- Thermostat circuit

- Pump Relays

FTG 2000-2400

24V Transformer – Secondary
(24V, 10A)

Secondary/left-side of 24V
Transformer (on control
panel)

24V Transformer – Primary
(120V, 5A)

Primary/right-side of 24V
Transformer (on control
panel)

24V Transformer

FTG 2200-2400

120V Transformer – Primary
(208/240V, 10A)

Primary/left-side of 120V
Transformer (behind control
panel)

120V Transformer

120V Transformer –
Secondary
(120V, 10A)

Secondary/right-side of 120V
Transformer (behind control
panel)

All 120V Components:

- 24V Transformer

- Ignition Transformer

- Convenience Outlet

- L1 120V Power Supply to Line

Voltage Junction Box

3Ph Fuse Block
(208/240V, 15A, X 3)

3Ph Fuse Block, left of 120V
Transformer (behind control
panel)

All 208/240V Components:

- Combustion Blower

- 120V Transformer

Note:

1

Refer to Figure 16-1 for locating internal fusing.

FTG │Installation & Operation Manual

16.0 TROUBLESHOOTING

Servicing the Boiler

 Disconnect or shutoff all energy sources to the boiler: 120VAC power, water and gas.
 Identify and mark wires before disconnecting or removing them.
 Never bypass electrical fuses or limit devices except temporarily for testing.
 Use proper personal protective equipment (PPE) i.e. eye protection, safety footwear.

These procedures should only be performed by qualified service personnel, when abnormal operation of the
boiler is suspected. The boiler incorporates a sophisticated microprocessor based control which normally
responds appropriately to varying conditions. If the boiler operation appears to be incorrect, or it is not
responding at all to a demand for heat, the following is suggested to determine and correct the problem.

Internal Fusing

The power supply to the FTG boiler must be externally fused (or protected via a circuit breaker) according to its
rating plate. In addition, each FTG integrates internal circuit protection, as defined in Table 16-1.

Table 16-1 Internal Circuit Protection – Fusing

Observe the following precautions when servicing the boiler. Failure to comply with

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

Before undertaking any troubleshooting procedures it is highly recommended to have

available a digital multimeter (s) capable of measuring AC and DC volts, Amperes,

Resistance (Ohms) and Continuity.

58

Figure 16-1 FTG Internal Fusing

SHOCK HAZARD – Failure to turn the power supply off at the source prior to

accessing and testing fuses may result in electrical short causing component failure,
fire and property damage, or electrical shock causing serious injury or death.

Only replace fuses with identical parts, see Figure 16-1. Failure to follow this warning
may result in component failure, fire, property damage, serious injury or death.

Control Panel

Cover

120V Transformer

(FTG 2200-2400 Only)

o 208/240V Primary – 10A Fuse
o 120V Secondary – 10A Fuse

24V Transformer (FTG 600-1400)

o 24V Secondary – Circuit Breaker

24V Transformer (FTG 2000-2400)

o 120V Primary – 5A Fuse
o 24V Secondary – 10A Fuse

3Ph Fuse Block (remove
cover to access fuses –

FTG 2200-2400 Only)

o 208/240V – 3 x 15A Fuses

Ignition Transformer Fuse

(right-side of control panel)

o 120V – 7A Fuse

Installation & Operation Manual │ FTG

Summary and Diagnostics Display – The FTG controller and Touchscreen display provides detailed

operational and diagnostic information for aid in troubleshooting. When power is applied to the appliance the
initial page displayed is the Summary page. Information presented on the Summary page includes Demand
source, Burner state, status of sensors and pumps, and so forth. Any current Alert or Lockout condition is also
displayed. Accessible from the Summary page are the Configuration, Diagnostics, Details and History pages.
Refer to Appendix A - Controller and Touchscreen Display Instructions for more information.

Lockout and Alert History – The controller maintains a record of the fifteen (15) most recent events for both

Lockouts and Alerts. To display the logs, touch the History button on the Summary page (refer to Appendix
A - Controller and Touchscreen Display Instructions). In any situation where a malfunction is suspected,

always check the Alerts and Lockouts history. Entries recorded in the history provide useful information for
determining the cause of the malfunction.

59

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

Burner not operating

Heat demand satisfied; no call for heat

Check Demand and Setpoints via Touchscreen.
Check thermostat and DHW aquastat settings (as
applicable).

Appliance outlet temperature exceeds
“Setpoint - On Hysteresis”

Check outlet temperature, setpoint and hysteresis
settings via Touchscreen.

Hold, Delay or Lockout

Check Summary page on Touchscreen for code.

Burner switch off

Check Summary page, if Demand indicates “Burner

switch off” go to diagnostics burner test page and

switch on.

Lockout 2 – Waiting for safety
data verification

Safety parameter(s) has been adjusted

Changing settings that are considered safety
parameters require “Safety data verification”. Refer
to Appendix A.

Lockout 9 – Flame bias out of
range

4-20mA input being overdriven.

If using 4-20mA input, check to ensure current is
not greater than 21mA.

Control malfunction

Cycle power, if problem returns replace control.

Hold 27 – Flame sensor shorted
to ground detected

A flame circuit shorted to ground may
show up as a flame circuit timeout.
Zero-Ohm shorts can display as Hold

27.

Check to ensure condensate drain is not blocked.
Check to ensure no external voltage is applied to R
& CH terminals. If using 4-20mA input, check to
ensure current is not greater than 21mA.

Hold 61 – Anti short-cycle

Normal operation

Allow timer to expire, or reduce Anti short-cycle
setting as needed (See Appendix A)

Hold 62 – Fan speed not proved

Normal Operation (Drive to Lightoff)

Hold 62 is momentarily displayed prior to burner
ignition during the Drive to Lightoff.

Wiring defect

Inspect blower wiring, ensure connectors at Sola
controller and blower are securely attached.

- Faulty Sola controller

- Faulty Blower

If Hold 62 persists for 15 seconds or more, while
the blower is running, check "Fan speed" indicated
on display. If "LOW RPM", "HIGH RPM", “0” or
rapidly changing RPM value is displayed, try
connecting another Sola controller. If problem
remains, replace blower.

Hold 63 – LCI OFF (Limit
control input)

Incorrect Sola controller.

Replace control with correct model (Replacement
part number 85421)

Hold 65 – Interrupted Air
Switch OFF

Incorrect Sola controller.

Replace control with correct model (Replacement
part number 85421)

Hold 66 – Interrupted air switch
ON

Incorrect Sola controller.

Replace control with correct model (Replacement
part number 85421)

Hold / Lockout 67 – ILK OFF

LWCO Switch

Low Water Cutoff switch has opened – check for
proper water level and pressure; ensure the air is
adequately purged from the boiler system. Reset
the LWCO then clear lockout. If error continues,
clean LWCO probe or replace LWCO.

Bloc’d Condensate Switch

Blocked Condensate Switch has opened –
condensate is not draining from the boiler, or the
exhaust venting is too restrictive or has a blockage.
Check for blockages in the condensate trap and
drain; clean accordingly. If drain is not blocked,
check for blockages/restrictions in the exhaust
venting, then clear the lockout.

FTG │Installation & Operation Manual

60

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

Bloc’d Filter Switch

Blocked Air Filter Switch has opened – clean or
replace the air filter and clear the lockout.

WARNING: DO NOT OPERATE THE
BOILER WITHOUT THE AIR FILTER,
CONTAMINANTS WILL ENTER THE
BURNER RESULTING IN INPROPER
OPERATION LEADING TO PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.

Lo Gas Pres. Switch

Low Gas Pressure Switch has opened – the
incoming gas line pressure has dropped below 3.5
in. w.c., causing the low gas pressure switch
(mounted to the side of the gas valve) to open.
Correct gas line pressure problem then clear the
lockout.

Hi Gas Pres. Switch

High Gas Pressure Switch has opened – the gas
valve manifold pressure exceed 3 in. w.c., causing
the high gas pressure switch (installed down-stream
of the gas valve) to open. CONTACT NTI FOR
ASSISTANCE

Ext. Limit Switch

An External Limit Device (field installed and wired

to the “Ext. Limit” contact of the boiler) has

opened. Not a problem with boiler, check the
external limit device.

Aux. Proof Switch

Auxilary Proof Switch (field installed and wired to

the “Aux. Proof” contact of the boiler) has opened.

Not a problem with the boiler, check the auxiliary
proof switch.

Lockout or Hold 79 – Outlet
High Limit

CH or DHW settings

Check if CH and/or DHW setpoint temperature plus
off hysteresis exceed “High limit” setpoint – factory
setting = 210°F (99°C).

CH or DHW pump problem

See "Inoperative CH or DHW pump" below.

