Installation & Operation Manual Models: 400, 500, 600

Installation & Operation Manual Models: 400, 500, 600
FTXL-I-O Rev C
Installation & Operation Manual
Models: 400, 500, 600, 725,
& 850
This manual must only be used by
 WARNING a qualified heating installer / service
technician. Read all instructions,
including this manual and the FTXL
Service Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
THE FTXL -- HOW IT WORKS....................................... 4-5
RATINGS ........................................................................... 6
1. DETERMINE BOILER LOCATION
Provide Air Openings to Room .......................................... 9
Flooring and Foundation ................................................... 9
Residential Garage Installation .......................................... 9
Vent and Air Piping ............................................................ 9
Prevent Combustion Air Contamination ............................. 9
Corrosive Contaminants and Sources ............................. 10
Using an Existing Vent System to Install a New Boiler ... 10
Removing a Boiler from Existing Common Vent.............. 11
2. PREPARE BOILER
Remove Boiler from Wood Pallet ..................................... 14
Gas Conversions ......................................................... 14-15
Model 400 - 500.......................................................... 14
Models 600 - 850 ........................................................ 15
3. GENERAL VENTING
Direct Venting Options ..................................................... 16
Install Vent and Combustion Air Piping ........................... 17
Requirements for Installation in Canada .......................... 18
Sizing ............................................................................... 18
Min./Max. Combustion Air & Vent Piping Lengths ............ 18
Materials ............................................................................ 18
Optional Room Air ............................................................ 19
PVC/CPVC .................................................................. 20-21
Polypropylene................................................................... 22
Stainless Steel Vent ......................................................... 23
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 24-27
Determine Location................................................ 24-26
Prepare Wall Penetrations ..................................... 26-27
Multiple Vent/Air Terminations ......................................... 27
Sidewall Termination - Optional Concentric Vent ....... 28-30
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical .................................... 31-32
Determine Location..................................................... 31
Prepare Roof Penetrations ......................................... 32
Multiple Vent/Air Terminations ......................................... 32
Vertical Termination - Optional Concentric Vent ......... 33-34
Alternate Vertical Concentric Venting ......................... 35-36
6. HYDRONIC PIPING
System Water Piping Methods ......................................... 37
Low Water Cutoff Device ................................................. 37
Chilled Water System....................................................... 37
Freeze Protection ............................................................. 37
General Piping Information .............................................. 37
Relief Valve Installation ................................................... 38
Near Boiler Piping Components ....................................... 39
Circulator Sizing ............................................................... 39
Near Boiler Piping Connections ....................................... 40
Piping Diagrams .....................................................42-47
7. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 48
Natural Gas ...................................................................... 49
Pipe Sizing for Natural Gas ........................................ 49
Natural Gas Supply Pressure Requirements ............. 49
Propane Gas .................................................................... 49
Pipe Sizing for Propane Gas ...................................... 49
Propane Supply Pressure Requirements ................... 49
Check Inlet Gas Supply ................................................... 50
Gas Pressure ................................................................... 51
Gas Valve Replacement .................................................. 51
8. FIELD WIRING
Line Voltage Connections ................................................ 52
Low Voltage Connections ................................................ 52
Wiring of the Cascade ...................................................... 54
9. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 56
10. STARTUP ............................................................. 57-62
11. OPERATING INFORMATION
General............................................................................. 63
Cascade ........................................................................... 66
Sequence of Operation ............................................... 67-68
FTXL Control Module ....................................................... 69
Status Display Screens ............................................... 70-72
12. MAINTENANCE
Maintenance and Annual Startup ................................ 73-77
13. DIAGRAMS
Wiring Diagram ........................................................... 78
Ladder Diagram ......................................................... 79
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
 DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
 WARNING injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
 CAUTION injury.
CAUTION
NOTICE
2
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Installation & Operation Manual
Please read before proceeding
 WARNING
Installer – Read all instructions, including
this manual and the FTXL Service Manual,
before installing. Perform steps in the
order given.
User – This manual is for use only by
a qualified heating installer/service
technician. Refer to the User’s Information
Manual for your reference.
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
NOTICE
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
 WARNING
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
 WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
 WARNING DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 10).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Boiler water –
• Thoroughly flush the system (without boiler connected)
to remove sediment. The high-efficiency heat exchanger
can be damaged by build-up or corrosion due to sediment.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure. Addition of oxygen carried in by
makeup water can cause internal corrosion in system
components. Leaks in boiler or piping must be repaired
at once to prevent makeup water.
 CAUTION Do not use petroleum-based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
Do not use “homemade cures” or “boiler
 CAUTION patent medicines”. Serious damage to the
boiler, personnel, and/or property may
result.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
3
Installation & Operation Manual
The FTXL - How it works...
1.
Stainless steel heat exchanger
Allows system water to flow around specially designed tubes for
maximum heat transfer, while providing protection against flue gas
corrosion.
2.
Heat exchanger top plate
Removal of the top plate allows access to the combustion chamber
and tube sheet.
3.
4.
Blower
7.
23. Condensate trap
The condensate trap is sized for a 1" PVC outlet connection
pipe.
25. Ignition electrode
Venturi
Provides access to the gas train, heat exchanger, and display.
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides a view of the burner surface
and flame.
Flue gas sensor (limit rated)
27. Gas shutoff valve (Models 500 - 850 only)
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if the flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
28. Relief valve (field installed, not shown)
Boiler outlet temperature sensor (limit rated)
Boiler inlet temperature sensor
This sensor monitors return water temperature (system return). If
`selected as the controlling sensor, the control module adjusts the
boiler firing rate so the inlet temperature is correct.
9.
Conduit connection points for the low voltage connection
board.
Gas valve
This sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control module
adjusts boiler firing rate so the outlet temperature is correct.
8.
22. Low voltage wiring connections (knockouts)
24. Bezel (hinged)
The venturi controls air and gas flow into the burner.
6.
The connection board provides easy access for connecting
external low voltage devices.
The blower pulls in air and gas through the venturi (item 5). Air
and gas mix inside the blower and are pushed into the burner, where
they burn inside the combustion chamber.
The gas valve senses the negative pressure created by the blower,
allowing gas to flow only if the gas valve is powered and combustion
air is flowing.
5.
21. Low voltage connection board
Temperature and pressure gauge (field installed, not
shown)
Monitors the outlet temperature of the boiler as well as the
system water pressure.
10. Electronic LCD display
The display features a high resolution liquid crystal screen, four (4)
buttons, and a navigation dial. A serial and USB port support
additional communication with the control.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
boiler.
12. Burner (not shown)
Made with metal fiber and stainless steel construction, the burner
uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet (system supply)
A 2" or 2-1/2" NPT (depending on the model) water connection that
supplies hot water to the system.
14. Water inlet (system return)
A 2" or 2-1/2" NPT (depending on the model) water connection that
returns water from the system to the heat exchanger.
15. Gas connection pipe
Threaded pipe connection of 1". This pipe should be connected to
the incoming gas supply for the purpose of delivering gas to the
boiler.
16. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and external
signals to regulate the blower, gas valve, and pump functions to meet
heating demand. An optional remote connectivity allows boiler
settings to be monitored and modified when connected to the
internet.
17. Manual air vent
A manual air vent is used to remove trapped air from the heat
exchanger shell.
18. Air intake adapter
Allows for the connection of the PVC air intake pipe to the boiler.
19. High voltage junction box
The junction box contains the connection points for the line voltage
power and all pumps.
20. Boiler drain connection
A 1" NPT drain connection is provided for easy access in the
event the boiler needs to be drained .
4
A manual valve is provided to isolate the gas valve from the
boiler.
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 50 PSI.
29. Flame sensor
Used by the control module to detect the presence of burner
flame.
30. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
31. Front panel
Removable panel to gain access to the internal components.
32. Power switch
Turns 120 VAC ON/OFF to the boiler.
33. Pump relay board
The pump relay board is used to connect the boiler, system and
DHW pumps.
34. Transformer
The transformer provides 24V power to the integrated control.
35. High limit sensor (housed with the outlet temperature
sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will break
the control circuit, shutting the boiler down.
36. Low water cutoff probe (LWCO)
Protects the heat exchanger from overheating, by ensuring
adequate water is supplied to the boiler. In the event of
inadequate water levels, the boiler will shut down.
37. Stainless steel flue collector
Flue gas and condensate enter the stainless steel flue collector
through the firetubes. A 1" drain connection allows condensate
to flow through the collector into a condensate trap for
disposal.
38. Reset switch
Reset switch for the low water cutoff. Hold the switch for 10
seconds to reset.
39. Test switch
The test switch permits manual triggering of the LWCO safety
circuit to test the contacts and evaluate the integrity of the
circuit. Hold the switch for 10 seconds to test.
40. Combustion measurement port
A port near the flue vent which provides access for a combustion
analyzer probe.
41. Burner plate (not shown)
The burner plate attaches the blower to the burner and the heat
exchanger. Removal allows easy access to the burner for
inspection or replacement.
Installation & Operation Manual
The FTXL - How it works...
(continued)
Models 400 - 850
Front View
Rear View
Left Side (inside unit)
Right Side (inside unit)
5
Installation & Operation Manual
Ratings
FTXL Boiler
AHRI Rating
Input
MBH
Model Number
(Note 4)
Note: Change “N” to
“L” for L.P. gas models.
Other Specifications
Gross
Output
MBH
Net
AHRI
Ratings
Water,
MBH
Boiler
Water
Content
Gallons
Water
Gas
Air
Connections Connections Size
Vent
Size
Min
Max
(Note 1)
(Note 2)
FTX400N
40
399
392
341
13.2
2"
1"
4"
4"
FTX500N
50
500
489
425
11.9
2"
1"
4"
4"
FTX600N
85.7
600
585
509
11.9
2"
1"
4"
4"
FTX725N
103.5
725
705
613
17.2
2 1/2"
1"
4"
6"
FTX850N
121.5
850
825
717
15.9
2 1/2”
1”
4”
6”
NOTICE
(Note 3)
Maximum allowed working pressure is located on the rating plate.
Notes:
1. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
6. Ratings have been confirmed by the Hydronics Section of
AHRI.
2. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
7. FTXL boilers comply with the requirements of CSD-1
Section CW-400 requirements as a temperature operation
control. The manual reset high limit provided with the
FTXL is listed to UL353.
3. FTXL boilers require special gas venting. Use only the vent
materials and methods specified in the FTXL Installation
and Operation Manual.
4.
Standard FTXL boilers are equipped to operate from sea
level to 4,500 feet only with no adjustments. The boiler
will de-rate by 4% for each 1,000 feet above sea level up to
4,500 feet.
5. High altitude FTXL boilers are equipped to operate from
3,000 to 12,000 feet only. The boiler will not de-rate up
to 5,400 feet and will de-rate by 1.6% for each 1,000 feet
above 5,400 feet. High altitude models are manufactured
with a different control module for altitude operation, but
the operation given in this manual remains the same as the
standard boilers. A high altitude label (as shown in Fig. A)
is also affixed to the unit.
De-rate values are based on proper combustion calibration
and CO2’s adjusted to the recommended levels.
Figure A High Altitude Label Location
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Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
The FTXL gas manifold and controls
NOTICE
met safe lighting and other performance
criteria when the boiler underwent tests
specified in ANSI Z21.13 – latest edition.
 WARNING
This appliance is certified as an indoor
appliance. Do not install the appliance
outdoors or locate where the appliance will
be exposed to freezing temperatures or to
temperatures that exceed 100°F.
Do not install the appliance where the
relative humidity may exceed 93%. Do not
install the appliance where condensation
may form on the inside or outside of the
appliance, or where condensation may fall
onto the appliance.
Failure to install the appliance indoors
could result in severe personal injury,
death, or substantial property damage.
 WARNING
This appliance requires a special venting
system. The vent connection to the appliance
must be made with the starter CPVC/
stainless steel pipe section provided with
the appliance. The field provided PVC vent
fittings must be cemented to the CPVC pipe
section. Use only the vent materials, primer
and cement specified in this manual to make
the vent connections. Failure to follow this
warning could result in fire, personal injury,
or death.
Before locating the boiler, check:
1.
Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the
appliance. The pan must not restrict combustion air
flow. Under no circumstances is the manufacturer to be
held responsible for water damage in connection with
this appliance, or any of its components.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
Failure to keep boiler area clear and free
 WARNING of combustible materials, gasoline, and
other flammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
4. The FTXL must be installed so that gas control system
components are protected from dripping or spraying
water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
• System leaks causing oxygen corrosion or heat exchanger
cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system
and boiler to freeze and leak.
6. Check around the boiler for any potential air contaminants
that could risk corrosion to the boiler or the boiler
combustion air supply (see Table 1A on page 10).
Prevent combustion air contamination. Remove any of
these contaminants from the boiler area.
DO NOT install units in rooms or
 WARNING environments that contain corrosive
contaminants (see Table 1A on page 10).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
Closet and alcove installations
A closet is any room the boiler is installed in which is less than
171 cubic feet for FTX400 models, 193 cubic feet for FTX500
models, 223 cubic feet for FTX600 models, 247 cubic feet for
FTX725 models and 278 cubic feet for FTX850 models.
An alcove is any room which meets the criteria for a closet with
the exception that it does not have a door.
Example: Room dimensions = 5 feet long, 4 feet wide, and
8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would be
considered a closet for a FTXL Boiler.
For closet and alcove installations as shown
 WARNING
in FIG.’s 1-1 and 1-2, CPVC or stainless
steel vent material must be used inside
the structure. The ventilating air openings
shown in FIG.’s 1-1 and 1-2 are required
for this arrangement. Failure to follow this
warning could result in fire, personal injury,
or death.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6 mm) from combustible
materials.
2. Vent pipe – at least 1" (25 mm) from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance
minimums.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 8 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
boiler without removing it from the space.
7
Installation & Operation Manual
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(continued)
Figure 1-1 Closet Installation - Minimum Required Clearances
 WARNING
For closet installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used in
a closet structure due to elevated
temperatures. Failure to follow
this warning could result in fire,
personal injury, or death.
 WARNING
For alcove installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used in
an alcove structure due to elevated
temperatures. Failure to follow
this warning could result in fire,
personal injury, or death.
Figure 1-2 Alcove Installation - Minimum Required Clearances
8
Installation & Operation Manual
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Determine boiler location
Provide air openings to room:
Residential garage installation
FTXL alone in boiler room
Precautions
1. No air ventilation openings into the boiler room are
needed when clearances around the FTXL are at least
equal to the SERVICE clearances shown in FIG.’s 1-1
and 1-2. For spaces that do NOT supply this clearance,
provide two openings as shown in FIG. 1-1. Each
opening must provide one square inch free area per
1,000 Btu/hr of boiler input.
Take the following precautions when installing the appliance
in a residential garage. If the appliance is located in a
residential garage, it should be installed in compliance with
the latest edition of the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CGA-B149 Installation Code.
Recommended service clearances
FRONT
TOP
REAR
- 30" (762 mm)
- 18" (610 mm)
- 24" (610 mm)
FTXL in same space with other gas or oil-fired
appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
 WARNING
The space must be provided with
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the FTXL.
Do not install the boiler in an attic.
Failure to comply with the above warnings
could result in severe personal injury,
death, or substantial property damage.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed
for the FTXL because it takes its combustion air from
outside (direct vent installation).
Flooring and foundation
Flooring
The FTXL is approved for installation on combustible
flooring, but must never be installed on carpeting.
Do not install the boiler on carpeting even
 WARNING
if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
• Appliances located in residential garages and in
adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
all burners and burner ignition devices are located not
less than 18 inches (46 cm) above the floor.
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
Vent and air piping
The FTXL requires a special vent system, designed for
pressurized venting.
The boiler is to be used for either direct vent installation or
for installation using indoor combustion air. When room
air is considered, see the General Venting Section. Note
prevention of combustion air contamination below when
considering vent/air termination.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. You may use any of the vent/air piping
methods covered in this manual. Do not attempt to install the
FTXL using any other means.
Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits given in this
manual.
Prevent combustion air contamination
Install air inlet piping for the FTXL as described in this
manual. Do not terminate vent/air in locations that can allow
contamination of combustion air. Refer to Table 1A, page
10 for products and areas which may cause contaminated
combustion air.
 WARNING
You must pipe combustion air to the boiler
air intake. Ensure that the combustion air
will not contain any of the contaminants
in Table 1A, page 10. Contaminated
combustion air will damage the boiler,
resulting in possible severe personal injury,
death or substantial property damage. Do
not pipe combustion air near a swimming
pool, for example. Also, avoid areas
subject to exhaust fumes from laundry
facilities. These areas will always contain
contaminants.
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Installation & Operation Manual
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Determine boiler location
Table 1A Corrosive Contaminants and Sources
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
(continued)
When using an existing vent system to
install a new boiler:
 WARNING
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
Check the following venting components before installing:
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other
similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
• Material - For materials listed for use with this appliance,
see Section 3 - General Venting. For polypropylene or
stainless steel venting, an adapter of the same
manufacturer must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3A.
Check to see that this size is used throughout the vent
system.
• Manufacturer - For a stainless steel or polypropylene
application, you must use only the listed manufacturers
and their type product listed in Tables 3E and 3G for CAT
IV positive pressure venting with flue producing
condensate.
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
• Terminations - Carefully review Sections 3 through 5 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section. For
stainless steel vent, only use terminations listed in Table
3H for the manufacturer of the installed vent.
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 11.
With polypropylene and stainless steel vent, seal and connect
all pipe and components as specified by the vent manufacturer
used; with PVC/CPVC vent, see the Installing Vent or Air
Piping Section on pages 20 and 21.
If any of these conditions are not met,
 WARNING the existing system must be updated
or replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
10
Installation & Operation Manual
1
Determine boiler location
(continued)
When removing a boiler from existing
common vent system:
 DANGER
Do not install the FTXL into a common
vent with any other appliance. This
will cause flue gas spillage or appliance
malfunction, resulting in possible severe
personal injury, death, or substantial
property damage.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while
the other appliances remaining connected to the common
venting system are not in operation.
g. Any improper operation of the common venting
system should be corrected so the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and/or CAN/CSA B149.1, Natural Gas and Propane
Installation Code. When resizing any portion of the
common venting system, the common venting system
should be resized to approach the minimum size as
determined using the appropriate tables in Part 11
of the National Fuel Gas Code, ANSI Z223.1/NFPA
and/or CAN/CSA B149.1, Natural Gas and Propane
Installation Code.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage
or restriction, leakage, corrosion, or other deficiencies,
which could cause an unsafe condition.
c.
Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space
in which the appliances remaining connected to the
common venting system are located and other spaces of
the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e.
Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from another source.
f.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined herein, return
doors, windows, exhaust fans, fireplace dampers, and any
other gas-burning appliance to their previous conditions
of use.
11
Installation & Operation Manual
1
Determine boiler location
Combustion
and
ventilation
air
requirements for appliances drawing air
from the equipment room
Provisions for combustion and ventilation air must be in
accordance with Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, NFPA 54 / ANSI
Z223.1, in Canada, the latest edition of CGA Standard B149
Installation Code for Gas Burning Appliances and Equipment,
or applicable provisions of the local building codes.
The equipment room MUST be provided with properly sized
openings and/or be of sufficient volume to assure adequate
combustion air and proper ventilation for all gas fired appliances
in the equipment room to assure adequate combustion air and
proper ventilation.
IMG01075
Figure 1-4_Combustion Air Through Ducts
2.
The requirements shown are for the appliance only; additional
gas fired appliances in the equipment room will require an
increase in the net free area and/or volume to supply adequate
combustion air for all appliances.
If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the
equipment room, each of the two openings should be
sized based on a minimum free area of one square inch
per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-4).
No combustion air openings are needed when the appliance is
installed in a space with a volume NO LESS than 50 cubic feet
per 1,000 Btu/hr of all installed gas fired appliances and the
building MUST NOT be of “Tight Construction”3.
A combination of indoor and outdoor combustion air may
be utilized by applying a ratio of available volume to required
volume times the required outdoor air opening(s) size(s). This
must be done in accordance with the National Fuel Gas Code,
NFPA 54 / ANSI Z223.1.
IMG01076
Figure 1-5_Combustion Air from Interior Space
3.
If air is taken from another interior space combined with
the equipment room:
(a) Two spaces on same story: Each of the two openings
specified above should have a net free area of one square
inch for each 1000 Btu/hr (22 cm2 per kW) of input, but
not less than 100 square inches (645 cm2) (see FIG. 1-5).
(b) Two spaces on different stories: One or more openings
should have a net free area of two square inches per 1000
Btu/hr (44 cm2 per kW).
IMG01074
Figure 1-3_Combustion Air Direct from Outside
1.
If air is taken directly from outside the building
with no duct, provide two permanent openings to
the equipment room each with a net free area of one square
inch per 4000 Btu/hr input (5.5 cm2 per kW) (see FIG. 1-3).
12
IMG01077
Figure 1-6_Combustion Air from Outside - Single Opening
Installation & Operation Manual
1
4.
Determine boiler location
(continued)
If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the
opening must be sized based on a minimum free area
of one square inch per 3000 Btu/hr (7 cm2 per kW). This
opening must be located within 12” (30 cm) of the top of
the enclosure (see FIG. 1-6).
Combustion air requirements are based on the latest edition
of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in
Canada refer to the latest edition of CGA Standard CAN/CSA
B149.1. Check all local code requirements for combustion air.
All dimensions based on net free area in square inches. Metal
louvers or screens reduce the free area of a combustion air
opening a minimum of approximately 25%. Check with
louver manufacturers for exact net free area of louvers.
Where two openings are provided, one must be within 12"
(30 cm) of the ceiling and one must be within 12" (30 cm) of
the floor of the equipment room. Each opening must have a
net free area as specified in Table 1B. Single openings shall
commence within 12" (30 cm) of the ceiling. The minimum
dimension of air openings shall not be less than 3" (80 mm).
FIG. 1-3
Model
Number
FTX400
FTX500
FTX600
FTX725
FTX850
*Outside Air from
2 Openings Directly from
Outdoors1
 CAUTION
Under no circumstances should the
equipment room ever be under negative
pressure. Particular care should be taken
where exhaust fans, attic fans, clothes dryers,
compressors, air handling units, etc., may
take away air from the unit.
The combustion air supply must be completely free of any
flammable vapors that may ignite or chemical fumes which may
be corrosive to the appliance. Common corrosive chemical
fumes which must be avoided are fluorocarbons and other
halogenated compounds, most commonly present as refrigerants
or solvents, such as Freon, trichlorethylene, perchlorethylene,
chlorine, etc. These chemicals, when burned, form acids which
quickly attack the stainless steel heat exchanger, headers, flue
collectors, and the vent system.
The result is improper combustion and a non-warrantable,
premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts air
from the equipment room may deplete the combustion air
supply and/or cause a downdraft in the venting system. Spillage
of flue products from the venting system into an occupied
living space can cause a very hazardous condition that must be
corrected immediately.
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
FIG. 1-4
FIG. 1-5
*Outside Air from
2 Ducts Delivered from
Outdoors1
Inside Air from
2 Ducts Delivered from Interior
Space2
Same Story
Top
Opening, in2
(cm2)
Bottom
Opening, in2
(cm2)
Top
Opening, in2
(cm2)
Bottom
Opening, in2
(cm2)
Top
Opening, in2
(cm2)
Bottom
Opening, in2 (cm2)
100
(646)
125
(807)
150
(968)
182
(1,174)
213
(1,374)
100
(646)
125
(807)
150
(968)
182
(1,174)
213
(1,374)
200
(1,291)
250
(1,613)
300
(1,936)
363
(2,342)
425
(2,742)
200
(1,291)
250
(1,613)
300
(1,936)
363
(2,342)
425
(2,742)
400
(2,581)
500
(3,226)
600
(3,871)
725
(4,677)
850
(5,484)
400
(2,581)
500
(3,226)
600
(3,871)
725
(4,677)
850
(5,484)
FIG. 1-6
*Outside Air from
1 Opening Directly from
Outdoors, in2
(cm2)1
134
(865)
167
(1,078)
200
(1,291)
242
(1,561)
284
(1,832)
The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase
in the net free area and/or volume to supply adequate combustion air for all appliances.
No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per
1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”3.
Outside air openings shall directly communicate with the outdoors.
1
Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.
2
”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight
Construction”, provide air openings into the building from outside.
3
13
Installation & Operation Manual
2
Prepare boiler
Remove boiler from wood pallet
Models 400 and 500 Only (Venturi w/LP
1. After removing the outer shipping carton from the boiler, Orifices)
remove the parts box.
2. To remove the boiler from the pallet (after removing the
front door):
a. Remove the lag bolts from the wood pallet inside the
boiler (FIG. 2-1).
b. Disconnect the ribbon cable and remove the bezel
(no tools required for removal) before removing the
boiler from the pallet or moving the boiler.
c. Detach the boiler from the lag bolts in the front and
rear of the unit, see FIG. 2-1.
Do not drop the boiler or bump the jacket
NOTICE
on the floor or pallet. Damage to the boiler
can result.
2. Disconnect the air inlet piping from the venturi by loosening
the band clamp around the rubber boot coupling. Slide the
rubber boot off of the venturi.
3. Disconnect gas piping from the venturi by loosening the
threaded nut on the venturi (replace gasket if damaged).
4. Remove the bolts connecting the venturi to the fan and then
proceed to remove the Natural venturi from the unit (FIG.’s
2-2A and 2-2B).
5. Install the LP venturi onto the fan taking note of the
following:
a. The UP arrow on the plastic housing is indeed
pointing up.
Figure 2-1 Boiler Mounted on Shipping Pallet
REAR
FRONT
1. Remove the top bezel from the unit (no tools required for
removal).
b. The threaded connection for the gas piping is facing
towards the front of the unit. Reinstall the
bolts connecting the venturi to the fan.
6. Reassemble the gas pipe to the threaded connection on
the venturi. Install the new gasket provided in the kit and
ensure it is seated properly before tightening the nut.
LAG BOLTS
(QTY. 3)
LAG BOLTS
(QTY. 3)
IMG00984
7. Reconnect the rubber boot on the air inlet to the venturi
inlet and tighten the band clamp at this connection.
8. After installation is complete, attach the propane conversion
label (in the conversion kit bag) next to the boiler rating
For a boiler already installed, you must
plate. Attach the LP caution label (in the conversion kit bag)
 WARNING
turn off gas supply, turn off power and
to the rear of the boiler underneath the gas supply piping.
allow boiler to cool before proceeding.
You must also completely test the boiler 9. Replace the top bezel removed in Step 1 and resume
operation.
after conversion to verify performance
as described under Start-up, Section 10
After converting to LP, check combustion
of this manual. Failure to comply could
 WARNING
result in severe personal injury, death, or
per the Start-up procedure in Section 10
substantial property damage.
of this manual. Failure to check and verify
combustion could result in severe personal
For the 400 and 500 Models you must
injury, death, or substantial property damage.
install a propane venturi to operate the
FTXL on propane gas.
Models 400 and 500: Inspect the O-ring
Models 600 - 850 do not require a venturi
 DANGER when the blower is disassembled. The O-ring
change for propane operation, but they
must be in good condition and must be
will require a valve adjustment.
installed. Failure to comply will cause a gas
leak, resulting in severe personal injury or
death.
Table 2A LP Conversion Kit
Gas conversions
Model
Description
Kit Number
400 - 500
LP Kit
LPK30017
14
Installation & Operation Manual
2
Prepare boiler
(continued)
Figure 2-2A 400 Model_Venturi with LP Orifice
Models 600 - 850
1. Lift the top bezel (prop the bezel up for service).
2. Remove the cover on top of the gas valve (FIG. 2-3).
3. Use a combustion analyzer to verify CO2 is within the range
of 9.0 – 11.0%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-3).
4. After adjustment is complete, attach the propane
conversion label (in the conversion kit bag) next to the
boiler rating plate. Attach the LP caution label (in the
conversion kit bag) to the rear of the boiler underneath
the gas supply piping.
5. Replace the gas valve cover and lower the bezel.
 WARNING
Figure 2-2B 500 Model_Venturi with LP Orifice
Failure to check and verify combustion
could result in severe personal injury,
death, or substantial property damage.
Figure 2-3 Gas Valve Adjustment - Models 600 - 850
15
Installation & Operation Manual
3
General venting
Direct venting options - Sidewall Vent
PVC/CPVC Concentric Sidewall
Models 400 - 600 Only
See page 28 for more details
Two Pipe Sidewall
See page 24 for more details
Direct venting options - Vertical Vent
Two Pipe Vertical
See page 31 for more details
16
PVC/CPVC
Concentric Vertical
Models 400 - 600 Only
See page 33 for more details
Vertical Vent, Sidewall Air
Installation & Operation Manual
3
General venting
(continued)
Install vent and combustion air piping
 DANGER
 WARNING
The FTXL boiler must be vented and
supplied with combustion and ventilation
air as described in this section. Ensure the
vent and air piping and the combustion
air supply comply with these instructions
regarding vent system, air system, and
combustion air quality. See also Section 1
of this manual.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
This appliance requires a special venting
system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and
fittings listed in Tables 3E, 3F, and 3H for
vent pipe, and fittings. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
The FTXL boiler vent and air piping can be installed through
the roof or through a sidewall. Follow the procedures in this
manual for the method chosen. Refer to the information in
this manual to determine acceptable vent and air piping length.
You may use any of the vent/air piping methods covered in this
manual. Do not attempt to install the FTXL boiler using any
other means.
You must also install air piping from outside to the boiler
air intake adapter unless following the Optional Room Air
instructions on page 19 of this manual. The resultant installation
is direct vent (sealed combustion).
The FTXL is certified as a Category II/IV boiler. All venting
systems used with this boiler must be suitable for Category IV
operation except for factory approved common vent systems
operating as allowed in the Common Venting Section on page
20.
Air intake/vent connections
1.
DO NOT mix components from different
 WARNING systems. The vent system could fail,
causing leakage of flue products into the 2.
living space. Mixing of venting materials
will void the warranty and certification of
the appliance.