Incorrect “Outlet high limit” setting

Increase “Outlet high limit” setting; maximum

setting = 210°F (99°C).

Lockout or Hold 81 – Delta T
limit
OR
Appliance making banging or
hissing sounds

Insufficient water flow

 Check appliance pump.
 Ensure plumbing is correct. Refer to Section

10.0 System Piping. Check that water pressure is
at least 15PSI.

 Boiler heat transfer surfaces may be fouled with

scale or magnetite. Clean with Fernox DS-40
Descaler and Cleanser. See Table 10-1.

Lockout 82 – Stack limit

Dirty heat exchanger

Inspect and if required clean the combustion
chamber and/or heat exchanger. Refer to Section

15.0 Annual Maintenance and Inspection and
Section 10.0 Boiler and Heating System Piping.

Incorrect “Stack limit setpoint”

Unless installed in Canada with PVC exhaust

venting, set “Stack limit setpoint” to maximum

setting of 220ºF (104ºC). In Canada PVC exhaust
venting is limited to 149ºF (65ºC).

Faulty sensor

Check resistance of sensor and compare to
thermistor resistance chart, see Table 16-2.

Lockout or Hold 85 –
Inlet/Outlet Inversion Limit

Pump flowing in the wrong direction

Ensure water circulation through the boiler is in the
correct direction, see Figure 10-1.

Incorrect factory sensor wiring

Disconnect flue sensor cable; screen should display
“Hold 95 – Stack sensor fault”; if not contact NTI.

Installation & Operation Manual │ FTG

61

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

Lockout or Hold 88 – Outlet T
Rise limit

Insufficient water flow

See Lockout or Hold 81.

Hold 91– Inlet sensor fault

Sensor disconnected

Check sensor connection located on the bottom of
the heat exchanger. Check connection on control
board.

Faulty sensor

Check resistance of sensor and compare to
thermistor resistance chart, see Table 16-2.

Hold 92 – Outlet sensor fault

Sensor disconnected

Check sensor connection located on the top of the
heat exchanger. Check connection on control
board.

Faulty sensor

Check resistance of sensor and compare to
thermistor resistance chart, see Table 16-2. (Note
the Outlet sensor incorporates two sensors, check
resistance individually.)

Hold 95 – Stack sensor fault

Sensor disconnected

Check sensor connection located at the bottom of
the flue pipe inside the boiler cabinet. Check
connection on control board.

Hold 95 – Stack sensor fault

Faulty sensor

Check resistance of sensor and compare to
thermistor resistance chart, see Table 16-2. (Note
the Outlet sensor incorporates two sensors, check
resistance individually.)

Lockout 109 – Ignition failure
occurred

Spark cable disconnected

Ensure that the high voltage spark cable is securely
connected to the spark generator and the igniter
electrode. Check that the green ground wire is
securely attached to the ¼” quick connect tab on the
igniter electrode.

Blocked venting

Check for blockage of the exhaust-vent, air-inlet,
combustion blower, gas valve venturi, burner heat
exchanger etc.

Blocked condensate drain.

Clean condensate trap, inspect condensate drain for
blockages and build-up – correct accordingly.

Insufficient gas line pressure

Ensure the manual gas shutoff valve is open. Refer
to Section 9.0 GAS VALVE AND BURNER
SETUP.

Flame sensor disconnected

Verify that the flame rod signal wire is securely
attached to the flame rod and the Sola controller.

No 120VAC to Spark Generator

Check wiring from Sola controller to spark
generator. With an AC voltmeter measure voltage
across J5-6 and ground (the Sola controller chassis
is connected to the 120VAC supply ground) during
trial for ignition.

Faulty Spark Generator

During trial for ignition check for arc on spark
electrode via the observation port located next to the
spark electrode in the burner door. If the spark
generator is receiving 120VAC and no spark is
observed, replace the spark generator.

No 24VAC to Gas Valve

Check the wiring harness for loose or interrupted
connections of the gas valve wiring. With an AC
voltmeter, measure the voltage between Sola
controller terminals J5-2 to J4-10. There should be
24VAC present during trial for ignition, if not
replace Sola controller.

FTG │Installation & Operation Manual

62

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

Faulty Gas Valve

The gas valve emits an audible click when it
switches on or off. If the Sola controller is providing
24VAC to the gas valve, and the wiring is intact, it
should be possible to detect if the valve is
responding.

Lockout 113 – Flame circuit
timeout

A flame circuit shorted to ground may
show up as a flame circuit timeout.
High resistance shorts can display as
Lockout 113.

Check to ensure condensate drain is not blocked.
Check to ensure no voltage is applied to R & CH
terminals. If using 4-20mA input, check to ensure
current is not greater than 21mA.

Lockout 122 – Lightoff rate
proving failed

Blower is not turning on

See “Blower not operating” below.

Missing or incorrect blower feedback
signal

See Hold 62 above.

Blower is always on

See “Blower operating at high speed while burner is
off” below.

Alert 128 - Modulation rate was
limited due to IAS open

Incorrect Sola controller.

Replace control with correct model.
Hold 137 – ILK failed to close

See Hold / Lockout 67

Lockout 138 – Flame too low

Blocked venting

Check for blockage of the exhaust-vent, Air-inlet,
combustion blower, gas valve venturi, heat
exchanger etc.

Fowled or faulty flame sensor

Inspect flame sensor for cracks of fowling, clean or
replace as necessary.

Incorrect combustion settings

Check combustion settings, correct accordingly.

Lockout 173 - Pilot relay
feedback incorrect

Lockout 174 – Safety relay
feedback incorrect

External Electrical Noise

Look for sources of electrical noise, i.e. a large
motor or multiple pieces of equipment starting at the
same time.

Failing Limit Switch in ILK circuit

Check operation of internal LWCO, and/or external

limit (i.e. devise connected between “R” and
“LIM”); replace as necessary

Hardware failure of Sola controller

Reset power, If problem persists replace Sola
controller.

Alert 206 – Lead Lag header
temperature was invalid

System Sensor not connected

If desired, install System Sensor and wire to
SENSOR input connections “SYSTEM” and
“COM”. Otherwise ignore Alert 206

Alert 233 – Lead Lag outdoor
temperature was invalid

See Alert 248

Alert 248 – CH outdoor
temperature was invalid

Outdoor sensor not connected

The FTG is factory set with Outdoor Reset enabled.
Connect outdoor sensor or disable Outdoor Reset.

Outdoor sensor wiring

Check wiring of outdoor sensor. Wires should

connect to SENSOR inputs “OUTDOOR” and

“COM”.

Faulty sensor

Check sensor. Should be free of ice and snow.
Check resistance of sensor and compare to
thermistor resistance chart, see Table 16-2.

Alert 448 – Flame too low

Blocked venting, dirty heat
exchanger, failing flame sensor, poor
combustion settings.

Indicates that the burner had to shut down due to
insufficient flame signal. If Alert persists, refer to
Lockout 138.

Alert 449 – Modulation rate
was limited due to flame
strength

Normal operation

Indicates that the minimum permissible modulation
rate was temporarily increased due to low flame
signal strength. If Alert persists, refer to Lockout

138.

Inoperative CH and/or DHW

Blown fuse

Check Fuse "B".

Installation & Operation Manual │ FTG

63

PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

pump

Faulty Sola controller

If Fuse “B” not blown, and Sola controller is
operating, navigate to pump diagnostic on display.
Manually switch pump on, check for 120VAC at
pump connection terminal on line voltage barrier
strip. If 120VAC not detected, replace Sola
controller.

Faulty pump

If 120VAC supplied to pump, and pump does not
operate, replace pump.

Blower operating at high speed
while burner is off

Blower signal cable disconnected

 Verify that the 5-position Molex connector on

the wiring harness is securely connected to its
mating connector on the blower.

 Check that the 4-position Molex connector on

wiring harness is securely connected to its
mating connector on the Sola controller.

No 24VAC to Sola controller

 Check Power LED on Sola controller.
 Reset breaker at 24VAC transformer.
 With an AC voltmeter measure voltage at

terminals J8 1 & 2, 24VAC should be present.

Blower not operating

Blower power disconnected

Verify that the 3-position Molex connector on the
wiring harness is securely connected to its mating
connector on the blower.

Faulty blower

Measure voltage across pins 1 & 2 (black and white
wires) of 3-position connector on wiring harness. If
120VAC detected, reconnect then and remove 5­position signal connector. Blower should rotate at
high speed. If blower does not rotate, replace
blower.

Table 16-2 Thermistor Resistance vs. Temperature

Temp °F (°C)

Resistance Ohms (Ω)

Temp °F (°C)

Resistance Ohms (Ω)

-22 (-30)

176,133

122 (50)

3,603

-4 (-20)

96,761

131 (55)

2,986

14 (-10)

55,218

140 (60)

2,488

32 (0)

32,650

149 (65)

2,083

41 (5)

25,390

158 (70)

1,752

50 (10)

19,900

167 (75)

1,481

59 (15)

15,710

176 (80)

1,258

68 (20)

12,490

185 (85)

1,072

77 (25)

10,000

194 (90)

918

86 (30)

8,057

203 (95)

789

95 (35)

6,531

212 (100)

680

104 (40)

5,327

230 (110)

506

113 (45)

4,369 - -

FTG │Installation & Operation Manual

64

Table 16-3 Hold and Lockout Codes

Code

Description

Note

0

None

Hold / No lockout

1

Unconfigured safety data

Lockout

2

Waiting for safety data verification

Lockout

3

Internal fault: Hardware fault

Hold

4

Internal fault: Safety Relay key feedback error

Hold

5

Internal fault: Unstable power (DCDC) output

Hold

6

Internal fault: Invalid processor clock

Hold

7

Internal fault: Safety relay drive error

Hold

8

Internal fault: Zero crossing not detected

Hold

9

Internal fault: Flame bias out of range

Hold

10

Internal fault: Invalid Burner control state

Lockout

11

Internal fault: Invalid Burner control state flag

Lockout

12

Internal fault: Safety relay drive cap short

Hold

13

Internal fault: PII shorted to ILK

Hold / Lockout

14

Internal fault: HFS shorted to LCI

Hold / Lockout

15

Internal fault: Safety relay test failed due to feedback ON

Lockout

16

Internal fault: Safety relay test failed due to safety relay OFF

Lockout

17

Internal fault: Safety relay test failed due to safety relay not OFF

Lockout

18

Internal fault: Safety relay test failed due to feedback not ON

Lockout

19

Internal fault: Safety RAM write

Lockout

20

Internal fault: Flame ripple and overflow

Hold

21

Internal fault: Flame number of sample mismatch

Hold

22

Internal fault: Flame bias out of range

Hold

23

Internal fault: Bias changed since heating cycle starts

Hold

24

Internal fault: Spark voltage stuck low or high

Hold

25

Internal fault: Spark voltage changed too much during flame sensing time

Hold

26

Internal fault: Static flame ripple

Hold

27

Internal fault: Flame rod shorted to ground detected

Hold

28

Internal fault: A/D linearity test fails

Hold

29

Internal fault: Flame bias cannot be set in range

Hold

30

Internal fault: Flame bias shorted to adjacent pin

Hold

31

Internal fault: SLO electronics unknown error

Hold

32

Internal fault: Safety Key 0

Lockout

33

Internal fault: Safety Key 1

Lockout

34

Internal fault: Safety Key 2

Lockout

35

Internal fault: Safety Key 3

Lockout

36

Internal fault: Safety Key 4

Lockout

37

Internal fault: Safety Key 5

Lockout

38

Internal fault: Safety Key 6

Lockout

39

Internal fault: Safety Key 7

Lockout

40

Internal fault: Safety Key 8

Lockout

41

Internal fault: Safety Key 9

Lockout

42

Internal fault: Safety Key 10

Lockout

43

Internal fault: Safety Key 11

Lockout

44

Internal fault: Safety Key 12

Lockout

45

Internal fault: Safety Key 13

Lockout

46

Internal fault: Safety Key 14

Lockout

47

Flame rod to ground leakage

Hold

48

Static flame (not flickering)

Hold

Installation & Operation Manual │ FTG

65

Table 16-3 Hold and Lockout Codes

Code

Description

Note

49

24VAC voltage low/high

Hold

50

Modulation fault

Hold

51

Pump fault

Hold

52

Motor tachometer fault

Hold

53

AC inputs phase reversed

Lockout

54

Safety GVT model ID doesn’t match application’s model ID

Lockout

55

Application configuration data block CRC errors

Lockout

56-57

RESERVED

58

Internal fault: HFS shorted to IAS

Lockout

59

Internal fault: Mux pin shorted

Lockout

60

Internal fault: HFS shorted to LFS

Lockout

61

Anti short cycle

Hold

62

Fan speed not proved

Hold

63

LCI OFF

Hold

64

PII OFF

N/A

65

Interrupted Airflow Switch OFF

Hold

66

Interrupted Airflow Switch ON

Hold

67

ILK OFF

Hold

68

ILK ON

N/A

69

Pilot test hold

Hold

70

Wait for leakage test completion

Hold

71

Input power frequency mismatch

Lockout

72-77

RESERVED

78

Demand lost in run

Hold

79

Outlet high limit

Hold

80

DHW high limit

Disabled

81

Delta T limit

Hold / Lockout

82

Stack limit

Lockout

83

Delta T exchanger/outlet limit

Disabled

84

Delta T inlet/exchanger limit

Disabled

85

Inlet/Outlet inversion limit (See Table 16-2)

Hold

86

Exchanger/outlet inversion limit

Disabled

87

Inlet/exchanger inversion limit

Disabled

88

Outlet T-Rise limit (See Table 16-2)