NOTICE
Installation must comply with local
requirements and with the National
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
 WARNING
For closet and alcove installations, CPVC,
polypropylene or stainless steel material
MUST BE used in a closet/alcove structure.
Failure to follow this warning could result
in fire, personal injury, or death.
 CAUTION
Improper installation of venting systems
may result in injury or death.
NOTICE
Combustion Air Intake Connector (FIG. 3-1) - Used to
provide combustion air directly to the unit from outdoors. A
fitting is provided on the unit for final connection.
Combustion air piping must be supported per guidelines
listed in the National Mechanical Code, Section 305, Table
305.4 or as local codes dictate.
Vent Connector (FIG.'s 3-2 thru 3-7) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
Figure 3-1 Near Boiler Air Piping
Follow the instructions in Section 1, page
11 of this manual when removing a boiler
from an existing vent system.
 WARNING Do not connect any other appliance to
the vent pipe or multiple boilers to a
common vent pipe. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
17
Installation & Operation Manual
3
General venting
Requirements for installation in
Canada
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Equivalent
Installations must be made with a vent pipe system
Model
Kit Number
Vent
Length
certified to ULC-S636.
400
CVK3007
5'
(1.5
m)
2. The first three (3) feet of plastic vent pipe from the
500
600
CVK3007
30'
(9
m)
appliance flue outlet must be readily accessible for visual
inspection.
Air inlet pipe materials:
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted The air inlet pipe(s) must be sealed. Choose acceptable
pipe/fittings. For concentric vent installations, the inner combustion air inlet pipe materials from the following list:
vent tube must be replaced with field supplied certified vent
PVC, CPVC, Polypropylene or ABS
material to comply with this requirement.
Dryer Vent or Sealed Flexible Duct (not recommended for
4. The 4" Concentric Vent Kit available from Lochinvar (see
rooftop air inlet)
Section 4 – Sidewall Termination – Optional Concentric
Galvanized steel vent pipe with joints and seams sealed as
Vent) and the 4" Concentric Vent Kit available from IPEX
specified in this section.
are both approved for use on the FTXL (400 - 600
Type “B” double-wall vent with joints and seams sealed as
models only) boiler. Both kits are listed to the ULC-S636
specified in this section.
standard for use in Canada.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
Sizing
1.
The FTXL uses model specific combustion air intake and vent
piping sizes as detailed in Table 3A below.
*Plastic pipe may require an adapter (not provided)
to transition between the air inlet connection on the
appliance and the plastic air inlet pipe.
Table 3A Air Intake/Vent Piping Sizes
Model
Pipe Diameter
Air Intake
Vent
De-rate per 25 feet of Vent
Direct Vent
Room Air
400
4" (102 mm) 4" (102 mm)
0.00%
0.00%
500
4" (102 mm) 4" (102 mm)
0.40%
0.40%
600
4" (102 mm) 4" (102 mm)
1.20%
1.20%
725
4" (102 mm) 6" (152 mm)
1.20%
1.20%
850
4" (102 mm) 6" (152 mm)
1.40%
1.40%
NOTICE
Increasing or decreasing combustion air
or vent piping sizes is not authorized.
Minimum
/
Maximum
allowable
combustion air and vent piping lengths
are as follows:
Combustion Air = 12 equivalent feet (3.7 m) minimum /
100 equivalent feet (30.5 m) maximum
Vent = 12 equivalent feet (3.7 m) minimum / 100 equivalent
feet (30.5 m) maximum
When determining equivalent combustion air and vent
length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m)
for each 45° elbow.
EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows +
(3) 45° elbows + (1) concentric vent kit (CVK3007) = 49
equivalent feet (15 m) of piping.
The appliance output rating will reduce
NOTICE
by up to 1.5% for each 25 feet of vent
length.
18
 WARNING
NOTICE
Using air intake materials other than
those specified can result in personal
injury, death or property damage.
The use of double-wall vent or insulated
material for the combustion air inlet
pipe is recommended in cold climates
to prevent the condensation of airborne
moisture in the incoming combustion
air.
Sealing of Type “B” double-wall vent material or
galvanized vent pipe material used for air inlet piping
on a sidewall or vertical rooftop Combustion Air Supply
System:
a. Seal all joints and seams of the air inlet pipe using
either Aluminum Foil Duct Tape meeting UL
Standard 723 or 181A-P or a high quality UL Listed
silicone sealant such as those manufactured by Dow
Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three (3) sheet
metal screws or pop rivets. Apply Aluminum Foil
Duct Tape or silicone sealant to all screws or rivets
installed in the vent pipe.
d. Ensure that the air inlet pipes are properly supported.
Installation & Operation Manual
3
General venting
(continued)
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe
should use a silicone sealant to ensure a proper seal at the
appliance connection and the air inlet cap connection. Dryer
vent or flex duct should use a screw type clamp to seal the vent
to the appliance air inlet and the air inlet cap. Proper sealing
of the air inlet pipe ensures that combustion air will be free of
contaminants and supplied in proper volume.
Follow the polypropylene manufacturer’s instructions when
using polypropylene material as an inlet pipe.
When a sidewall or vertical rooftop combustion air supply
system is disconnected for any reason, the air inlet pipe must
be resealed to ensure that combustion air will be free of
contaminants and supplied in proper volume.
Failure to properly seal all joints and seams
 DANGER
as required in the air inlet piping may
result in flue gas recirculation, spillage
of flue products and carbon monoxide
emissions causing severe personal injury
or death.
Optional room air
NOTICE
Optional room air is intended for
commercial applications. Combustion
air piping to the outside is recommended
for residential applications.
Commercial applications utilizing the FTXL boiler may be
installed with a single pipe carrying the flue products to the
outside while using combustion air from the equipment
room. In order to use the room air venting option the
following conditions and considerations must be followed.
•
•
•
•
The unit MUST be installed with the appropriate
bird screen (Table 3C).
The equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
Using the room air kit makes the unit vulnerable to
combustion air contamination from within the
building.
Please review Section 1, Prevent
Combustion Air Contamination, to ensure proper
installation.
Vent system and terminations must comply with the
standard venting instructions set forth in this
manual.
NOTICE
When utilizing the single pipe method,
 WARNING provisions for combustion and ventilation
air must be in accordance with Air for
Combustion and Ventilation, of the latest
edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition
of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment, or applicable provisions of
the local building codes.
Table 3C Optional Room Air Kit
Model
Description
Kit Number
400 - 850
Room Air Kit
KIT30053
Air contamination
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds. When
these chemicals pass through the boiler, they can form strong
acids. The acid can eat through the boiler wall, causing serious
damage and presenting a possible threat of flue gas spillage or
boiler water leakage into the building.
Please read the information given in Table 1A, page 10,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
If the boiler combustion air inlet is located in
a laundry room or pool facility, for example,
these areas will always contain hazardous
contaminants.
To prevent the potential of severe personal
 WARNING
injury or death, check for areas and products
listed in Table 1A, page 10 before installing
the boiler or air inlet piping.
 WARNING
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
• Relocate air inlet and vent terminations
to other areas.
There will be a noticeable increase in the
noise level during normal operation from
the inlet air opening.
19
Installation & Operation Manual
3
General venting
Common venting
Table 3D Flue Damper Kits
FTXL boilers may be common vented; however, the following
criteria MUST BE followed:
Flue Damper Kits
1.
2.
3.
4.
5.
Only FTXL boilers may be connected to the common
vent. DO NOT mix other manufacturer’s appliances or
other Lochinvar models.
Model
Damper Size
Kit Number
400
4"
DRH30006
FTXL boilers connected to the common vent must all be
of the same size.
500
4”
DRH30006
600
4”
DRH30006
Each FTXL boiler must have a Lochinvar supplied flue
damper installed (see Table 3D).
725
6”
DRH30007
850
6”
DRH30007
Only vertical direct vent, positive pressure, Category
IV or vertical/chimney vent, negative pressure, Category
II may be used when common venting FTXL boilers.
Sidewall common venting is not allowed.
FTXL boilers in a common vent must be connected and
controlled with the integral FTXL SMART SYSTEM
Cascade.
a.
The Leader may be controlled through the FTXL
SMART SYSTEM control through BMS (external
0 - 10V signal), ModBus, BACnet, or its own internally
calculated set point.
b.
The Cascade (Members) must be controlled by the
FTXL Leader boiler using the Lead/Lag Cascade
option.
For approved common vent sizing, contact the factory.
When FTXL boilers are common vented,
 WARNING the criteria above MUST BE followed.
Failure to follow all these requirements
will result in severe personal injury, death,
or substantial property damage.
NOTICE
20
When FTXL boilers are common vented,
hot water generators must be piped to the
primary heating loop and tank thermostats
must not be connected to the FTXL.
PVC/CPVC
This product has been approved for use with the PVC/CPVC
vent materials listed in Table 3E on page 21.
Installing vent and air piping
 WARNING The vent connection to the appliance must
be made with the starter CPVC pipe section
provided with the appliance if PVC/CPVC
vent is to be used. The field provided
vent fittings must be cemented to the
CPVC pipe section using an “All Purpose
Cement” suitable for PVC and CPVC pipe.
Use only the vent materials, primer, and
cement specified in Table 3E to make
the vent connections. Failure to follow
this warning could result in fire, personal
injury, or death.
NOTICE
Use only cleaners, primers, and solvents
that are approved for the materials which
are joined together.
All PVC vent pipes must be glued, properly
supported, and the exhaust must be
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
Insulation should not be used on PVC
 WARNING
or CPVC venting materials. The use of
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
NOTICE
Installation & Operation Manual
3
General venting
(continued)
Table 3E PVC/CPVC Vent Pipe, and Fittings
5.
Dry fit vent or air piping to ensure proper fit up
before assembling any joint. The pipe should go
a third to two-thirds into the fitting to ensure
proper sealing after cement is applied.
6.
ANSI/ASTM D2564
Priming and Cementing:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
c. Apply a second primer coat to the fitting
socket.
ANSI/ASTM F493
d.
Approved PVC/CPVC Vent Pipe and Fittings
Item
Material
Standard
PVC Schedule 40, 80 ANSI/ASTM D1785
Vent pipe
PVC - DWV
ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
Vent fittings
PVC Schedule 40
ANSI/ASTM D2466
PVC Schedule 80
ANSI/ASTM D2467
CPVC Schedule 80
ANSI/ASTM F439
Pipe Cement / PVC
Primer
CPVC
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/
primer must be ULC-S636 certified.
1.
2.
Work from the boiler to vent or air termination. Do not
exceed the lengths given in this manual for the air or vent
piping.
Cut pipe to the required lengths and deburr the inside
and outside of the pipe ends.
3.
Chamfer outside of each pipe end to ensure even
cement distribution when joining.
4.
Clean all pipe ends and fittings using a clean dry rag.
(Moisture will retard curing and dirt or grease will prevent
adhesion.)
Figure 3-2 Near Boiler PVC/CPVC Venting - Models 400 - 600
e.
f.
g.
While primer is still wet, apply an even coat of
approved cement to the pipe equal to the depth of
the fitting socket along with an even coat of
approved cement to the fitting socket.
Apply a second coat of cement to the pipe.
While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
sufficient cement was not applied and joint could
be defective.
Wipe excess cement from the joint removing
ring or beads as it will needlessly soften the
pipe.
Figure 3-3 Near Boiler PVC/CPVC Venting - Models
725 - 850
21
Installation & Operation Manual
3
General venting
NOTICE
Polypropylene
This product has been approved for use with polypropylene
vent with the manufacturers listed in Table 3F.
All terminations must comply with listed options in this manual
and be a single-wall vent offering.
The installer must use a specific vent starter
adapter at the flue collar connection. The
adapter is supplied by the vent manufacturer
to adapt to its vent system. See Table 3F
for approved vent adapters. Discard CPVC
starter piece.
All vent connections MUST be secured by the
vent manufacturer's joint connector (FIG.
3-5).
Insulation should not be used on
 WARNING
polypropylene venting materials. The use
of insulation will cause increased vent wall
temperatures, which could result in vent pipe
failure.
Use only the adapters and vent system listed in
 WARNING
Tables 3F and 3G. DO NOT mix vent systems
of different types or manufacturers. Failure
to comply could result in severe personal
injury, death, or substantial property damage.
Installations must comply with applicable
NOTICE
national, state, and local codes. For Canadian
installation, polypropylene vent must be listed
as a ULC-S636 approved system.
Installation of a polypropylene vent system
NOTICE
should adhere to the vent manufacturer’s
installation instructions supplied with the
vent system.
NOTICE
For support and special connections required, see the
manufacturer's instructions. All vent is to conform to standard
diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length
for polypropylene single-wall piping:
•
1 foot of Duravent 4 inch single-wall pipe is equivalent
to 1.6 feet of piping
Flexible polypropylene
For use of flex pipe, it is recommended to have the vent material
in 32°F or higher ambient space before bending at installation.
No bends should be made to greater than 45° and ONLY
installed in vertical or near vertical installations (FIG. 3-4).
Figure 3-4 Near Boiler Flexible Polypropylene Venting
Figure 3-5 Near Boiler Polypropylene Venting
Table 3F Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make
Model
Centrotherm Eco Systems
Duravent (M & G Group)
InnoFlue SW/Flex
PolyPro Single-Wall / PolyPro Flex
Table 3G Approved Polypropylene Terminations
Model
Manufacturer Vent Model
Vent Type
Adapter Number
Joint Connector
Centrotherm
Single-Wall
Innoflue
ISAAL0404
IANS04
Eco Systems
Flex
400-600 DuraVent
Single-Wall
PolyPro
4PPS-AD
4PPS-LB
(M & G)
Flex
Centrotherm
Single-Wall
Innoflue
ISAAL0606
-Eco Systems
Flex
725-800 DuraVent
Single-Wall
FSA-6PVCMPolyPro
-(M & G)
Flex
6PPS
* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 27).
22
Sidewall Kit*
Retaining Bracket /
Adapter*
--
IATP0404/
ISTAGL0404
4PPS-HLK
--
--
IATP0606 /
ISTAGL0606
6PPS-HLK
--
Installation & Operation Manual
3
General venting
(continued)
Stainless steel vent
Figure 3-6 Near Boiler Stainless Steel Venting Models
400 - 600
This product has been approved for use with stainless steel
using the manufacturers listed in Table 3H.
Use only the materials, vent systems, and
 WARNING terminations listed in Tables 3G and 3I.
DO NOT mix vent systems of different
types or manufacturers. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
NOTICE
NOTICE
NOTICE
The installer must use a specific vent starter
adapter at the flue collar connection,
supplied by the vent manufacturer to
adapt to its vent system. See Table 3I for
approved vent adapters. Discard CPVC
starter piece.
Installations must comply with applicable
national, state, and local codes. Stainless
steel vent systems must be listed as a
UL-1738 approved system for the United
States and a ULC-S636 approved system
for Canada.
Installation of a stainless steel vent system
should adhere to the stainless steel vent
manufacturer’s installation instructions
supplied with the vent system.
Figure 3-7 Near Boiler Stainless Steel Venting Models
725 - 850
Table 3H Stainless Steel Vent Pipe and Fittings
Approved Stainless Steel Vent Manufacturers
Manufacturer
Model
Dura Vent (M & G)
Z-Flex
FasNSeal Vent / FasNSeal
Flex*
Z-Vent
Heat Fab
Metal Fab
Security Chimney
Saf-T Vent
Corr/Guard
Secure Seal
*Use of FasNSeal Flex smooth inner wall vent is to be used
in vertical or near vertical sections only, taking precaution to
ensure no sagging occurs of the vent system. Connect to the
FasNSeal rigid vent using specially designed adapters and sealing
method, see manufacturer’s instructions.
Table 3I Approved Stainless Steel Adapters and Terminations
Model
400-600
725-850
Manufacturer
Adapter
Termination
Flue
Intake
DuraVent (M & G)
(Fas-N-Seal)
FSA-04-PVC
F303759
Heat Fab (Saf-T-Vent)
9401PVC
9401PVC
Z-Flex (Z-Vent)
2SVSLA04
2SVSLA04
Metal Fab (Corr/Guard)
4CGPVCA
4CGPVCA
Security Chimney
(Secure Seal)
DuraVent (M & G)
(Fas-N-Seal)
SS4PVCU
SS4PVCU
FSA-06PVC-06FNS
300538
F303759
Heat Fab (Saf-T-Vent)
9601PVC
9601PVC
Metal Fab (Corr/Guard)
6FCGPVCA
6FCGPVCA
Security Chimney
(Secure Seal)
SS6PVCU
SS6PVCU
Flue
FSBS4
FSRC4 (R.C.)
Intake
FSAIH04
303888
0492
5400CI
9414TERM
2SVSTP04
2SVSRCX04
4CGSWHT
4CGSWC
SS4STU
SS4RCBU
2SVSTEX0490
4CGSW90LT
SS4ST90AU
FSBS6
FSAIH04
303888
9601PVC
9601PVC
6FCGSWMC
6FCGSWC
SS6STU
SS6RCBU
6CGSW90L
SS6ST90AU
23
Installation & Operation Manual
4
Sidewall direct venting
Vent/air termination – sidewall
 WARNING
 WARNING
Follow instructions below when
determining vent location to avoid
possibility of severe personal injury, death,
or substantial property damage.
A gas vent extending through an exterior
wall shall not terminate adjacent to a
wall or below building extensions such
as eaves, parapets, balconies, or decks.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
f.
g.
Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
Locate or guard vent to prevent condensate damage
to exterior finishes.
Figure 4-1A PVC/CPVC/ Polypropylene Sidewall
Termination of Air and Vent w/Field Supplied Fittings
 WARNING Do not connect any other appliance to the
vent pipe or multiple boilers to a common
vent pipe except as noted in Section 3
on page 20. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
 CAUTION
Sidewall venting commercial products will
result in large exhaust plumes in cold
climates. Consideration should be taken
when locating in proximity to windows,
doors, walkways, etc.
NOTICE
Installation must comply with local
requirements and with the National Fuel
Gas Code, NFPA 54 / ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
Determine location
3. The air piping must terminate in a down-turned elbow
as shown in FIG. 4-1A. This arrangement avoids
recirculation of flue products into the combustion air
stream.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1A.
Do not exceed the maximum lengths of the
Locate the vent/air terminations using the following
 WARNING
outside vent piping shown in FIG. 4-1B.
guidelines:
Excessive length exposed to the outside could
1. The total length of piping for vent or air must not exceed
cause freezing of condensate in the vent pipe,
the limits given in the General Venting Section on page
resulting in potential boiler shutdown.
18 of this manual.
2. You must consider the surroundings when terminating
Figure 4-1B PVC/CPVC/Polypropylene Sidewall
the vent and air:
Termination of Air and Vent
a. Position the vent termination where vapors will
not damage nearby shrubs, plants or air
conditioning equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of
condensate and water/ice buildup where flue
products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
e. Do not locate the terminations where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent Table 4A Sidewall Vent Kits
buildings or surfaces, window wells, stairwells,
alcoves, courtyards, or other recessed areas.
Centerline
 WARNING
24
Sidewall vent and air inlet terminations
must terminate in the same pressure
zone.
Model
Kit #
Air
Vent
Width
400 - 600 KIT30046 4" (102 mm) 4" (102 mm) 5 5/8" (143 mm)
725 - 850 KIT30048 4" (102 mm) 6" (152 mm) 7 3/4" (197 mm)
Installation & Operation Manual
4
Sidewall direct venting
(continued)
Vent/air termination – sidewall
c.
Figure 4-2A PVC/CPVC/ Polypropylene Sidewall
Termination Models 400 - 850 w/Field Supplied Fittings
Do not terminate closer than 4 feet (1.2 m)
horizontally from any electric meter, gas meter,
regulator, relief valve, or other equipment. Never
terminate above or below any of these within 4 feet
(1.2 m) horizontally.
6. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
Figure 4-3A Clearance to Gravity Air Inlets w/Field
Supplied Fittings
Figure 4-2B Stainless Steel Sidewall Termination Models
725 - 850 w/Field Supplied Fittings
Figure 4-3B Clearance to Gravity Air Inlets
NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.
5.
Maintain clearances as shown in FIG.’s 4-1A thru 4-4B,
pages 24 thru 26. Also maintain the following:
a. Vent must terminate:
• At least 6 feet (1.8 m) from adjacent walls.
• No closer than 12 inches (305 mm) below roof
overhang.
• At least 7 feet (2.1 m) above any public walkway.
• At least 3 feet (.9 m) above any forced air intake
within 10 feet (3 m).
• No closer than 12 inches (305 mm) below or
horizontally from any door or window or any other
gravity air inlet.
b. Air inlet must terminate at least 12 inches (305 mm)
above grade or snow line; at least 12 inches (305 mm)
below the vent termination (FIG. 4-1B); and the vent
pipe must not extend more than 24 inches (610 mm)
vertically outside the building.
25
Installation & Operation Manual
4
Sidewall direct venting
Vent/air termination – sidewall
Figure 4-4A Clearance to Forced Air Inlets w/Field
Supplied Fittings
3. Use a sidewall termination plate as a template for correct
location of hole centers.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
Figure 4-5A A Typical Sidewall Termination Assembly - Models
400 - 850 PVC/CPVC/ Polypropylene or Stainless Steel
Figure 4-4B Clearance to Forced Air Inlets
Prepare wall penetrations
Supplied Option)
1.
(Factory
Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside
diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole
with at least a 1/2 inch clearance around the vent pipe
outer diameter:
• 5½ inch hole (140 mm) hole for 4 inch (102 mm)
vent pipe
• 7½ inch hole (191 mm) hole for 6 inch (152 mm)
vent pipe
Prepare wall penetrations
1.
2.
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the vent
pipe outer diameter:
• 5½ inch hole (140 mm) hole for 4 inch (102 mm)
vent pipe
• 7½ inch hole (191 mm) hole for 6 inch (152 mm)
vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-5A.
26
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
2.
3.
For Polypropylene Only: Install the vent and air intake
sidewall adapters from Table 3G on page 22 into the vent
plate. Slide the sidewall retaining bracket down the
sidewall adapters flush to the vent plate (FIG. 4-4A).
For PVC/CPVC Only: Install the vent and air intake
piping through the wall into the vent plate openings.
Use RTV silicone sealant to seal the air pipe. Use the
cement/primer listed in Table 3E on page 21 to seal the
vent pipe.
Installation & Operation Manual
4
4.
5.
6.
7.
8.
9.
Sidewall direct venting
(continued)
Mount and secure the vent plate to the wall using stainless Multiple vent/air terminations
steel screws.
Seal all gaps between the pipes and wall. Seal around the 1. When terminating multiple FTXL’s terminate
each vent/air connection as described in this manual
plate to the wall assuring no air gaps.
(FIG. 4-6A).
Assemble the vent cap to the vent plate (see FIG.’s 4-5B
and 4-5C). Insert the stainless steel screws into the vent
 WARNING All vent pipes and air inlets must terminate
cap screw hole openings and securely attach the vent cap
at the same height to avoid possibility of
to the vent plate.
severe personal injury, death, or substantial
property damage.
Seal all wall cavities.
PVC/CPVC terminations are designed to accommodate any 2. Place wall penetrations to obtain minimum clearance of
12 inches (305 mm) between vent pipe and adjacent air
wall thickness of standard constructions per the directions
inlet elbow, as shown in FIG. 4-6B for U.S. installations.
found in this manual.
For Canadian installations, provide clearances required
Stainless steel terminations are designed to penetrate walls
by CSA B149.1 Installation Code.
with a thickness up to 9.25 inches of standard construction.
Figure 4-5B PVC/CPVC Sidewall Termination Assembly
3. The air inlet of a FTXL is part of a direct vent connection.
It is not classified as a forced air intake with regard to
spacing from adjacent boiler vents.
Figure 4-6A Multiple Vent Terminations w/
Field Supplied Fittings (must also comply with
Figure 4-1A)
Table 4B Sidewall Vent Centerline Dimensions
Model
Air
Vent
Centerline Width
400 - 600 4" (102 mm) 4"(102 mm)
5 5/8" (143 mm)
725 - 850 4" (102 mm) 6" (152 mm)
7 3/4" (197 mm)
Figure 4-6B Multiple Vent Terminations (must also
comply with Figure 4-1B)
Figure 4-5C Polypropylene Sidewall Termination Assembly
27
Installation & Operation Manual
4
Sidewall direct venting
Sidewall termination – optional concentric vent: Models 400 - 600 Only
Description and usage
Lochinvar offers an optional concentric combustion air
and vent pipe termination kit (#CVK3007 for 4" (102 mm)
diameter - Models 400 - 600). Both combustion air and vent
pipes must attach to the termination kit. The termination kit
must terminate outside the structure and must be installed as
shown below in FIG. 4-7.
The required combustion vent pipe materials are listed in
Table 3E, on page 21 of this manual.
Figure 4-7 Concentric Sidewall Termination - Models
400 - 600
Sidewall termination installation
1. Determine the best location for the termination kit
(see FIG. 4-7).
2. Reference the Determine Location Section on page 24 of
this manual for general termination considerations.
28
3. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007
installations into the structure to install the termination kit.
4. Partially assemble the concentric vent termination kit.
Clean and cement using the procedures found in these
instructions.
a.
Cement the Y concentric fitting to the larger kit pipe
(FIG. 4-8).
b.
Cement the rain cap to the smaller diameter kit pipe
(FIG. 4-8).
Figure 4-8 Kit Contents_CVK3007 - Models 400 - 600
Installation & Operation Manual
4
Sidewall direct venting
(continued)
Sidewall termination – optional concentric vent: Models 400 - 600 Only
Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 600
"A"
"C" DIA.
"B" DIA.
"D"
3"
(76 MM)
"E"
"G"
"H" DIA.
"B" DIA. PVC
VENT / EXHAUST
A
60"
"F"
B
4"
(1524 MM) (102 MM)
C
6"
D
21 1/8"
(152 MM) (537 MM)
E
10"
F
7 5/8"
G
3"
H
6 5/8"
(254 MM)
(194 MM)
(76 MM)
(168 MM)
Instead of cementing the smaller pipe to
the rain cap, a field-supplied stainless steel
screw may be used to secure the two (2)
components together when field disassembly
is desired for cleaning (see FIG. 4-10).
5. Install the Y concentric fitting and pipe assembly through
the structure’s hole from an inside wall.
When using the alternate screw assembly
 WARNING method, drill a clearance hole in the rain
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
6. Install the rain cap and small diameter pipe assembly
into the Y concentric fitting and large pipe assembly
from an outside wall. Ensure small diameter pipe is
fastened tightly into the rubber adapter for #CVK3007
installations.
NOTICE
 WARNING
Do not operate the appliance with the rain
cap removed or recirculation of combustion
products may occur. Water may also collect
inside the larger combustion air pipe and
flow to the burner enclosure. Failure to
follow this warning could result in product
damage or improper operation, personal
injury, or death.
NOTICE
7. Secure the assembly to the structure as shown in
FIG. 4-11 using field-supplied metal strapping or
equivalent support material.
NOTICE
NOTICE
Figure 4-10 Rain Cap to Vent Pipe Alternate Assembly
STAINLESS STEEL SCREW
(FIELD SUPPLIED)
NOTICE
DRILL CLEARANCE HOLE IN
RAIN CAP & PILOT HOLE
IN VENT PIPE
Do not allow insulation or other materials
to accumulate inside the pipe assembly
when installing through the hole.
Ensure termination location clearance
dimensions are as shown in FIG. 4-7.
If assembly needs to be extended to allow
sidewall thickness requirement, the two
(2) pipes supplied in the kit may be
replaced by using the same diameter,
field-supplied standard schedule 40 PVC
for CVK3007. Do not extend dimension
D* more than 60 inches (1524 mm) (see
FIG. 4-9).
If assembly depth needs to be reduced,
dimension D can be as short as possible.
29
Installation & Operation Manual
4
Sidewall direct venting
Sidewall termination – optional concentric vent: Models 400 - 600 Only
Figure 4-11 Concentric Vent Sidewall Attachment
STRAP
(FIELD SUPPLIED)
ELBOW
(FIELD SUPPLIED)
COMBUSTION AIR
COMBUSTION AIR
VENT
VENT
CAUTION
DO NOT use field-supplied couplings
to extend pipes. Airflow restriction
will occur and may cause intermittent
operation.
8. Cement appliance combustion air and vent pipes to the
concentric vent termination assembly. See FIG. 4-11
for proper pipe attachment.
9. Operate the appliance one (1) heat cycle to ensure
combustion air and vent pipes are properly connected
to the concentric vent termination connections.
Multiventing sidewall terminations
When two (2) or more direct vent appliances are vented
near each other, each appliance must be individually vented
(see FIG. 4-12). When two (2) or more direct vent appliances
are vented near each other, two (2) vent terminations may
be installed as shown in FIG. 4-12. It is important that vent
terminations be made as shown to avoid recirculation of flue
gases.
Figure 4-12 Concentric Vent and Combustion Air Termination
30
Installation & Operation Manual
5
Vertical direct venting
Vent/air termination – vertical
 WARNING
Follow instructions below when
determining vent location to avoid
possibility of severe personal injury, death
or substantial property damage.
Figure 5-1A
PVC/CPVC/Polypropylene
Termination of Air and Vent
Vertical
Determine location
Locate the vent/air terminations using the following
guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page
18 of this manual.
2. Prepare the vent termination and the air termination
elbow (FIG. 5-1A) by inserting bird screens. Bird screens
should be obtained locally.
3. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least
2 feet above any part of a building within 10 horizontal
feet.
4. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet (.6 m) from the center
of the vent pipe. This placement avoids recirculation of
flue products into the combustion air stream.
5. The vent piping must terminate in an up-turned coupling
as shown in FIG. 5-1A. The top of the coupling must
be at least 1 foot above the air intake. When the vent
termination uses a rain cap as illustrated in FIG. 5-1B
maintain at least 36" (914 mm) above the air inlet. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than
2 feet (.6 m) apart and with the vent termination at least
1 foot above the air intake.