Lockout

89

Exchanger T-rise limit

Disabled

90

Heat exchanger high limit

Disabled

91

Inlet sensor fault

Hold

92

Outlet sensor fault

Hold

93

DHW sensor fault

Hold

94

Header sensor fault

Hold

95

Stack sensor fault

Hold

96

Outdoor sensor fault

Hold

97

Internal fault: A2D mismatch

Lockout

98

Internal fault: Exceeded VSNSR voltage tolerance

Lockout

99

Internal fault: Exceeded 28V voltage tolerance

Lockout

100

Pressure sensor fault

Hold

101

Exchanger sensor fault

Disabled

102-104

RESERVED

105

Flame detected out of sequence

Hold / Lockout

FTG │Installation & Operation Manual

66

Table 16-3 Hold and Lockout Codes

Code

Description

Note

106

Flame lost in MFEP

Lockout

107

Flame lost early in run

Lockout

108

Flame lost in run

Lockout

109

Ignition failed

Lockout

110

Ignition failure occurred

Hold

111

Flame current lower than WEAK threshold

Hold

112

Pilot test flame timeout

Lockout

113

Flame circuit timeout

Lockout

114-115

RESERVED

116

Wait for OK to Run

Disabled

117

Flap valve condensate fault

Disabled

118

Controller interaction system fault

Hold

119

Controller interaction communications fault

Hold

120

Flap valve backflow fault

Disabled

121

Flap valve fault

Disabled

122

Light off rate proving failed

Lockout

123

Purge rate proving failed

Lockout

124

High fire switch OFF

Hold

125

High fire switch stuck ON

Hold

126

Low fire switch OFF

Hold

127

Low fire switch stuck ON

Hold

128

Fan speed failed during pre-purge

Hold / Lockout

129

Fan speed failed during pre-ignition

Hold / Lockout

130

Fan speed failed during ignition

Hold / Lockout

131

Fan movement detected during standby

Hold

132

Fan speed failed during run

Hold

133-135

RESERVED

136

Interrupted Airflow Switch failed to close

Hold

137

ILK failed to close

Hold

138

Flame too low

Lockout

139-142

RESERVED

143

Internal fault: Flame bias out of range 1

Lockout

144

Internal fault: Flame bias out of range 2

Lockout

145

Internal fault: Flame bias out of range 3

Lockout

146

Internal fault: Flame bias out of range 4

Lockout

147

Internal fault: Flame bias out of range 5

Lockout

148

Internal fault: Flame bias out of range 6

Lockout

149

Flame detected

Hold / Lockout

150

Flame not detected

Hold

151

High fire switch ON

Hold / Lockout

152

Combustion pressure ON

Hold / Lockout

153

Combustion pressure OFF

Hold / Lockout

154

Purge fan switch ON

Hold / Lockout

155

Purge fan switch OFF

Hold / Lockout

156

Combustion pressure and Flame ON

Hold / Lockout

157

Combustion pressure and Flame OFF

Lockout

158

Main valve ON

Lockout

159

Main valve OFF

Lockout

160

Ignition ON

Lockout

Installation & Operation Manual │ FTG

67

Table 16-3 Hold and Lockout Codes

Code

Description

Note

161

Ignition OFF

Lockout

162

Pilot valve ON

Lockout

163

Pilot valve OFF

Lockout

164

Block intake ON

Lockout

165

Block intake OFF

Lockout

166-168

RESERVED

169

Safety opto bad in test state

Lockout

170

Safety relay opto feedback incorrect

Lockout

171

Safety relay feedback incorrect in run

Lockout

172

Main relay feedback incorrect

Lockout

173

Pilot relay feedback incorrect

Lockout

174

Safety relay feedback incorrect

Lockout

175

Safety relay open

Lockout

176

Main relay ON at safe start check

Lockout

177

Pilot relay ON at safe start check

Lockout

178

Safety relay ON at safe start check

Lockout

179-180

RESERVED

181

Invalid Blocked condensate enable setting

Disabled

182

Invalid J7-1 configuration, both LFS and Blocked condensate

Disabled

183

Invalid J7-2 configuration, both HFS and Flap valve

Disabled

184

Invalid BLOWER/HSI output setting

Lockout

185

Invalid Delta T limit enable setting

Lockout

186

Invalid Delta T limit response setting

Lockout

187

Invalid DHW high limit enable setting

Lockout

188

Invalid DHW high limit response setting

Lockout

189

Invalid Flame sensor type setting

Lockout

190

Invalid interrupted air switch enable setting

Lockout

191

Invalid interrupted air switch start check enable setting

Lockout

192

Invalid Igniter on during setting

Lockout

193

Invalid Ignite failure delay setting

Lockout

194

Invalid Ignite failure response setting

Lockout

195

Invalid Ignite failure retries setting

Lockout

196

Invalid Ignition source setting

Lockout

197

Invalid Interlock open response setting

Lockout

198

Invalid Interlock start check setting

Lockout

199

Invalid LCI enable setting

Lockout

200

Invalid light off rate setting

Lockout

201

Invalid Light off rate proving setting

Lockout

202

Invalid Main Flame Establishing Period time setting

Lockout

203

Invalid MFEP flame failure response setting

Lockout

204

Invalid NTC sensor type setting

Lockout

205

Invalid Outlet high limit response setting

Lockout

206

Invalid Pilot Flame Establishing Period setting

Lockout

207

Invalid PII enable setting

Lockout

208

Invalid pilot test hold setting

Lockout

209

Invalid Pilot type setting

Lockout

210

Invalid Post-purge time setting

Lockout

211

Invalid Power up with lockout setting

Lockout

212

Invalid Pre-ignition time setting

Lockout

FTG │Installation & Operation Manual

68

Table 16-3 Hold and Lockout Codes

Code

Description

Note

213

Invalid Pre-purge rate setting

Lockout

214

Invalid Pre-purge time setting

Lockout

215

Invalid Purge rate proving setting

Lockout

216

Invalid Run flame failure response setting

Lockout

217

Invalid Run stabilization time setting

Lockout

218

Invalid Stack limit enable setting

Lockout

219

Invalid Stack limit response setting

Lockout

220

Unconfigured Delta T limit set point setting

Lockout

221

Unconfigured DHW high limit set point setting

Lockout

222

Unconfigured Outlet high limit set point setting

Lockout

223

Unconfigured Stack limit set point setting

Lockout

224

Invalid DHW demand source setting

Lockout

225

Invalid Flame threshold setting

Lockout

226

Invalid Outlet high limit set point setting

Lockout

227

Invalid DHW high limit set point setting

Lockout

228

Invalid Stack limit set point setting

Lockout

229

Invalid Modulation output setting

Lockout

230

Invalid CH demand source setting

Lockout

231

Invalid Delta T limit delay setting

Lockout

232

Invalid Pressure sensor type setting

Lockout

233

Invalid IAS closed response setting

Lockout

234

Invalid Outlet high limit enable setting

Lockout

235

Invalid Outlet connector type setting

Lockout

236

Invalid Inlet connector type setting

Lockout

237

Invalid DHW connector type setting

Lockout

238

Invalid Stack connector type setting

Lockout

239

Invalid Header connector type setting

Lockout

240

Invalid Outdoor connector type setting

Lockout

241

Exchanger sensor not allowed with stack connector setting

Lockout

242

Invalid DHW auto detect configuration

Lockout

243

Invalid UV with spark interference not compatible with Igniter on throughout

Lockout

244

Internal fault: Safety relay test invalid state

Lockout

245

Invalid Outlet connector type setting for T-rise

Lockout

246

4-20mA cannot be used for both modulation and setpoint control

Lockout

247

Invalid ILK bounce detection enable

Lockout

248

Invalid forced recycle interval

Lockout

249

STAT cannot be demand source when Remote Stat is enabled

Lockout

250

Invalid Fan speed error response

Lockout

251

Lead drop-stage on error setting does not match drop method configuration

Lockout

252

Invalid Line frequency setting

Lockout

253

Lead Lag modulation sensor not valid with setpoint source

Lockout

254

Lead Lag modulation sensor not valid with local setpoint source

Lockout

255

Lead Lag modulation sensor not valid with local modulation source

Lockout

256

Selected Controller interaction enable setting is not allowed

Lockout

257

Controller interaction enable does not match neighbor stack fault setting

Lockout

258

Controller ID must be non-zero if controller interaction is enabled

Lockout

259

Modulation output must be fan if controller interaction is enabled

Lockout

260

Asymmetrical paired (no flap) is set but flap switch input is energized

Lockout

261

Neighbor burner control blower fault detected

Lockout

Installation & Operation Manual │ FTG

69

Table 16-3 Hold and Lockout Codes

Code

Description

Note

262

Blower fault detected during flap test

Lockout

263

Invalid DHW demand temperature setting

Lockout

264

Invalid preferred outlet high limit setting

Lockout

265

Invalid preferred lightoff rate setting

Lockout

266

Invalid preferred stack limit rate setting

Lockout

Table 16-4 Alert Codes

Code

Description

0

None (No alert)

1

Alert PCB was restored from factory defaults

2

Safety configuration parameters were restored from factory defaults

3

Configuration parameters were restored from factory defaults

4

Invalid Factory Invisibility PCB was detected

5

Invalid Factory Range PCB was detected

6

Invalid range PCB record has been dropped

7

EEPROM lockout history was initialized

8

Switched application annunciation data blocks

9

Switched application configuration data blocks

10

Configuration was restored from factory defaults

11

Backup configuration settings was restored from active configuration

12

Annunciation configuration was restored from factory defaults

13

Annunciation configuration was restored from backup

14

Safety group verification table was restored from factory defaults

15

Safety group verification table was updated

16

Invalid Parameter PCB was detected

17

Invalid Range PCB was detected

18

Alarm silence time exceeded maximum

19

Invalid safety group verification table was detected

20

Backdoor password could not be determined

21

Invalid safety group verification table was not accepted

22

CRC errors were found in application configuration data blocks

23

Backup Alert PCB was restored from active one

24

RESERVED

25

Lead Lag operation switch was turned OFF

26

Lead Lag operation switch was turned ON

27

Safety processor was reset

28

Application processor was reset

29

Burner switch was turned OFF

30

Burner switch was turned ON

31

Program Module (PM) was inserted into socket

32

Program Module (PM) was removed from socket

33

Alert PCB was configured

34

Parameter PCB was configured

35

Range PCB was configured

36

Program Module (PM) incompatible with product was inserted into socket

37

Program Module application parameter revision differs from application processor

38

Program Module safety parameter revision differs from safety processor

39

PCB incompatible with product contained in Program Module

FTG │Installation & Operation Manual

70

Table 16-4 Alert Codes

Code

Description

40

Parameter PCB in Program Module is too large for product

41

Range PCB in Program Module was too large for product

42

Alert PCB in Program Module was too large for product

43

IAS start check was forced on due to IAS enabled

44

Low voltage was detected in safety processor

45

High line frequency occurred

46

Low line frequency occurred

47

Invalid subsystem reset request occurred

48

Write large enumerated Modbus register value was not allowed

49

Maximum cycle count was reached

50

Maximum hours count was reached

51

Illegal Modbus write was attempted

52

Modbus write attempt was rejected (NOT ALLOWED)

53

Illegal Modbus read was attempted

54

Safety processor brown-out reset occurred

55

Application processor watchdog reset occurred

56

Application processor brown-out reset occurred

57

Safety processor watchdog reset occurred

58

Alarm was reset by the user at the control

59

Burner control firing rate was > absolute max rate

60

Burner control firing rate was < absolute min rate

61

Burner control firing rate was invalid, % vs. RPM

62

Burner control was firing with no fan request

63

Burner control rate (non-firing) was > absolute max rate

64

Burner control rate (non-firing) was < absolute min rate

65

Burner control rate (non-firing) was absent

66

Burner control rate (non-firing) was invalid, % vs. RPM

67

Fan off cycle rate was invalid, % vs. RPM

68

Set point was over ridden due to sensor fault

69

Modulation was over ridden due to sensor fault

70

No demand source was set due to demand priority conflicts

71

CH 4-20mA signal was invalid.

72

Flame strength rate differential was invalid

73

Flame strength step rate was invalid

74

Periodic forced recycle

75

Absolute max fan speed was out of range

76

Absolute min fan speed was out of range

77

Fan gain down was invalid

78

Fan gain up was invalid

79

Fan minimum duty cycle was invalid

80

Fan pulses per revolution was invalid

81

Fan PWM frequency was invalid

82-83

RESERVED

84

Lead Lag CH 4-20mA water temperature setting was invalid

85

No Lead Lag add stage error threshold was configured

86

No Lead Lag add stage detection time was configured

87

No Lead Lag drop stage error threshold was configured

88

No Lead Lag drop stage detection time was configured

89

Lead Lag all boiler off threshold was invalid

Installation & Operation Manual │ FTG

71

Table 16-4 Alert Codes

Code

Description

90

Modulation output type was invalid

91

Firing rate control parameter was invalid

92

Forced rate was out of range vs. min/max modulation

93

Forced rate was invalid, % vs. RPM

94

Slow start ramp value was invalid

95

Slow start degrees value was invalid

96

Slow start was ended due to outlet sensor fault

97

Slow start was end due to reference set point fault

98

CH max modulation rate was invalid, % vs. RPM

99

CH max modulation rate was > absolute max rate

100

CH modulation range (max minus min) was too small (< 4% or 40 RPM)

101

DHW max modulation rate was invalid, % vs. RPM

102

DHW max modulation rate was > absolute max rate

103

DHW modulation range (max minus min) was too small (< 4% or 40 RPM)

104

Min modulation rate was < absolute min rate

105

Min modulation rate was invalid, % vs. RPM

106

Manual rate was invalid, % vs. RPM

107

Slow start enabled, but forced rate was invalid

108

Analog output hysteresis was invalid

109

Analog modulation output type was invalid

110

IAS open rate differential was invalid

111

IAS open step rate was invalid

112

Mix max modulation rate was invalid, % vs. RPM

113

Mix max modulation rate was > absolute max or < absolute min rates

114

Mix modulation range (max minus min) was too small (< 4% or 40 RPM)

115

Fan was limited to its minimum duty cycle

116

Manual rate was > CH max modulation rate

117

Manual rate was > DHW max modulation rate

118

Manual rate was < min modulation rate

119

Manual rate in Standby was > absolute max rate

120

Modulation commanded rate was > CH max modulation rate

121

Modulation commanded rate was > DHW max modulation rate

122

Modulation commanded rate was < min modulation rate

123

Modulation rate was limited due to outlet limit

124

Modulation rate was limited due to Delta-T limit

125

Modulation rate was limited due to stack limit

126

Modulation rate was limited due to anti-condensation

127

Fan Speed out of range in RUN

128

Modulation rate was limited due to IAS was open

129

Slow start ramp setting of zero will result in no modulation rate change

130

No forced rate was configured for slow start ramp

131

CH demand source was invalid

132

CH P-gain was invalid

133

CH I-gain was invalid

134

CH D-gain was invalid

135

CH OFF hysteresis was invalid

136

CH ON hysteresis was invalid

137

CH sensor type was invalid

138

CH hysteresis step time was invalid

FTG │Installation & Operation Manual

72

Table 16-4 Alert Codes

Code

Description

139

CH remote control parameter was invalid

140

CH ODR not allowed with remote control

146

CH control was suspended due to fault

147

CH header temperature was invalid

148

CH outlet temperature was invalid

149

CH steam pressure was invalid

151

Minimum water temperature parameter was greater than setpoint

152

Minimum water temperature parameter was greater than time of day setpoint

155

CH modulation rate source parameter was invalid

157

DHW demand source was invalid

158

DHW P-gain was invalid

159

DHW I-gain was invalid

160

DHW D-gain was invalid

161

DHW OFF hysteresis was invalid

162

DHW ON hysteresis was invalid

163

DHW hysteresis step time was invalid

164

DHW sensor type was invalid

165

Inlet sensor type was invalid for DHW

166

Outlet sensor type was invalid for DHW

167

DHW storage OFF hysteresis was invalid

168

DHW storage ON hysteresis was invalid

169

DHW modulation sensor type was invalid

170

DHW modulation sensor was not compatible for Auto mode

171

DHW control was suspended due to fault

172

DHW temperature was invalid

173

DHW inlet temperature was invalid

174

DHW outlet temperature was invalid

175

DHW high limit must be disabled for Auto mode

176

DHW sensor type was not compatible for Auto mode

177

DHW priority source setting was invalid

178

DHW priority method setting was invalid

179

CH S5 (J8-11) sensor was invalid

180

CH Inlet temperature was invalid

181

CH S10 (J10-7) sensor was invalid

182

Lead Lag CH setpoint source was invalid

183

Lead Lag P-gain was invalid

184

Lead Lag I-gain was invalid

185

Lead Lag D-gain was invalid

186

Lead Lag OFF hysteresis was invalid

187

Lead Lag ON hysteresis was invalid

188

Lead Lag slave enable was invalid

189

Lead Lag hysteresis step time was invalid

190

No Lead Lag Modbus port was assigned

191

Lead Lag base load common setting was invalid

192

Lead Lag DHW demand switch setting was invalid

193

Lead Lag Mix demand switch setting was invalid

194

Lead Lag modulation sensor setting was invalid

195

Lead Lag backup modulation sensor setting was invalid

196

Lead Lag slave mode setting was invalid

Installation & Operation Manual │ FTG

73

Table 16-4 Alert Codes

Code

Description

197

Lead Lag rate allocation setting was invalid

198

Lead selection setting was invalid

199

Lag selection setting was invalid

200

Lead Lag slave return setting was invalid

201

Lead Lag add stage method setting was invalid

202

STAT may not be a Lead Lag CH demand source when Remote Stat is enabled

203

Lead Lag base load rate setting was invalid

204

Lead Lag master was suspended due to fault

205

Lead Lag slave was suspended due to fault

206

Lead Lag header temperature was invalid

207

Lead Lag was suspended due to no enabled Program Module installed

208

Lead Lag slave session has timed out

209

Too many Lead Lag slaves were detected

210

Lead Lag slave was discovered

211

Incompatible Lead Lag slave was discovered

212

No base load rate was set for Lead Lag slave

213

Lead Lag slave unable to fire before demand to fire delay expired

214

Adding Lead Lag slave aborted due to add requirement change

215

No Lead Lag slaves available to service demand

216

No Lead Lag active service was set due to demand priority conflicts

217

No Lead Lag add stage method was specified

218

No Lead Lag drop stage method was specified

219

Using backup Lead Lag header sensor due to sensor failure

220

Lead Lag frost protection rate was invalid

221

Lead Lag drop stage method setting was invalid

222

CH frost protection temperature was invalid

223

CH frost protection inlet temperature was invalid

224

DHW frost protection temperature was invalid

225

No anticondensation setpoint was configured for frost protection

226

RESERVED

227

DHW priority override time was not derated due to invalid outdoor temperature

228

Warm weather shutdown was not checked due to invalid outdoor temperature

229

Lead Lag slave communication timeout

230

RESERVED

231

LL set point was invalid

232

LL time of day set point was invalid

233

LL outdoor temperature was invalid

234

LL ODR time of day set point was invalid

235

LL ODR time of day set point exceeded normal set point

236

LL max outdoor set point was invalid

237

LL min outdoor set point was invalid

238

LL min water set point was invalid

239

LL outdoor temperature range was too small (minimum 12 C / 22 F)

240

LL water temperature range was too small (minimum 12 C / 22 F)

241

Lead Lag DHW setpoint was invalid

243

Lead Lag CH demand switch was invalid

244

Lead Lag ODR min water temperature was invalid

245

RESERVED

246

CH set point was invalid

FTG │Installation & Operation Manual

74

Table 16-4 Alert Codes

Code

Description

247

CH time of day set point was invalid

248

CH outdoor temperature was invalid

249

CH ODR time of day setpoint was invalid

250

CH ODR time of day set point exceeds normal set point

251

CH max outdoor set point was invalid

252

CH min outdoor set point was invalid

253

CH min water set point was invalid

254

CH outdoor temperature range was too small (minimum 12 C / 22 F)

255

CH water temperature range was too small (minimum 12 C / 22 F)