6. Maintain the required dimensions of the finished
termination piping as shown in FIG. 5-1A.
Figure 5-1B Stainless Steel Vertical Termination of Air
and Vent
ALTERNATE INTAKE LOCATIONS:
INTAKE PIPES MAY BE LOCATED
ANYWHERE WITHIN 24” (610 MM)
OF VENT PIPE
BIRD SCREEN
(TYPICAL)
VENT
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
COM,BUSTION
AIR
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
8. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
7. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
 WARNING Rooftop vent and air inlet terminations
must terminate in the same pressure zone,
unless vertical vent sidewall air is set up as
shown in the General Venting - Vertical
Vent, Sidewall Air Section.
31
Installation & Operation Manual
5
Vertical direct venting
Vent/air termination – vertical
Prepare roof penetrations
1.
2.
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Figure 5-2 Vertical Terminations with Multiple Boilers
Vent pipe penetration:
a.
Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the
vent pipe outer diameter:
• 5½ inch hole (140 mm) hole? for 4 inch (102 mm)
vent pipe
• 7½ inch hole (191 mm) hole? for 6 inch (152 mm)
vent pipe
b.
Insert a galvanized metal thimble in the vent pipe
hole (when required by local codes).
3. Space the air and vent holes to provide the minimum
spacing shown in FIG.’s 5-1A and 5-1B, page 31.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Multiple vent/air terminations
1. When terminating multiple FTXL boilers, terminate each
vent/air connection as described in this manual (FIG.
5-2).
 WARNING
Terminate all vent pipes at the same height
and all air pipes at the same height to
avoid recirculation of flue products and
the possibility of severe personal injury,
death, or substantial property damage.
2. Place roof penetrations to obtain minimum clearance
of 12 inches (305 mm) between edge of air intake
elbow and adjacent vent pipe of another boiler for U.S.
installations (see FIG. 5-2). For Canadian installations,
provide clearances required by CSA B149.1 Installation
Code.
3. The air inlet of a FTXL boiler is part of a direct vent
connection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
32
Figure 5-3 Alternate Vertical Terminations with Multiple
Boilers
Installation & Operation Manual
5
Vertical direct venting
(continued)
Vertical termination – optional concentric vent: Models 400 - 600 Only
Description and usage
Lochinvar offers an optional concentric combustion air and
vent pipe termination kit. Both combustion air and vent
pipes must attach to the termination kit. The termination kit
must terminate outside the structure and must be installed as
shown in FIG. 5-4.
Field supplied pipe and fittings are required to complete the
installation.
The required combustion vent pipe fittings are listed in
Table 3E, on page 21 of this manual.
2. Cut one (1) hole (7 inch (178 mm) diameter for #CVK3007
installations) into the structure to install the termination
kit.
3. Partially assemble the concentric vent termination kit.
Clean and cement following the cleaning procedures in
these instructions.
a. Cement the Y concentric fitting to the larger
diameter kit pipe (see FIG. 4-8, page 28).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG. 4-8, page 28).
Vertical termination installation
1. See Section 5, Vertical Direct Venting - Determine
Location (where applicable).
Figure 5-4 Concentric Vertical Termination
NOTICE
Instead of cementing the smaller pipe
to the rain cap, a field supplied stainless
steel screw may be used to secure the
two (2) components together when field
disassembly is desired for cleaning (see
FIG. 4-10, page 29).
 WARNING When using the alternate screw assembly
method, drill a clearance hole in the rain
cap and a pilot hole in the vent pipe for
the screw size being used. Failure to drill
adequate holes may cause cracking of PVC
components, allowing combustion products
to be recirculated. Failure to follow this
warning could result in personal injury or
death.
Figure 5-5 Do Not Install U-Bend to Rain Cap
33
Installation & Operation Manual
5
Vertical direct venting
Vertical termination – optional concentric vent: Models 400 - 600 Only
 WARNING
Do not operate the appliance with
the rain cap removed or recirculation
of combustion products may occur.
Water may also collect inside the larger
combustion air pipe and flow to the
burner enclosure. Failure to follow this
warning could result in product damage
or improper operation, personal injury,
or death.
CAUTION
6.
Install the rain cap and the small diameter pipe assembly
into the roof penetration assembly. Ensure the small
diameter pipe is fastened tightly into the rubber adapter
for #CVK3007 installations.
7.
Cement the appliance combustion air and vent pipes to
the concentric vent termination assembly. See FIG. 5-6
for proper pipe attachment.
8.
Operate the appliance through one (1) heat cycle to ensure
combustion air and vent pipes are properly connected to
the concentric vent termination connections.
4. Install the Y concentric fitting pipe assembly up through
the structure’s hole and field supplied roof boot/flashing.
NOTICE
Do not allow insulation or other materials
to accumulate inside the pipe assembly
when installing through the hole.
5. Secure the assembly to the roof structure as shown
below in FIG. 5-6 using field supplied metal strapping or
equivalent support material.
Figure 5-6 Concentric Vent Roof Installation
DO NOT use field-supplied couplings
to extend pipes. Airflow restriction will
occur.
Multiventing vertical terminations
When two (2) or more direct vent appliances are vented
near each other, each appliance must be individually vented
(see FIG. 5-7). NEVER common vent or breach vent this
appliance. When two (2) or more direct vent appliances
are vented near each other, two (2) vent terminations may
be installed as shown in FIG. 5-7. It is important that vent
terminations be made as shown to avoid recirculation of flue
gases.
Figure 5-7 Concentric Vent and Combustion Air Vertical
Termination
NOTICE
NOTICE
34
Ensure termination height is above the
roof surface or anticipated snow level
(12 inches (305 mm) in U.S.A. or 18
inches (457 mm) in Canada) as shown in
FIG. 5-4, page 33.
If assembly is too short to meet height
requirement, the two (2) pipes supplied
in the kit may be replaced by using the
same diameter, field supplied standard
schedule 40 PVC for CVK3007. Do not
extend dimension D* more than 60 inches
(1524 mm) (see FIG. 4-9, page 29).
Installation & Operation Manual
5
Vertical direct venting
(continued)
Alternate vertical concentric venting
This appliance may be installed with a concentric vent
arrangement where the vent pipe is routed through an
existing unused venting system; or by using the existing
unused venting system as a chase for vent and combustion
air routing.
Figure 5-8 Concentric Vent Example 1
Concentric Venting Arrangement
The venting is to be vertical through the roof. The annular
space between the O.D. of the vent pipe and the I.D. of the
existing unused venting system is utilized for the combustion
air source.
The minimum size of the existing vent system required to
achieve enough annular space for combustion air can be
found in Table 5A.
The upper and lower termination as well as any other unsealed
joints in the existing vent system must be sealed to ensure that
all combustion air is drawn from under the vent cap as shown
in FIG.’s 5-8 and 5-9.
Approved venting materials must be used as specified in
Table 3E on page 21.
Follow all vent / air termination and clearance requirements
per this section to the appropriate example. Installation must
comply with local requirements and with the National Fuel
Gas Code.
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
Figure 5-9 Concentric Vent Example 2
The maximum allowable equivalent vent and air intake
lengths for this venting arrangement are to be determined
from the General Venting Section.
If an existing unused venting system is converted for use
with this method of concentric venting, the installer must
ensure that the existing venting system is clean and free from
particulate contamination that will harm this appliance and
cause increased nuisance calls or maintenance. See Table 1A
on page 10 for a list of corrosive contaminants and sources.
Two example scenarios of a concentric venting arrangement
are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
Model
Vent / Air
Inlet Size
Minimum Existing
Vent / Chase Size
400 - 600
4"
7"
725 - 850
6"
10"
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
35
Installation & Operation Manual
5
Vertical direct venting
Existing vent as a chase
Follow all existing termination and clearance requirements and
allowable pipe lengths. Use only approved venting materials
listed in the General Venting Section of this manual.
Figure 5-10 Existing Vent as a Chase
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
36
Installation & Operation Manual
6
Hydronic piping
System water piping methods
The FTXL is designed to function in a closed loop system
pressurized to not less than 12 psi (83 kPa). A temperature
and pressure gauge is included to monitor system pressure
and outlet temperature and should be located on the boiler
outlet.
It is important to note that the boiler has a minimal amount
of pressure drop which must be accounted for when sizing
the circulators. Each boiler installation must have an air
elimination device, which will remove air from the system.
Install the boiler so the gas ignition system components
are protected from water (dripping, spraying, etc.) during
appliance operation or basic service of circulator replacement,
valves, and others.
Observe a minimum of 1/4 inch (6 mm) clearance around all
un-insulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
Low water cutoff device
This boiler comes equipped with a low water cutoff device.
On a boiler installed above radiation level, some states and
local codes require a low water cutoff device at the time of
installation.
Chilled water system
If the boiler supplies hot water to heating coils in air handler
units, flow control valves or other devices must be installed to
prevent gravity circulation of heater water in the coils during
the cooling cycle. A chilled water medium must be piped in
parallel with the heater.
Freeze protection
Freeze protection for new or existing systems must use
glycol that is specially formulated for this purpose. This
includes inhibitors, which prevent the glycol from attacking
the metallic system components. Make certain to check that
the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once
a year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
 WARNING
Use only inhibited propylene glycol
solutions, which are specifically formulated
for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used
in hydronic systems.
General piping information
Basic steps are listed below along with illustrations on the
following pages (FIG.’s 6-5 through 6-10), which will guide you
through the installation of the FTXL (reference FIG.’s 6-3A and
6-3B).
1.
Connect the system return marked “Inlet”.
2.
Connect the system supply marked “Outlet”.
3.
Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
4.
Install a backflow preventer on the cold feed make-up water
line.
5.
Install a pressure reducing valve on the cold feed make-up
water line, (15 psi (103 kPa) nominal). Check temperature
and pressure gauge (shipped separately), which should read
a minimum pressure of 12 psi (83 kPa).
6.
Install a circulator as shown on the piping diagrams in this
section. Make sure the circulator is properly sized for the
system and friction loss.
7.
Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
8.
Install an air elimination device on the system supply.
9.
Install a drain valve at the lowest point of the system.
Note: The boiler cannot be drained completely of water
without purging the unit with an air pressure of 15 psi
(103 kPa).
10. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). Pipe the discharge of the
safety relief valve to prevent injury in the event of pressure
relief. Pipe the discharge to a drain. Provide piping that is
the same size as the safety relief valve outlet. Never block
the outlet of the safety relief valve.
 WARNING The relief valve, tee and any other necessary
fittings are shipped in the install kit with the
boiler and are to be field installed (FIG.’s 6-1
and 6-2).
11. On any pre-existing system, it is good practice to install
a field supplied strainer to prevent damage to the heat
exchanger.
See the piping illustrations included in this section, FIG.’s 6-5
and 6-10 for suggested guidelines in piping the FTXL.
NOTICE
Please note that these illustrations are
meant to show system piping concept only,
the installer is responsible for all equipment
and detailing required by local codes.
37
Installation & Operation Manual
6
Hydronic piping
Relief valve and temperature
pressure gauge installation
and
Figure 6-1 Flow Switch, Relief Valve and Temperature and
Pressure Gauge Installation_Models 400 - 600
Basic steps are listed below to guide you through the
installation of the relief valve, and temperature and pressure
gauge provided with the unit.
1.
Install the tee directly to the outlet connection of the
heat exchanger with the 3/4 inch fitting positioned
vertically and on the top (see FIG. 6-2).
2.
For Models 725 - 850 install the 3/4 inch close nipple
in the tee. Install the relief valve on the 3/4 inch close
nipple (FIG. 6-2). For Models 400 - 600 install the
relief valve directly into the 3/4 inch fitting on the tee
(FIG. 6-1).
3.
Install the close nipple on the downstream side of
the relief valve tee (FIG. 6-1).
4.
Install the tee with the 1 inch fitting positioned
vertically and on the top (FIG. 6-1).
5.
Install a field provided close nipple on the downstream
side of the flow switch (if used), see FIG.’s 6-1 and 6-2.
6.
Install a field provided tee with the gauge fitting
positioned vertically and on the top (FIG.’s 6-1 and
6-2)
Figure 6-2 Flow Switch, Relief Valve and Temperature and
Install the temperature and pressure gauge provided Pressure Gauge Installation_Models 725 - 850
7.
with the unit into the top fitting of the tee (a bushing
may be necessary) installed in Step 6 (FIG.’s 6-1 and
6-2).
NOTICE
38
If using a flow switch, be sure to install
the flow switch so that the arrow on the
flow switch is pointing in the direction
of the flow.
Installation & Operation Manual
6
Hydronic piping
(continued)
Near boiler piping components
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe
requirements listed in Table 6B. Reducing the pipe size
can restrict the flow rate through the boiler, causing
inadvertent high limit shutdowns and poor system
performance. Flow rates are based on a full flow
application.
2. Boiler system circulating pump:
Field supplied. The boiler circulating pump should be
based on system requirements.
3. Domestic hot water circulating pump:
Field supplied. The pump MUST be sized to meet
the specified minimum flow requirements listed in
FIG. 6-4. Consult the indirect water heater operating
guide to determine flow characteristics for the selected
product used.
4. Variable speed boiler circulator:
FTXL boilers are capable of controlling a variable speed
boiler circulator. Variable speed circulators MUST
be sized to meet the specified minimum flow requirements
listed in FIG. 6-4 on page 41 at full speed. To be used
in primary/secondary systems only.
5. Boiler isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
12. Boiler purge valve:
Field supplied. The boiler purge valve is used to
remove entrapped air from the heat exchanger during
start-up.
13. System temperature sensor:
Lochinvar supplies a system temperature sensor. The
sensor is to be installed in the heating loop downstream
from the boiler hot water piping and heating loop
junction. The sensor should be located far enough
downstream to sense system diluted water temperature.
14. Y-Strainer:
Field supplied. A Y-strainer or equivalent multipurpose
strainer is recommended at the inlet of the heat exchanger
to remove system particles from older hydronic systems
and protect newer systems.
15. Motorized isolation valve (optional):
Field supplied. A motorized isolation valve can be used
to isolate the boiler from the system piping.
Circulator sizing
The FTXL heat exchanger does have a pressure drop, which
must be considered in your system design. Refer to the
graphs in FIG. 6-4 for pressure drop through the FTXL heat
exchanger.
6. Check valves:
Field supplied. Check valves are recommended for
installation as shown in FIG.’s 6-5 through 6-10. Failure
to install check valves could result in a reverse flow
condition during pump(s) off cycle.
7. Domestic indirect hot water isolation valves:
Field supplied. Full port ball valves are required. Failure
to use full port ball valves could result in a restricted flow
rate through the boiler.
8. Anti-scald mixing valve:
Field supplied. An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F (46°C).
9. Unions:
Field supplied. Recommended for unit serviceability.
10. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is
shipped loose. It is the responsibility of the contractor to
install the temperature and pressure gauge on the boiler
water outlet.
11. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
39
Installation & Operation Manual
6
Hydronic piping
Near boiler piping connections
Variable speed pump option
Variable speed pump setup
Before operation, ensure the following:
-
Pump is set for an input signal of 0 - 10VDC
by the dip switches on the pump control
-
Pump is set for external signal control
(if applicable)
-
Pump is set for linear output (if applicable)
-
If pump does not come equipped with a
0 - 10 VDC input option, an optional module
will be required from the vendor
Figure 6-3A Near Boiler Piping w/Y-Strainer
SMART SYSTEM / Multi-temperature
loop control option
Figure 6-3B Near Boiler Piping w/Low Loss Header
The FTXL boiler is capable of producing up to
three (3) set point temperatures to meet different
space heating demands. When using more than one
temperature demand it is necessary to protect the
lower temperature loop(s) from overheating. To help
aid with this protection, Lochinvar offers the MultiTemperature Loop Control Board Kit (RLY30086).
The maximum allowable water flow rate
 CAUTION
through a single FTXL boiler is 105 GPM
(Models 400 - 600) and 150 GPM (Models
725 - 850). Exceeding this flow rate will
result in damage to the heat exchanger and/
or piping.
Reference Table 6A1 for the minimum
NOTICE
recommended flow rate through a single
FTXL boiler at full fire to maintain a 80°F
temperature rise. Reference Table 6A2 for
the absolute minimum flow rate through a
single FTXL boiler.
Table 6A1 Minimum Flow Rate with the Boiler at Full Fire
TEMPERATURE RISE APPLICATIONS
MODEL
FLOW RATE (GPM)
FTX(N,L)400
FTX(N,L)500
FTX(N,L)600
FTX(N,L)725
FTX(N,L)850
10
12
15
18
21
[Based on 80°F Temperature Rise]
Table 6A2 Absolute Minimum Flow Rate @ Low Fire
ABSOLUTE MINIMUM FLOW RATE
MODEL
FLOW RATE (GPM)
40
FTX(N,L)400
4
FTX(N,L)500
FTX(N,L)600
4
4
FTX(N,L)725
4
FTX(N,L)850
4
Installation & Operation Manual
6
Hydronic piping
(continued)
Figure 6-4 Pressure Drop vs. Flow
HEX Pressure Drop
(Full Flow Application)
Pressure Drop (Feet of Head)
FTX725-850
FTX400-600
15 ft
14 ft
13 ft
12 ft
11 ft
10 ft
9 ft
8 ft
7 ft
6 ft
5 ft
4 ft
3 ft
2 ft
1 ft
0 ft
15 ft
FTX725 -850 14 ft
13 ft
12 ft
11 ft
10 ft
9 ft
8 ft
7 ft
6 ft
5 ft
4 ft
3 ft
2 ft
1 ft
0 ft
FTX400-600
Flow Rate
Table 6B Sizing Information for Temperature Rise Applications_20°F, 30°F, 40°F, 60°F and 80°F
TEMPERATURE RISE APPLICATIONS
MINIMUM
Model
PIPE
SIZE
20°F
30°F
40°F
80°F
60°F
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
GPM
FT/HD
400
2"
39
3.5
26
2.8
20
2.5
13
2.4
10
2.3
500
2"
49
4.8
33
3.4
24
2.9
16
2.5
12
2.4
600
2"
59
4.4
39
3.2
29
2.8
20
2.5
15
2.3
725
2 1/2"
71
4.9
47
3.5
35
3.0
24
2.7
18
2.6
850
2 1/2"
83
5.7
55
3.9
41
3.3
28
2.8
21
2.6
41
Installation & Operation Manual
6
Hydronic piping
Figure 6-5 Multiple Boilers - Alternate - Fixed or Variable Flow Primary System Piping
Number of Units
CAUTION
NOTICE
42
Model
2
400
500
600
725
850
3 1/2 (89)
3 1/2 (89)
3 1/2 (89)
4 (102)
4 (102)
3
4
5
6
7
Manifold Pipe Sizes in Inches (mm)
4 (102)
4 (102)
4 (102)
5 (127)
5 (127)
5 (127)
5 (127)
5 (127)
6 (152)
6 (152)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8
10 (254)
10 (254)
10 (254)
10 (254)
10 (254)
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Installation & Operation Manual
6
Hydronic piping
(continued)
Figure 6-6 Single Boiler - Multiple Temperatures
CAUTION
NOTICE
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
43
Installation & Operation Manual
6
Hydronic piping
Figure 6-7 Single Boiler - Primary/Secondary Piping
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not exceed indirect water heater transfer capabilities.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
44
Installation & Operation Manual
6
Hydronic piping
(continued)
Figure 6-8 Multiple Boilers - Multiple Temperatures
Number of Units
Model
2
400
500
600
725
850
3 1/2 (89)
3 1/2 (89)
3 1/2 (89)
4 (102)
4 (102)
3
4
5
6
7
Manifold Pipe Sizes in Inches (mm)
4 (102)
4 (102)
4 (102)
5 (127)
5 (127)
5 (127)
5 (127)
5 (127)
6 (152)
6 (152)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8
10 (254)
10 (254)
10 (254)
10 (254)
10 (254)
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not exceed indirect water heater transfer capabilities.
CAUTION
Mixing valves are required for the protection of low temperature loops.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
45
Installation & Operation Manual
6
Hydronic piping
Figure 6-9 Multiple Boilers - Primary/Secondary Piping
Number of Units
Model
2
400
500
600
725
850
3 1/2 (89)
3 1/2 (89)
3 1/2 (89)
4 (102)
4 (102)
3
4
5
6
7
Manifold Pipe Sizes in Inches (mm)
4 (102)
4 (102)
4 (102)
5 (127)
5 (127)
5 (127)
5 (127)
5 (127)
6 (152)
6 (152)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
6 (152)
6 (152)
6 (152)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8 (203)
8
10 (254)
10 (254)
10 (254)
10 (254)
10 (254)
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not exceed indirect water heater transfer capabilities.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
NOTICE
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
46
Installation & Operation Manual
6
Hydronic piping
(continued)
Figure 6-10 Single Boiler - Multiple Temperatures with DHW Piped as a Zone
CAUTION
Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler
output does not exceed indirect water heater transfer capabilities.
CAUTION
Mixing valves are required for the protection of low temperature loops.
NOTICE
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
47
Installation & Operation Manual
7
Gas connections
Connecting gas supply piping
1. Remove the top access panel and refer to FIG.’s 7-1 and
7-2 to pipe gas to the boiler.
a. Install ground joint union for servicing, when
required.
b. Install a manual shutoff valve in the gas supply
piping outside boiler jacket when required by local
codes or utility requirements.
c. In Canada – When using manual main shutoff
valves, it must be identified by the installer.
3. Support piping with hangers, not by the boiler or its
accessories.
2. Install sediment trap / drip leg.
4. Purge all air from the gas supply piping.
Figure 7-1 Gas Supply Piping - Model 400 - 600
The gas valve and blower will not support
 WARNING the weight of the piping. Do not attempt
to support the weight of the piping with
the boiler or its accessories. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
5. Before placing the boiler in operation, check the boiler
and its gas connection for leaks.
a. The appliance must be disconnected from the gas
supply piping system during any pressure testing of
that system at a test pressure in excess of 1/2 PSIG
(3.5 kPa).
b.
The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
(3.5 kPa).
c.
The appliance and its gas connection must be leak
tested before placing it in operation.
 WARNING
Figure 7-2 Gas Supply Piping - Models 725 - 850
48
Do not check for gas leaks with an open
flame – use the bubble test. Failure to
use the bubble test or check for gas leaks
can cause severe personal injury, death, or
substantial property damage.
6. Use pipe sealing compound compatible with propane
gases. Apply sparingly only to male threads of the pipe
joints so that pipe dope does not block gas flow.
Installation & Operation Manual
7
Gas connections
 WARNING
(continued)
Failure to apply pipe sealing compound
as detailed in this manual can result
in severe personal injury, death, or
substantial property damage.
Use two wrenches when tightening gas
 WARNING
piping at boiler (FIG. 7-3), using one
wrench to prevent the boiler gas line
connection from turning. Failure to
support the boiler gas connection pipe
to prevent it from turning could damage
gas line components.
Figure 7-3 Inlet Pipe with Backup Wrench
USE BACKUP WRENCH TO
PREVENT PIPE FROM ROTATING
Natural gas:
Pipe sizing for natural gas
1. Refer to Table 7A for pipe length and diameter. Based on
rated boiler input (divide by 1,000 to obtain cubic feet per
hour).
a.
Table 7A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.3 inches w.c.
b.
For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.5 kPa) with no flow
(lockup) or with boiler on.
• Minimum 4 inches w.c. (.99 kPa) with gas flowing (verify
during boiler startup).
2. Install 100% lockup gas pressure regulator in supply line
if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any
time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa)
maximum.
Propane Gas:
 WARNING
NOTICE
Maximum inlet gas pressure must not
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
FTXL boilers are typically shipped ready to
fire on natural gas. Check boiler rating plate
to determine which fuel the boiler is set for.
If set to natural gas, it may be converted to
LP by installing a LP venturi or by making a
gas valve adjustment (see pages 14 and 15).
In order to operate on LP gas, a LP venturi
MUST BE installed or a gas valve adjustment
MUST BE made. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100% lockup
gas pressure regulator.
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. (3.2 kPa) maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.2 kPa) with no flow (lockup)
or with boiler on.
• Minimum 8 inches w.c. (1.9 kPa) with gas flowing (verify
during boiler startup).
 WARNING
Ensure that the high gas pressure regulator
is at least 10 feet (3 m) upstream of the
appliance.
49
Installation & Operation Manual
7
Gas connections
Table 7A Natural Gas Pipe Size Chart
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 specific gravity, 0.30" w.c. pressure drop)
Pipe
Size
(Inches)
10
20
30
40
50
60
70
80
90
100
125
150
175
200
1/2
131
90
72
62
55
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
3/4
1
1 1/4
273
514
1,060
188
353
726
151
284
583
129
243
499
114
215
442
104
195
400
95
179
368
89
167
343
83
157
322
79
148
304
70
131
269
63
119
244
58
109
224
N/A
102
209
1 1/2
1,580
1,090
873
747
662
600
552
514
482
455
403
366
336
313
2
3,050
2,090
1,680
1,440
1,280
1,160
1,060
989
928
877
777
704
648
602
2 1/2
4,860
3,340
2,680
2,290
2,030
1,840
1,690
1,580
1,480
1,400
1,240
1,120
1,030
960
3
8,580
5,900
4,740
4,050
3,590
3,260
3,000
2,790
2,610
2,470
2,190
1,980
1,820
1,700
4
17,500 12,000
9,660
8,270
7,330
6,640
6,110
5,680
5,330
5,040
4,460
4,050
3,720
3,460
Length of Pipe in Straight Feet
Check inlet gas supply
NOTICE
 WARNING
CSA or UL listed flexible gas connections
are acceptable, but you must exercise
caution to ensure that the line has adequate
capacity to allow your boiler to fire at full
rate. Consult with local codes for proper
installation or service procedures.
DO NOT adjust gas valve outlet pressure.
Attempting to alter the gas valve outlet
pressure could result in damage to the valve,
causing potential severe personal injury,
death, or substantial property damage.
The gas piping must be sized for the proper flow and length of
pipe, to avoid excessive pressure drop. Both the gas meter and
the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c.
(249 Pa), the meter, regulator, or gas line is undersized or in
need of service. Perform the steps below when checking inlet
gas supply:
1.
Turn the main power switch to the “OFF” position.
2.
Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
3.
On Models 400 - 500 loosen the set screw one (1) full turn
from inside the pressure tap on top of the gas valve. On
Models 600 - 850 remove the 1/8" (3 mm) pipe plug on the
inlet flange to the valve and install a suitable 1/8" (3 mm)
fitting (field supplied) for the manometer tubing. Place
the tubing of the manometer over the tap once the set
screw is loosened or the 1/8" (3 mm) fitting is installed
(depending on model) as shown in FIG.’s 7-5 and 7-6 on
page 51.
50
4.
Slowly turn on the gas supply at the field installed
manual gas valve.
5.
Turn the power switch to the “ON” position.
6.
Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to call for heat.
7.
Observe the gas supply pressure as the burner fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
8.
Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
9.
If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
11. Turn the power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
13. Remove the manometer from the pressure tap on top of
the gas valve. On Models 400 - 500 re-tighten the set
screw inside the pressure tap. On Models 600 - 850
remove the 1/8" (3 mm) field supplied fitting and
reinstall the pipe plug removed in Step 3.
Installation & Operation Manual
7
Gas connections
(continued)
When re-tightening the set screw, be sure
 WARNING to tighten securely to prevent gas leaks.
Do not check for gas leaks with an open
flame -- use the bubble test. Failure to
use the bubble test or check for gas leaks
can cause severe personal injury, death, or
substantial property damage.
14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to the desired
water temperature so the appliance will call for heat.
17. Check burner performance by cycling the system while
you observe burner response. The burner should ignite
promptly. Flame pattern should be stable. Turn system
off and allow burner to cool, then cycle burner again to
ensure proper ignition and flame characteristics.
Figure 7-5 Inlet Gas Supply Check - Model 400 - 500
Gas pressure
The gas pressure must remain between 4 inches w.c.
(.99 kPa) minimum and 14 inches w.c. (3.5 kPa) maximum
for Natural gas and between 8 inches w.c. (1.9 kPa) minimum
and 14 inches w.c. (3.2 kPa) maximum for LP gas during
standby (static) mode and while in operating (dynamic)
mode. If an in-line regulator is used, it must be a minimum
of 10 feet (3 m) from the FTXL boiler. It is very important
that the gas line is properly purged by the gas supplier
or utility company. Failure to properly purge the lines or
improper line sizing, will result in ignition failure.
The problem is especially noticeable in NEW LP installations
and also in empty tank situations. This can also occur when
a utility company shuts off service to an area to provide
maintenance to their lines.
Gas valve replacement
The gas valve MUST NOT be replaced with a conventional
gas valve under any circumstances. As an additional safety
feature, this gas valve has a flanged connection to the venturi
and blower.
 WARNING
Failure to follow all precautions could
result in fire, explosion, or death!
 WARNING
DO NOT adjust gas valve outlet pressure.
Attempting to alter the gas valve outlet
pressure could result in damage to the
valve, causing potential severe personal
injury, death, or substantial property
damage.
Figure 7-6 Inlet Gas Supply Check - Models 600 - 850
51
Installation & Operation Manual
8
Field wiring
 WARNING
NOTICE
 CAUTION
ELECTRICAL SHOCK HAZARD – For
your safety, turn off electrical power
supply before making any electrical
connections to avoid possible electric
shock hazard. Failure to do so can cause
severe personal injury or death.
Wiring must be N.E.C. Class 1.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 8-1.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 8-1).
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
3. When connecting a domestic hot water (DHW) pump,
connect the wiring to the line voltage terminal strip as
shown in FIG. 8-1.
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
4. To activate a system pump, wire as shown in FIG. 8-1. Dry
contacts are sized for 1.5 hp/120V, 3 hp/240V or 30 amps.
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
1. Route all low voltage wires through the knockouts in the
rear of the boiler, as shown in FIG. 8-2.
2. Continue to route the wires through the plastic bushings to
the left of the low voltage connection board.
3. Connect low voltage wiring to the low voltage connection
board as shown in FIG. 8-3 on page 55 of this manual and
the boiler wiring diagram. Make certain the wires will stay
well away from the top of the heat exchanger.
Figure 8-1 Line Voltage Field Wiring Connections
Low voltage connections
Figure 8-2 Routing Field Wiring
Thermostat
1. Connect the room thermostats or end switches (isolated
contact only) to heat/loop demand 1, 2, or 3, as shown in
FIG. 8-3.
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,
and any local codes.
52
2. Install the thermostat on the inside wall away from
influences of drafts, hot or cold water pipes, lighting
fixtures, television, sunlight, or fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to match
total electrical power requirements of connected
devices. See device manufacturers’ specifications
and thermostat instructions for details.
Installation & Operation Manual
8
Field wiring
(continued)
Outdoor temperature sensor
Low gas pressure switch
1. Mount the sensor on an exterior wall, shielded from
direct sunlight or flow of heat or cooling from other
sources.
2. Route sensor wires through a knockout at the rear of the
boiler (see FIG. 8-2).
3. Connect the outdoor temperature sensor (FIG. 8-3) to
the outdoor sensor terminals on the connection board
to enable outdoor reset operation of the FTXL. If fixed
temperature operation is required, do not install outdoor
sensor.
1. If a switch is provided to detect low gas pressure, remove
the jumper wire from the terminals on the connection
board and connect them to its normally open contacts
(FIG. 8-3).
DHW
(Domestic
thermostat
Hot
Water)
Connect storage indirect water heater (DHW) thermostat
(FIG. 8-3) to the DHW thermostat terminals on the
connection board. If a tank sensor is connected (see DHW
Tank Sensor below) the tank thermostat is ignored.
DHW tank sensor
By installing a tank sensor, the SMART SYSTEM control can
perform the tank thermostat function. The SMART SYSTEM
control automatically detects the presence of this sensor, and
generates a DHW call for heat when the tank temperature
drops 6°F (3°C) below the tank set point, and finishes the call
for heat when the tank temperature reaches the tank set point.
The tank sensor included with the Lochinvar Squire® indirect
DHW tanks (TST20015) is the only sensor suitable for use
with the SMART SYSTEM control. Connect the sensor leads
to the Tank Sensor terminals on the low voltage connection
board (FIG. 8-3).
 WARNING
Failure to use the correct sensor may
result in the tank temperature being either
above or below the set point.
2. If both a high and low gas pressure switch is used, connect
their respective contacts in series, and connect them to the
terminals on the connection board (FIG. 8-3).
Variable speed system pump
If a variable speed pump is used in the primary loop, and
a 0-10V signal is available from the pump speed control,
this signal can be used by the SMART SYSTEM control to
anticipate changes in the building heat load. By connecting this
0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the boiler
(or cascade) can modulate up and down as the primary flow
increases and decreases.
Boiler pump speed output
This 0 - 10V output is available to control the speed of a variable
speed boiler pump. The SMART SYSTEM control will vary the
speed of this pump in order to maintain a minimum T across
the heat exchanger, as well as prevent high limit lockouts when
the flow in the primary loop is extremely low. NOTE: This
feature is to be used with Primary / Secondary piping systems
only. A system supply sensor MUST be installed. Connect this
output to the 0 - 10V input on the boiler pump speed control.
Rate output
This output provides a 0 - 10V signal that is proportional to the
firing rate of the boiler. This may be used by a BMS system to
monitor the actual rate of the boiler.
ModBus/BACnet
If TST20015 is not compatible with the indirect tank, a
tank thermostat can be used to control the boiler. The
tank thermostat should be installed per the manufacturer’s
instructions and wired to the DHW Thermostat terminals on
the low voltage connection board (FIG. 8-3).
When an optional ModBus or BACnet interface module is
installed, the RS-485 cable is connected to these terminals. Use
shielded, 2-wire twisted pair cable. If desired, the shield can
be connected to ground by installing a jumper wire between
terminals 1 and 3 on connector X5 on the optional ModBus or
BACnet interface module.
Louver proving switch
Flow switch
1. When the operation of the louvers needs to be verified
before the boiler fires, remove the jumper wire from
these terminals and connect them to the normally open
contacts on its proving switch (FIG. 8-3).
1. A flow switch is used to guarantee flow through the boiler
before allowing it to fire. The flow switch must be installed
at the boiler outlet.
2. Remove the jumper wire from the terminals on the
connection board and connect these terminals to the
normally open contacts on the flow switch (FIG. 8-3).
High gas pressure switch
1. If a switch is provided to detect excessive gas pressure,
remove the jumper wire from the terminals on the
connection board, and then connect them to its normally
closed contacts (FIG. 8-3).
System supply sensor
1. By installing the system supply sensor into the supply of the
primary loop, the temperature of the system supply can be
controlled. The SMART SYSTEM control automatically
detects the presence of this sensor, and controls the boiler
firing rate to maintain the system supply temperature to
the set point (if outlet sensor control is currently selected).
53
Installation & Operation Manual
8
Field wiring
See the FTXL Service Manual for instructions on how to
use the inlet sensor as the controlling sensor. When the
inlet sensor is programmed as the controlling sensor, it is
vital that the SYSTEM SUPPLY sensor be installed. DO
NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO
THE SYSTEM RETURN.
2. The TST2032 sensor provided with the boiler must be used
for the system sensor.
3. Connect these terminals to the system supply sensor
(FIG. 8-3).
Boiler management system
1. An external control may be connected to control either
the firing rate or the set point of the boiler. If the
external control uses a set of contacts to enable the boiler,
connect the contacts to the heat/loop demand 1 terminals.
Otherwise, the SMART SYSTEM control will be enabled by
the 0-10V signal.
2. Make sure the (-) terminal is connected to the (-) or
common output terminal of the external control, and the
(+) terminal is connected to the 0 - 10 VDC or (+) terminal
of the external control. Make sure that the (-) voltage is not
below ground.
Runtime contacts
The SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
The SMART SYSTEM control closes another set of contacts
whenever the boiler is locked out or the power is turned off.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down.
DHW recirculation sensor
The FTXL is able to control a DHW recirculation pump. To
operate this feature, a TST2032 temperature sensor must be
installed in the circulation loop return. Connect this sensor to
the DHW recirculation sensor terminals on the Low Voltage
Connection Board.
DHW recirculation pump
When the DHW recirculation sensor (as described above) is
connected, the FTXL SMART SYSTEM control will output
24VAC to control a DHW recirculation pump relay (field
supplied). Connect the coil of the DHW recirculation pump
relay to the 24VAC recirculation pump relay coil terminals on
the Low Voltage Connection Board.
Wiring of the cascade
Connect the system supply sensor and outdoor air sensor (if
used) to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
location of the system supply sensor should be downstream
of the boiler connections in the main system loop (FIG.’s 6-5
through 6-10). The system supply sensor should be wired to
the Low Voltage Connection Board at the terminals marked
for the system sensor (see FIG. 8-3). The Leader control will
use the water temperature at the system supply sensor to
control the operation of the Cascade.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 8-3). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature
set point that is programmed into the control.
If a Thermostat or Zone Control enable output is available,
it should be wired to the Low Voltage Connection Board
on the Leader boiler at the terminals marked for one of the
heat/loop demands 1-3 (FIG. 8-3). If the boilers are to run
continuously, connect a jumper wire between the R and W
terminals for the heat/loop demand input. This will initiate a
call for heat on the Cascade.
Communication between the Leader boiler and the Member
boilers is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to Cascade terminal A on each of the Low Voltage Connection
boards, and the other wire of the twisted pair to Cascade
terminal B on each of the Low Voltage Connection Boards.
Connect the shield wires to one of the shield terminals on
the Low Voltage Connection Boards (FIG. 8-3). If more than
two boilers are on the Cascade, daisy chain the wiring from
the Cascade terminals on the second boiler to the Cascade
terminals on the third boiler, then from the third to the forth,
and so on. The connections between boilers can be made in
any order, regardless of the addresses of the boilers. Try to
keep each cable as short as possible.
When the Member 1 boiler is programmed as an alternate
leader this allows the Member 1 boiler to automatically
assume control of the Cascade should it lose communication
with the Leader boiler. When programmed to YES, it is
recommended that the Member 1 boiler have its own set of
external sensors installed (such as the system supply sensor),
to maintain the same level of temperature control as with the
Leader boiler. Voltage signals (such as 0 - 10V system pump
speed input) can be connected to both boilers.
 WARNING
Do not connect the sensors connected to
the Leader boiler to the Member 1 boiler.
The actual water temperatures will be
higher than expected, which could lead
to property damage, personal injury, or
death.
When wiring the boilers for Cascade operation, select one boiler
as the Leader boiler. The remaining boilers will be designated When communication is re-established with the Leader boiler,
as Members. See page 62 “Configuration of the Cascade” for a Member 1 will automatically relinquish control of the Cascade
detailed explanation of this procedure.
to the Leader boiler.
54
Installation & Operation Manual
8
Field wiring
(continued)
Figure 8-3 Low Voltage Field Wiring Connections
55
Installation & Operation Manual
9
Condensate disposal
Condensate drain
1. The FTXL is a high efficiency appliance that produces
condensate.
2. The condensate trap is sized for a 1" PVC outlet
connection pipe.
3. Plug the wiring connection from the condensate trap into
the connector located on the back of the unit.
4. Slope condensate tubing down and away from the boiler
into a drain or condensate neutralizing filter. Condensate
from the FTXL will be slightly acidic (typically with a pH
from 3 to 5). Install a neutralizing filter if required by
local codes.
A Neutralizer Kit (FIG. 9-1) is available from the factory
(KIT3087 for Models 400 - 500 and KIT3046 for Models
600 - 850). KIT3046 must be placed on a surface that
is a minimum of 3 inches lower than the condensate
trap with field supplied piping (vacuum break) installed
between the condensate trap and the neutralizer kit.
5. Do not expose condensate line to freezing temperatures.
NOTICE
NOTICE
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493. For Canada use CSA or ULC certified
PVC or CPVC pipe, fittings, and cement. Do
not use copper or black iron pipe, or fittings.
To allow for proper drainage on large
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch (25 mm).
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to freeze
in the line or if the line is obstructed in any
other manner, condensate can exit from
the boiler tee, resulting in potential water
damage to property.
6. A condensate removal pump is required if the boiler is
below the drain. When installing a condensate pump, select
one approved for use with condensing boilers and furnaces.
The pump should have an overflow switch to prevent
property damage from condensate spillage. The switch
should be wired in series with the blocked drain switch
inside the boiler (see FIG. 10-1 on page 58).
Figure 9-1 Condensate Disposal
KIT3046 shown for illustration purposes.
56
Installation & Operation Manual
10
Start-up
Check/control water chemistry
 CAUTION
Do not use petroleum-based cleaning or
sealing compounds in the boiler system.
Damage to elastomer seals and gaskets
in the system could occur, resulting in
substantial property damage.
Hardness less than 7 grains
1. Consult local water treatment companies for hard water
areas (above 7 grains hardness).
Chlorine concentration less than 200 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
2. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are much lower.
3. Do not use the boiler to directly heat swimming pool or
spa water.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids, follow fluid
manufacturer’s instructions.
2. Freeze protection fluid must be replaced periodically due
to degradation of inhibitors over time. Follow all fluid
manufacturer’s instructions.
Freeze protection (when used)
1.
Determine freeze protection fluid quantity using
system water content, following fluid manufacturer’s
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
2.
Local codes may require a backflow preventer or actual
disconnect from city water supply.
3.
When using freeze protection fluid with automatic fill,
install a water meter to monitor water makeup. Freeze
protection fluid may leak before the water begins to
leak, causing concentration to drop, reducing the freeze
protection level.
4.
The freeze protection set points may be lowered when
freeze protection fluid is used (see the FTXL Service
Manual).
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close manual and automatic air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a.
The minimum cold water fill pressure for a
commercial system is 12 psi (82.7 kPa).
b.
Pressure will rise when boiler is turned on and
system water temperature increases.
4. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
 WARNING Eliminate all system leaks. Continual
fresh makeup water will reduce boiler life.
Minerals can build up in the heat exchanger,
reducing heat transfer, overheating the heat
exchanger, and causing heat exchanger
failure.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve. Route the
hose to an area where water can drain and be seen.
b. Close the boiler or system isolation valve between
the purge valve and fill connection to the system.
c. Close zone isolation valves.
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
f. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close the
zone isolation valves and proceed with the next zone.
Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch
that system pressure rises to correct cold-fill
pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open
the manual air vents in the system one at a time,
beginning with the lowest floor. Close the vent when
water squirts out. Repeat with remaining vents.
2. Open automatic air vent (diaphragm-type or bladdertype expansion tank systems only) one turn.
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refill to correct pressure.
57
Installation & Operation Manual
10
Start-up
Check for gas leaks
 WARNING
 WARNING
Before starting the boiler, and during
initial operation, smell near the floor and
around the boiler for gas odorant or any
unusual odor. Remove the top access
panel and smell the interior of the boiler
enclosure. Do not proceed with startup
if there is any indication of a gas leak.
Use an approved leak detection solution.
Repair any leaks at once.
DO NOT adjust gas valve outlet pressure.
 WARNING
The gas valve is factory set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to each
of the heat/loop demand terminals on the connection
board.
2. Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve, and relay in the
external circuit one at a time and check the voltmeter
reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does appear under any condition, check and
correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
Figure 10-1 Condensate Trap
FROM CONDENSATE
VENT ON BOILER
TO FLOOR DRAIN
OR NEUTRALIZER KIT
1” PVC / CPVC CONNECTION
Propane boilers only – Your propane
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the
gas may no longer have an odor. Before
startup (and periodically thereafter), have
the propane supplier verify the correct
odorant level in the gas.
FROM CONDENSATE
DRAIN ON BOILER
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board. Allow the boiler to
cycle.
Inspect condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC
fittings and condensate trap.
58
Installation & Operation Manual
10
Start-up
(continued)
Final checks before starting the boiler
 Check vent piping and air piping
 Read the FTXL Service Manual to familiarize yourself with
SMART SYSTEM control module operation. Read this
manual, page 60 for proper steps to start boiler.
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
 Verify the boiler and system are full of water and all system
components are correctly set for operation.
 Verify the preparation procedures of Section 10, pages 57
and 58 have been completed.
 Verify electrical connections are correct and securely
attached.
 Inspect vent piping and air piping for signs of deterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed per
this manual.
Start the boiler
1. Read and follow the Operating instructions in FIG. 10-2,
page 60.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is boiler water temperature above 200°F (93°C)?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the FTXL Service Manual.
Check system and boiler
 Check water piping
1. Check system piping for leaks. If found, shut down the
boiler and repair immediately. (See WARNINGS on pages
57 and 58 (startup) regarding failure to repair leaks.)
2. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation and
cause heat distribution problems and noise.
 WARNING
Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
 Check gas piping
1. Check around the boiler for gas odor following the
procedure on page 48 of this manual (connecting gas
supply piping).