259

CH ODR min water temperature was invalid

260

RESERVED

261

DHW set point was invalid

262

DHW time of day set point was invalid

263

DHW storage setpoint was invalid

264

STAT may not be a DHW demand source when Remote Stat is enabled

265

No DHW anticondensation setpoint was configured

266

No CH anticondensation setpoint was configured

267

STAT may not be a CH demand source when Remote Stat is enabled

268

CH 4mA water temperature setting was invalid

269

CH 20mA water temperature setting was invalid

270

Steam 4mA water temperature setting was invalid

271

Steam 20mA water temperature setting was invalid

272

Abnormal Recycle: Pressure sensor fault

273

Abnormal Recycle: Safety relay drive test failed

274

Abnormal Recycle: Demand off during Pilot Flame Establishing Period

275

Abnormal Recycle: LCI off during Drive to Purge Rate

276

Abnormal Recycle: LCI off during Measured Purge Time

277

Abnormal Recycle: LCI off during Drive to Light off Rate

278

Abnormal Recycle: LCI off during Pre-Ignition test

279

Abnormal Recycle: LCI off during Pre-Ignition time

280

Abnormal Recycle: LCI off during Main Flame Establishing Period

281

Abnormal Recycle: LCI off during Ignition period

282

Abnormal Recycle: Demand off during Drive to Purge Rate

283

Abnormal Recycle: Demand off during Measured Purge Time

284

Abnormal Recycle: Demand off during Drive to Light off Rate

285

Abnormal Recycle: Demand off during Pre-Ignition test

286

Abnormal Recycle: Demand off during Pre-Ignition time

287

Abnormal Recycle: Flame was on during Safe Start check

288

Abnormal Recycle: Flame was on during Drive to Purge Rate

289

Abnormal Recycle: Flame was on during Measured Purge Time

290

Abnormal Recycle: Flame was on during Drive to Light off Rate

291

Abnormal Recycle: Flame was not on at end of Ignition period

292

Abnormal Recycle: Flame was lost during Main Flame Establishing Period

293

Abnormal Recycle: Flame was lost early in Run

294

Abnormal Recycle: Flame was lost during Run

295

Abnormal Recycle: Leakage test failed

296

Abnormal Recycle: Interrupted air flow switch was off during Drive to Purge Rate

297

Abnormal Recycle: Interrupted air flow switch was off during Measured Purge Time

298

Abnormal Recycle: Interrupted air flow switch was off during Drive to Light off Rate

Installation & Operation Manual │ FTG

75

Table 16-4 Alert Codes

Code

Description

299

Abnormal Recycle: Interrupted air flow switch was off during Pre-Ignition test

300

Abnormal Recycle: Interrupted air flow switch was off during Pre-Ignition time

301

Abnormal Recycle: Interrupted air flow switch was off during Main Flame Establishing Period

302

Abnormal Recycle: Ignition failed due to interrupted air flow switch was off

303

Abnormal Recycle: ILK off during Drive to Purge Rate

304

Abnormal Recycle: ILK off during Measured Purge Time

305

Abnormal Recycle: ILK off during Drive to Light off Rate

306

Abnormal Recycle: ILK off during Pre-Ignition test

307

Abnormal Recycle: ILK off during Pre-Ignition time

308

Abnormal Recycle: ILK off during Main Flame Establishing Period

309

Abnormal Recycle: ILK off during Ignition period

310

Run was terminated due to ILK was off

311

Run was terminated due to interrupted air flow switch was off

312

Stuck reset switch

313

Run was terminated due to fan failure

314

Abnormal Recycle: Fan failed during Drive to Purge Rate

315

Abnormal Recycle: Fan failed during Measured Purge Time

316

Abnormal Recycle: Fan failed during Drive to Light off Rate

317

Abnormal Recycle: Fan failed during Pre-Ignition test

318

Abnormal Recycle: Fan failed during Pre-Ignition time

319

Abnormal Recycle: Fan failed during Ignition period

320

Abnormal Recycle: Fan failed during Main Flame Establishing Period

321

Abnormal Recycle: Main Valve off after 10 seconds of RUN

322

Abnormal Recycle: Pilot Valve off after 10 seconds of RUN

323

Abnormal Recycle: Safety Relay off after 10 seconds of RUN

324

Abnormal Recycle: Hardware flame bias

325

Abnormal Recycle: Hardware static flame

326

Abnormal Recycle: Hardware flame current invalid

327

Abnormal Recycle: Hardware flame rod short

328

Abnormal Recycle: Hardware invalid power

329

Abnormal Recycle: Hardware invalid AC line

330

Abnormal Recycle: Hardware SLO flame ripple

331

Abnormal Recycle: Hardware SLO flame sample

332

Abnormal Recycle: Hardware SLO flame bias range

333

Abnormal Recycle: Hardware SLO flame bias heat

334

Abnormal Recycle: Hardware SLO spark stuck

335

Abnormal Recycle: Hardware SLO spark changed

336

Abnormal Recycle: Hardware SLO static flame

337

Abnormal Recycle: Hardware SLO rod shorted

338

Abnormal Recycle: Hardware SLO AD linearity

339

Abnormal Recycle: Hardware SLO bias not set

340

Abnormal Recycle: Hardware SLO bias shorted

341

Abnormal Recycle: Hardware SLO electronics

342

Abnormal Recycle: Hardware processor clock

343

Abnormal Recycle: Hardware AC phase

344

Abnormal Recycle: Hardware A2D mismatch

345

Abnormal Recycle: Hardware VSNSR A2D

346

Abnormal Recycle: Hardware 28V A2D

347

Abnormal Recycle: Hardware HFS IAS shorted

FTG │Installation & Operation Manual

76

Table 16-4 Alert Codes

Code

Description

348

Abnormal Recycle: Hardware PII INTLK shorted

349

Abnormal Recycle: Hardware HFS LCI shorted

350

Abnormal Recycle: Hardware HFS LFS shorted

351

Abnormal Recycle: Invalid zero crossing

352

Abnormal Recycle: fault stack sensor

353

Abnormal Recycle: stack limit

354

Abnormal Recycle: delta T limit

355

Abnormal Recycle: fault outlet sensor

356

Abnormal Recycle: outlet high limit

357

Abnormal Recycle: fault DHW sensor

358

Abnormal Recycle: DHW high limit

359

Abnormal Recycle: fault inlet sensor

360

Abnormal Recycle: Check Parameters Failed

361

Internal error: No factory parameters were detected in control

362

Internal error: PID iteration frequency was invalid

363

Internal error: Demand-Rate interval time was invalid

364

Internal error: Factory calibration parameter for modulation was invalid

365

Internal error: CH PID P-scaler was invalid

366

Internal error: CH PID I-scaler was invalid

367

Internal error: CH PID D-scaler was invalid

368

Internal error: DHW PID P-scaler was invalid

369

Internal error: DHW PID I-scaler was invalid

370

Internal error: DHW PID D-scaler was invalid

371

Internal error: Lead Lag master PID P-scaler was invalid

372

Internal error: Lead Lag master PID I-scaler was invalid

373

Internal error: Lead Lag master PID D-scaler was invalid

374

Abnormal Recycle: Hardware flame bias high

375

Abnormal Recycle: Hardware flame bias low

376

Abnormal Recycle: Hardware flame bias delta high

377

Abnormal Recycle: Hardware flame bias delta low

378

Abnormal Recycle: Hardware flame bias dynamic high

379

Abnormal Recycle: Hardware flame bias dynamic low

380

Abnormal Recycle: Fan Speed Not Proven

381

Abnormal Recycle: Fan Speed Range Low

382

Abnormal Recycle: Fan Speed Range High

383

Abnormal Recycle: Pre-Ignition test failed, recycle

384-388

RESERVED

389

Abnormal Recycle: AC power frequency Mismatch

390-447

RESERVED

448

Flame too low

449

Modulation rate was limited due to flame strength

450

RESERVED

451

Circulator control was invalid

452

Circulator P-gain was invalid

453

Circulator I-gain was invalid

454

Circulator temperature was invalid

455

Circulator outlet temperature was invalid

456

Circulator inlet temperature was invalid

457

Circulator outlet temperature was invalid

Installation & Operation Manual │ FTG

77

Table 16-4 Alert Codes

Code

Description

458

Circulator sensor choice was invalid

459

Circulator PID setpoint was invalid

460

LCI demand lost in run

461

Demand lost in run

462

STAT demand lost in run

463

Demand lost in run due to no flame

464

LCI lost in Combustion Pressure Establishing Period

465

LCI lost in Combustion Pressure Stabilizing Period

466

RESERVED

467

Internal error: EEPROM write was attempted before EEPROM was initialized

468

Internal error: EEPROM cycle count address was invalid

469

Internal error: EEPROM days count address was invalid

470

Internal error: EEPROM hours count address was invalid

471

Internal error: Lockout record EEPROM index was invalid

472

Internal error: Request to write PM status was invalid

473

Internal error: PM parameter address was invalid

474

Internal error: PM safety parameter address was invalid

475

Internal error: Invalid record in lockout history was removed

476

Internal error: EEPROM write buffer was full

477

Internal error: Data too large was not written to EEPROM

478

Internal error: Safety key bit 0 was incorrect

479

Internal error: Safety key bit 1 was incorrect

480

Internal error: Safety key bit 2 was incorrect

481

Internal error: Safety key bit 3 was incorrect

482

Internal error: Safety key bit 4 was incorrect

483

Internal error: Safety key bit 5 was incorrect

484

Internal error: Safety key bit 6 was incorrect

485

Internal error: Safety key bit 7 was incorrect

486

Internal error: Safety key bit 8 was incorrect

487

Internal error: Safety key bit 9 was incorrect

488

Internal error: Safety key bit 10 was incorrect

489

Internal error: Safety key bit 11 was incorrect

490

Internal error: Safety key bit 12 was incorrect

491

Internal error: Safety key bit 13 was incorrect

492

Internal error: Safety key bit 14 was incorrect

493

Internal error: Safety key bit 15 was incorrect

494

Internal error: Safety relay timeout

495

Internal error: Safety relay commanded off

496

Internal error: Unknown safety error occurred

497

Internal error: Safety timer was corrupt

498

Internal error: Safety timer was expired

499

Internal error: Safety timings

500

Internal error: Safety shutdown

550

Delta T inlet/outlet limit was exceeded

553

Inlet/outlet inversion occurred

564

Outlet T-rise limit was exceeded

600

Delta T inlet temperature was invalid

601

Delta T outlet temperature was invalid

603

CH ODR boost max offpoint temperature was invalid

FTG │Installation & Operation Manual

78

Table 16-4 Alert Codes

Code

Description

604

CH ODR boost max offpoint temperature was too low

605

Lead Lag ODR boost max offpoint temperature was invalid

606

Lead Lag ODR boost max offpoint temperature was too low

609

Time to rotate lead boiler to next firing slave

610

Time to rotate lead boiler to next available slave

611

Time to rotate lead boiler to first firing slave in order

612

Time to rotate lead boiler to lowest running slave

613

Lead boiler was rotated based on new firing sequence order

614

Lead boiler was rotated based on measured run time

615

Parameter PCB was switched to backup

616

Range PCB was switched to backup

622

Lead Lag modulation sensor was not valid with setpoint source

623

Lead Lag modulation sensor was not valid with local setpoint source

624

Lead Lag modulation sensor was not valid with local modulation rate source

629

Disagreement on number of interacting controls

Installation & Operation Manual │ FTG

79

Figure 17-1(a) Exploded View - Cabinet

42

62

63

55

53

64

66

72

73

74

75

76

77

80

98

50

51

51

77

17.0 PARTS LIST

For a list of parts that corresponds to the item numbers in the callouts, refer to Table 17-1. Note that some item
numbers may appear more than once in the parts list depending on which model number is being referenced.

Building Owners - Replacement parts are available from your stocking wholesaler. Contact your local Installer

or Wholesaler for assistance with parts.

Wholesalers - Contact NY Thermal Inc. directly when ordering replacement parts, 1-506-657-6000.
Installers - Contact NY Thermal Inc. directly if technical assistance required, 1-800-688-2575.

Figure 17-1(b) Exploded View – Control Panel

Figure 17-1(c) Exploded View – Trim/Install Kit

17

30

38

40

41

71

90

81

108

111

92

109

110

47

112 – LP Conversion Instructions

113 – LP Conversion Label

114 – Install & Operation Manual

115 – App. A, Touchscreen Manual

116 – User Instruction Manual

48

49

52

53

55

56

60

61

62

64

66

68,69

70

78

85

102

43

12

67

121

59

91

81

Figure 17-1(d) Exploded View – Heat Exchanger & Gas Train

26

1

2 3 4 5 20 7 9

10

13

13

27

15

16

19

15

15

27

44

6

14

22

25

28

29

31

32

33

34

36

37

39

82

101

88

89

89

45

46

Item

Part #

Model

Description

1

85289

FTG 600-800

Premix Burner, FTG 600-800

1

85744

FTG 1200-1400

Premix Burner, FTG 1200-1400

1

85549

FTG 2000-2400

Premix Burner, FTG 2000-2400

2

85398

FTG 600-2400

Gasket FTG Burner Plate-Burner

3

85335

FTG 600-1400

Blower Transition, FTG 600-1400

3

85527

FTG 2000-2400

Blower Transition, FTG 2000-2400

4

85329

FTG 600-1400

Gasket, Blower-Transition, FTG 600-1400

4

85660

FTG 2000-2400

Gasket, Venturi Inlet / Blower Outlet, FTG 2000-2400

5

85354

FTG 600-1400

Blower Assembly, 7.0H

5

85766

FTG 2000

Blower Assembly, 12.3 in., 120V

5

85682

FTG 2200-2400

Blower Assembly, 12.3 in., 240V 3PH

6

84084

FTG 600-1400

O-Ring, Venturi-Blower, 35101-4-5159

6

85753

FTG 2000-2400

O-Ring, Venturi-Blower,181 x 3.53 mm

7

85290

FTG 600-1200

Venturi, VMU185

7

84013

FTG 1400

Venturi, VMU300

7

85696

FTG 2000-2400

Venturi, VMU500

9

84012

FTG 600-1400

Gas Valve, V8730C

9

85669

FTG 2000-2400

Gas Valve, MBC-SE 2500

10

83870-1

FTG 600-2400

Ignition Electrode, Dual (c/w gasket)

12

85658

FTG 2200-2400

Fuseblock, 600V/30A

13

85291

FTG 600-1400

Gas Valve Outlet Adapter ¾ in. NPT (c/w O-ring & Hardware)

13

85666

FTG 2000-2400

Gas Valve Outlet Adapter 1 in. NPT (w/adjustable shutter)

14

84035

FTG 600-800

Gas Valve Inlet Adapter 1 in. NPT (c/w O-ring & Hardware)

14

85749

FTG 1200-1400

Gas Valve Inlet Adapter 1.25 in. NPT (c/w O-ring & Hardware)

14

85667

FTG 2000-2400

Gas Valve Inlet Adapter 1.5 in. NPT

15

85315

FTG 600-2400

Outlet/Inlet/Flue Sensor (Dual)

16

85128

FTG 600-2400

LWCO, CSD-1

17

85297

FTG 600-800

Pipe Coupling, groove joint, 2 in. (outlet)

17

85298

FTG 2000-2400

Pipe Coupling, groove joint, 3 in. (outlet/inlet)

18

TBD

FTG 600-800

Supply Pipe, FTG 600-800

18

TBD

FTG 1200-1400

Supply Pipe, FTG 1200-1400

18

TBD

FTG 2000-2400

Supply Pipe, FTG 2000-2400

19

84474

FTG 600-2400

Auto Air Vent, ½” NPT

20

85328

FTG 600-2400

Gasket, Transition-Burner, FTG

21

TBD

FTG 600-2400

Return Pipe, FTG

22

TBD

FTG 600-800

Flue Collector, FTG 600-800

22

TBD

FTG 1200-2400

Flue Collector, FTG 1200-2400

23

84423

FTG 600-2400

Receptacle, 120VAC

25

TBD

FTG 600-2400

Sight Glass (c/w gaskets)

26

85274

FTG 600-800

Heat Exchanger ASME, FTG 600-800 (c/w doors)

26

85296

FTG 1200-1400

Heat Exchanger ASME, FTG 1200-1400 (c/w doors)

Table 17-1 Parts List: FTG Series

83

Item

Part #

Model

Description

26

85302

FTG 2000-2400

Heat Exchanger ASME, FTG 2000-2400 (c/w doors)

27

85314

FTG 600-2400

Immersion Well, ½ in. NPT, Inlet/Outlet Sensor

28

TBD

FTG 600-2400

Gasket, Flue Collector to Condensate Dish

29

85310

FTG 600-2400

Elbow 0.375 ID x 0.5NPT Polypro

30

85311

FTG 600-2400

Condensate Trap

31

TBD

FTG 600-1400

Insulation/Gasket, Rear Door, FTG 600-1400

31

TBD

FTG 2000-2400

Insulation/Gasket, Rear Door, FTG 2000-2400

32

TBD

FTG 600-1400

Door, Combustion Chamber, Rear, FTG 600-1400

32

TBD

FTG 2000-2400

Door, Combustion Chamber, Rear, FTG 2000-2400

33

TBD

FTG 600-2400

Insulation/Gasket, Front Door, FTG 600-2400

34

TBD

FTG 600-2400

Door, Combustion Chamber, Front, FTG

36

84740-1

FTG 600-2400

Flame Sensor Electrode (c/w gasket)

37

85358

FTG 600-1400

Air-inlet Elbow to Venturi, FTG 600-1400

37

85657

FTG 2000-2400

Air-inlet Elbow to Venturi, FTG 2000-2400

38

83019

FTG 600-2400

Round Mesh Vent Screen, 6”

39

85313

FTG 600-1400

Air Filter, FTG 600-1400

39

85656

FTG 2000-2400

Air Filter, FTG 2000-2400

40

83718

FTG 600-2400

Hose Clamp, 1-1/16 to 1-1/2”

41

85360

FTG 600-800

Flue Outlet Adapter to CPVC, 6 in.

42

85358

FTG 600-800

Air Inlet Adapter PP/PVC/SS, 6 in.

42

85765

FTG 1200-2400

Air Inlet Adapter, Rubber, 8 in.

43

85317

FTG 600-2400

EnviraCOM - OD sensor

44

84497

FTG 600-2400

Exhaust Test Plug, EPDM

45

84094

FTG 600-1400

High Gas Pressure Switch C6097B1028

45

85672

FTG 2000-2400

High Gas Pressure Switch GMH-A2-4-4

46

85292

FTG 600-1400

Low Gas Pressure Switch C6097A1210

46

85673

FTG 2000-2400

Low Gas Pressure Switch GAO-A2-4-5

47

85298

FTG 600-2400

Pipe Coupling, groove joint, 3 in. (inlet)

48

TBD

FTG 600-2400

Air Switch Bracket

49

85163

FTG 600-2400

Blocked Condensate Drain / Blocked Vent Switch

50

TBD

FTG 600-800

Bottom, FTG 600-800

50

TBD

FTG 1200-1400

Bottom, FTG 1200-1400

50

TBD

FTG 2000-2400

Bottom, FTG 2000-2400

51

TBD

FTG 600-800

Leg, FTG 600-800 (c/w hardware)

51

TBD

FTG 1200-1400

Leg, FTG 1200-2400 (c/w hardware)

51

TBD

FTG 2000-2400

Leg, FTG 1200-2400 (c/w hardware)

52

84653

FTG 600-2400

Display S7999D, Black Touch Screen

53

TBD

FTG 600-2400

Electrical Junction Box Cover, Low Volt.

55

TBD

FTG 600-2400

Electrical Junction Box, Line Volt. (c/w barrier-strip)

56

85054-1

FTG 600-2400

Ignition Coil 4180002F

57

83724

FTG 600-2400

Spark Igniter Cable 12”

59

85664

FTG 2200-2400

Transformer 120V, 1kVA

Item

Part #

Model

Description

60

84047

FTG 600-1400

Transformer 24V, 75VA

60

85659

FTG 2000-2400

Transformer 24V, 250VA

61

85421

FTG 600-2400

Controller, R7910A, FTG

62

TBD

FTG 600-2400

Control Panel Cover, FTG

63

TBD

FTG 600-2400

Control Panel

64

TBD

FTG 600-2400

Electrical Junction Box, Low Volt. (c/w barrier-strip)

66

TBD

FTG 600-2400

Electrical Junction Box Cover, Low Volt.

67

82625

FTG 2200-2400

Fuse, 15A, 250VAC, Barrel Style, Slow Blow

68

84192

FTG 600-2400

Fuse Holder, Panel Mount, 20A, 250VAC max

69

83837

FTG 600-2400

Fuse, 7A, 250VAC, Barrel Style, Fast Blow

70

TBD

FTG 600-2400

Display Cover, FTG

71

83604

FTG 600-2400

Outdoor Sensor

72

TBD

FTG 600-2400

Front Cover, FTG

73

TBD

FTG 600-800

Right Side, FTG 600-800

73

TBD

FTG 1200-1400

Right Side, FTG 1200-1400

73a

TBD

FTG 2000-2400

Right Side Front, FTG 2000-2400

73b

TBD

FTG 2000-2400

Right Side Rear, FTG 2000-2400

74

TBD

FTG 600-800

Left Side, FTG 600-800

74

TBD

FTG 1200-1400

Left Side, FTG 1200-1400

74a

TBD

FTG 2000-2400

Left Side Front, FTG 2000-2400

74b

TBD

FTG 2000-2400

Left Side Rear, FTG 2000-2400

75

TBD

FTG 600-800

Front Top, FTG 600-800

75

TBD

FTG 1200-1400

Front Top, FTG 1200-1400

75

TBD

FTG 2000-2400

Front Top, FTG 2000-2400

76

TBD

FTG 600-800

Rear Top, FTG 600-800

76

TBD

FTG 1200-1400

Rear Top, FTG 1200-1400

76

TBD

FTG 2000-2400

Rear Top, FTG 2000-2400

77

TBD

FTG 600-800

Heat Exch. Support Frame, FTG 600-800 (c/w hardware)

77

TBD

FTG 1200-1400

Heat Exch. Support Frame, FTG 1200-1400 (c/w hardware)

77

TBD

FTG 2000-2400

Heat Exch. Support Frame, FTG 2000-2400 (c/w hardware)

78

84380

FTG 600-2400

Blocked Filter Switch

80

TBD

FTG 600-800

Rear Access Cover, FTG 600-800 (Set)

80

TBD

FTG 1200-2400

Rear Access Cover, FTG 1200-2400 (Set)

81

84010

FTG 600-2400

System Sensor, Pipe Sensor

82

84087

FTG 600-1400

Gasket, Cork, Square

85

TBD

FTG 600-2400

Spark Generator Support Bracket

88

84347

FTG 600-1400

Manual Shut Off Valve, 3/4" NPT

88

84025

FTG 2000-2400

Manual Shut Off Valve, 1" NPT

89

84599

FTG 600-1400

Nipple, ¾”, cls, blk

89

84351

FTG 2000-2400

Nipple, 1”, cls, blk

90

84025

FTG 600-800

Manual Shut Off Valve, 1" NPT

90

85312

FTG 1200-1400

Manual Shut Off Valve, 1.25" NPT

85

Item

Part #

Model

Description

90

85688

FTG 2000-2400

Manual Shut Off Valve, 1.5" NPT

91

TBD

FTG 2200-2400

Cover, Fuseblock

96

84069

FTG 600-800

Clamp, U-Bolt, 1" IPS

96

85653

FTG 1200-1400

Clamp, U-Bolt, 1.25" IPS

96

85691

FTG 2000-2400

Clamp, U-Bolt, 1.5" IPS

98

85355

FTG 600-2400

Leg Leveler

101

84011

FTG 600-1400

Gasket, Venturi Inlet, FTG 600-1400

101

85660

FTG 2000-2400

Gasket, Venturi Inlet / Blower Outlet, FTG 2000-2400

102

84056

FTG 600-2400

Relay, Omron

107

84490

FTG 600-2000

Rocker Power Switch, On/Off

107

85663

FTG 2200-2400

Switch Disconnect, 3-PH

108

84092

FTG 600-800

CPVC Pipe 6 in., System 636, 6.5 in. Long

109

84088

FTG 600-800

Pressure Relief Valve, ¾ x 1, ASME, 50 PSI

109

85768

FTG 1200-1400

Pressure Relief Valve, 1 x 1-1/4, ASME, 50 PSI

109

85690

FTG 2000-2400

Pressure Relief Valve, 1-1/4, ASME, 50 PSI

110

85295

FTG 600-2400

Pressure/Temp Gauge

111

83018

FTG 600-800

Round Mesh Vent Screen, 4 in.

112

85445

FTG 600-1400

Natural Gas to LP Conversion Instructions, FTG 600-1400

112

85759

FTG 2000-2400

Natural Gas to LP Conversion Instructions, FTG 2000-2400

113

85418

FTG 600-1400

LP Conversion Decal, FTG 600-1400

113

85758

FTG 2000-2400

LP Conversion Decal, FTG 2000-2400

114

85422

FTG 600-2400

Installation and Operation Manual, FTG

115

86570

FTG 600-2400

App. A, Controller & Display Manual

116

84491

FTG 600-2400

User Information Manual

119

85418-1

FTG 600-1400

NG to LP Conversion Kit, FTG 600-1400

119

85758-1

FTG 2000-2400

NG to LP Conversion Kit, FTG 2000-2400

121

84946

FTG 600-2400

ProtoNode RER Modbus-BACnet/N2 Gateway FPC-N34-0855 (Optional)

121

84947

FTG 600-2400

ProtoNode RER Modbus-LonWorks Gateway FPC-N35-0856 (Optional)

NOTES

87

NOTES

Visit us

online

NY Thermal Inc. 30 Stonegate Drive, Saint John, NB E2H 0A4 Canada

Technical Assistance: 1-800-688-2575

Website: www.ntiboilers.com

Fax: [phone]