 WARNING
If you discover evidence of any gas leak,
shut down the boiler at once. Find the
leak source with a bubble test and repair
immediately. Do not start the boiler again
until corrected. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
 Propane boilers – verify conversion
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
DO NOT adjust gas valve outlet pressure.
 WARNING
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
 WARNING FTXL boilers are typically shipped ready
to fire on natural gas. Check boiler rating
plate to determine which fuel the boiler
is set for. If set to natural gas, it may be
converted to LP by installing a LP venturi
or by making a gas valve adjustment (see
pages 14 and 15). In order to operate on
LP gas, a LP venturi MUST BE installed or
a gas valve adjustment MUST BE made.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
Check flame and combustion
1. Turn the main power off to the boiler by placing the
“On/Off” switch in the OFF position.
2. Remove the brass plug from the combustion
measurement port inside the flue collector. NOTE:
Combustion measurements will be made at this point.
3. Turn the main power on to the boiler by placing the
“On/Off” switch in the ON position.
59
Installation & Operation Manual
10
Start-up
Figure 10-2 Operating Instructions
60
Installation & Operation Manual
10
Start-up
(continued)
Check flame and combustion (continued)
Set space heating operation
4. Place the boiler into the active position by pressing the
RIGHT SELECT [ON] key (FIG. 11-1, page 69).
Determine controlling sensor
5. Locate the pinhole button above the RESET button on
the display board (FIG. 11-1). Insert a thin wire (such as
a paper clip) into the hole and press the button once and
hold for 5 seconds to place the boiler into Service Mode.
In Service Mode the boiler will fire at ignition speed and
will then modulate up to full fire.
6. Insert the probe from a combustion analyzer into the
combustion measurement port (see FIG. 10-3). There
is a stop underneath the combustion measurement port
to prevent the probe from collecting condensate at the
bottom of the flue collector.
7. Once the boiler has modulated up to full fire, measure
the combustion. The values should be in the range listed
in Table 10A below. The CO levels should be less than
150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference the Troubleshooting Section of the FTXL
Service Manual for possible causes and corrective actions.
Figure 10-3 Combustion Measurement Port
For space heating systems, the temperature control can be
based on one of three sensors; the inlet, outlet, or system
supply sensor. The SMART SYSTEM control is programmed
at the factory to control the temperature of the outlet
sensor. The control will automatically switch to the system
supply sensor once it is connected. If it is desired to base
the temperature control on the inlet sensor, the appropriate
parameter must be changed in the control. See the FTXL
Service Manual for a detailed explanation of this procedure.
Verify space heat circulator mode
The Space Heating Mode controls both the system pump
(if connected), and the boiler pump. When the SMART
SYSTEM control receives a space heating call for heat, it turns
on the system pump. If the set point is not met, or the system
sensor is not connected, it also turns on the boiler pump.
After the space heating call for heat ends, the system pump
continues to run for a short period of time. The system pump
can be programmed to run continuously, except during
outdoor shutdown. Other settings may affect the operation
of the boiler and system pumps, as explained on the following
pages. If the boiler pump was running, it continues to run
for a short period of time as well. These pump delays are
factory set to 30 seconds. If different delays are desired, the
appropriate parameters in the control must be changed. See
the FTXL Service Manual for a detailed explanation of this
procedure.
Adjust set point temperature(s)
NOTICE
Please note that the brackets ([]) denote
screen status.
The NAVIGATION dial may be used during normal
operation to adjust the space heating and tank set point
temperatures.
Table 10A Flue Products Chart
Natural Gas
1.
2.
Propane
CO2
O2
CO2
O2
8.0% - 10%
3.0% - 6.5%
9.0% - 11%
4.1% - 6.9%
8.
9.
Once the combustion analysis is complete, test the
safety shutoff device by turning the manual shutoff
valve to the OFF position and ensuring that the boiler
shuts down and registers an alarm. Turn the manual
shutoff switch to the ON position and reset the control.
Turn the main power off to the boiler and replace the
plug in the flue sample port.
3.
4.
5.
6.
7.
From the Status Screen press the NAVIGATION dial.
Turn the NAVIGATION dial counterclockwise to select
the appropriate set point.
Press the NAVIGATION dial to adjust the temperature.
Rotate the NAVIGATION dial to change the setting.
Once the desired temperature is displayed, press the
RIGHT SELECT [SAVE] key.
If necessary repeat Steps 3 and 4 to make adjustments to
additional set points.
Press the RIGHT SELECT [HOME[ key to upload the
changes.
If the RIGHT SELECT [SAVE] key is not pressed, the
new settings will be discarded.
10. Place the boiler back into normal operation.
 WARNING
You must replace the plug in the flue
sample port to prevent flue gas spillage
into the room. Failure to comply could
result in severe personal injury, death,
or substantial property damage.
61
Installation & Operation Manual
10
Start-up
Set domestic hot water (DHW) operation
Verify DHW mode
There are two (2) modes of operation for DHW. In Normal
Mode, when a DHW demand begins, the control will start
the DHW pump, turn off the boiler pump (if running), and
modulate to bring the outlet temperature to the DHW boiler
set point. The maximum firing rate may be limited in this
mode if desired.
In Zone Mode it is assumed that the indirect DHW tank is
piped as a zone on the primary loop. When a DHW demand
begins, the control will turn on the DHW pump output, and
raise the system temperature set point to the DHW boiler set
point (if higher). The boiler pump will be turned on. The
system pump may be forced on, forced off, or not changed,
depending on the System Pump Mode selected (reference
the FTXL Service Manual for details). In this mode, any
low temperature zones (such as radiant heating) may need
additional controls to limit the water temperature sent to
those zones.
Set DHW boiler target temperature
When in the DHW Mode, the control will modulate to
maintain the boiler outlet temperature or system supply
temperature to a set point. This set point is set at the factory
to 180°F. If a different set point is desired, the appropriate
parameter in the control must be changed. See the FTXL
Service Manual for a detailed explanation of this procedure.
7.
Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
8.
Turn the NAVIGATION dial to adjust the month. Press
the NAVIGATION dial.
9.
Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
11. Press the RIGHT SELECT [HOME] key.
NOTICE
The internal clock does not adjust for
Daylight Savings Time and therefore, will
require a manual adjustment.
The clock is automatically updated whenever a PC is connected
and the Win_Pro-Installer program is started.
Configuration of the cascade
NOTICE
Please note that the brackets ([]) denote
screen status.
When installed in a Cascade system, the individual controls must
be programmed for cascade operation. This is accomplished by
accessing the control parameters.
Set maximum DHW fan speed
If the rated input of the indirect tank is less than the maximum
output of the boiler, change the maximum DHW fan speed
setting to limit the boiler output accordingly. See the FTXL
Service Manual for a detailed explanation of this procedure.
Press the [MENU] key for at least five (5) seconds. Input
the Installer code as described in the FTXL Service Manual.
Once the control parameters have been accessed, use the
NAVIGATION DIAL to select the Control Mode parameters.
Press the NAVIGATION DIAL to access these parameters.
Set clock
Rotate the NAVIGATION dial to select the parameter “Cascade
Address”. Press the NAVIGATION dial to access this parameter.
Each appliance in the Cascade system must be programmed
with its own address. The boiler designated as the Leader will
have an address of 0. The remaining boilers in the Cascade
will be Members and have addresses from 1 - 7. Rotate the
NAVIGATION dial to select the appropriate address. Press the
RIGHT SELECT [SAVE] key.
Please note that the brackets ([]) denote
screen status.
The SMART SYSTEM control has a built-in clock that it
uses for its night setback feature and for logging events. This
clock must be set when the boiler is installed, and anytime the
boiler has been powered off for more than 4 hours. Use the
following procedure to set the clock:
NOTICE
1.
Press and hold the LEFT SELECT [MENU] key for at
least 5 seconds.
2.
The display changes to
with four (4) zeros below it.
3.
Press the RIGHT SELECT [SAVE] key.
4.
The display will then show a menu with the time and
date and temperature unit.
Press the NAVIGATION dial twice.
5.
6.
read
[PASSWORD],
Turn the NAVIGATION dial to adjust the hours. Press
the NAVIGATION dial.
62
Press the RIGHT SELECT [HOME] key to upload the address
into the control. Repeat this procedure for all boilers in the
Cascade, designating the Leader control and the Member
controls.
Installation & Operation Manual
11
Operating information
General
How the boiler operates
The FTXL uses an advanced stainless steel heat exchanger
and electronic control module that allows fully condensing
operation. The blower pulls in air and pushes flue products
out of the boiler through the heat exchanger and flue piping.
The control module regulates blower speed to control the
boiler firing rate. The gas valve senses the amount of air
flowing into the boiler and allows only the right amount of
gas to flow.
How the control module operates
The SMART SYSTEM control module receives inputs from
boiler sensors and external devices. The control module
activates and controls the blower and gas valves to regulate
heat input and switches the boiler, Domestic Hot Water
(DHW), DHW recirculation, and system pumps on and off
as needed. The user programs the module to meet system
needs by adjusting control parameters. These parameters set
operating temperatures and boiler operating modes. Boiler
operation can be based on boiler outlet water temperature,
boiler inlet water temperature, system temperature, a 0 - 10V
signal, Modbus, or BACnet, depending on the parameter
settings.
Control inputs and outputs
Room thermostat
There are three (3) heat/loop demand connections available
on this control. These inputs tell the boiler to provide water
for space heating. Each demand connection has its own set
point and outdoor air reset curve. When multiple demands
have a call for heat the control will give priority to the demand
with the highest set point.
Example: Assume that both heat/loop demand 1 and heat/
loop demand 2 have a call for heat. Demand 1 has a set point
of 110°F. Demand 2 has a set point of 140°F. The boiler will
regulate the system temperature to 140°F until Demand 2 has
been satisfied. Once Demand 2 has been satisfied the boiler
will provide 110°F water to the system.
When multiple temperature loops are
 CAUTION
used, mixing valves are required for the
protection of any low temperature loops.
SMART SYSTEM Multi-temp loop control
The FTXL boiler is capable of producing up to three (3) set
point temperatures to meet different space heating demands.
This device controls the temperatures of up to three (3)
separate loops, based on the settings for the three (3) heat/
loop demands (reference Lochinvar kit RLY30086).
0 - 10V input (set point or power)
The FTXL can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. The control can be
configured by the installer to use this signal to either control
set point or firing rate.
The FTXL can also be programmed to accept a call for heat
from a 0 - 10V signal, reference the FTXL Service Manual for
a detailed explanation of this procedure.
DHW priority
The SMART SYSTEM control allows the connection of a DHW
thermostat or tank sensor to the low voltage connection board.
When a tank sensor is connected, the DHW thermostat input
is ignored. When a boiler is programmed for DHW Normal
Mode, the maximum firing rate can be limited to match the
input rating of the indirect tank coil.
DHW / space heating (SH) cycling
If a DHW call for heat is received while a space heating call is
in progress, and the DHW is in Normal Mode, the control will
start the DHW pump and shut the boiler pump off. The system
pump will remain on. For stand-alone boilers, if the space
heating call is still active while the DHW call is in operation, the
control will wait for 30 minutes (time adjustable by installer)
then it will switch back to the space heating demand. There is
a timer to switch from space heating to DHW and a timer to
switch from DHW to space heating. The control will switch
back and forth until one of the heat demands end. This function
does not apply to cascade systems.
Programmable controlling sensor
The control module is programmed to use the outlet sensor
as the control sensor by default. If a system supply sensor is
connected, the control automatically uses it as the control
sensor. For stand-alone boilers, the control sensor can be
changed by the installer to the inlet sensor. If the inlet sensor
is chosen as the controlling sensor, it is recommended that the
system supply sensor be installed in the system supply in order
to provide the best control of the inlet temperature.
Anti-cycling
After the burner turns off, the control will delay the next burner
cycle for a set time period (time is adjustable by the installer).
The time delay will be bypassed if the inlet water temperature
drops too far during the delay.
Boiler and system pump control
The boiler pump will run whenever the burner is firing, unless
the DHW is programmed for Normal Mode and the boiler is
heating the DHW tank. The boiler pump will run during Freeze
Protection Mode as well. It will continue to run for a short time
after the burner turns off or the Freeze Protection Mode ends.
The system pump will run whenever there is a space heating call
for heat, or the boiler goes into Freeze Protection Mode. It may
be programmed to run during a DHW call for heat when the
DHW is programmed for Zone Mode. It will continue to run
for a short time after the end of the heat demand or the Freeze
Protection Mode. The system pump can be programmed to run
continuously if desired, except during outdoor shutdown and/
or a DHW call for heat.
DHW recirculation pump control
When a DHW recirculation loop is used, the FTXL boiler can
control the recirculation pump. To activate this function,
simply install the DHW recirculation sensor into the return
water from the DHW circulation loop. The control will turn on
the DHW recirculation pump when the return water drops 10°F
(5.5°C) below the DHW tank set point, and will turn back off
when the return water rises to within 5°F (2.5°C) of the DHW
tank set point. The control will turn the DHW recirculation
pump off whenever DHW night setback is active.
63
Installation & Operation Manual
11
Operating information
Temperature control
Protection features
Modulation
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F (90°C) the control will shut the unit
down until it cools off.
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F (102°C) the control will reduce the maximum fan speed.
If the flue temperature exceeds 240°F (115°C) the control will
shut the unit down. The unit will restart automatically once
the flue temperature drops 25°F (14°C) and the minimum off
time has expired.
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds 70°F
(39°C) the control will reduce the maximum fan speed. If the
temperature difference exceeds 80°F (44°C) the control will
shut the unit down. The unit will restart automatically once the
temperature difference has dropped below 70°F (39°C) and the
minimum off time has expired.
The FTXL is capable of modulating its firing rate from a
minimum of 10% to a maximum of 100%. The firing rate is
dictated by the call for heat (i.e., space heating or domestic
hot water), the heating load, ramp delay (if enabled), and
various other temperature limitations.
Ramp delay
For systems with lower flow, the SMART SYSTEM can
limit the firing rate (when enabled) when a space heating
call for heat starts, when the set point is controlled by
the BMS, or when switching from a DHW call for heat
to a space heating call for heat. There are six (6) limits
that can be programmed, as well as six (6) time intervals
corresponding to each limit. The sixth limit will also limit
the firing rate for the rest of the call for heat.
Gradient limiting
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate
to its lowest setting.
Outdoor air reset
If an outdoor air sensor is connected, the control module
will calculate the set points of the three (3) space heating
demands based on the programmed reset curves. The
installer can change the slope of the reset curves by several
adjustable parameters. The user can limit the maximum set
points for each demand using the space heating set points.
Boost function
If outdoor air reset is active, and any space heating
demand has been active continuously for a set period of
time (time adjustable by installer) and there has been no
DHW demands, the control can increase the set point of
that demand by a fixed number of degrees (adjustable by
installer). This process will continue until the space heating
demand ends, the set point reaches the programmed set
point or a maximum of 20 increases has occurred. Once the
system heat demand is satisfied, the set point will revert to
the value determined by the reset curve.
Night setback
The controller may be programmed to reduce the space
heating and DHW set points during certain times each week.
Seven different start and stop times may be programmed
for the space heating setback and seven start and stop times
for the DHW setback.
Vacation mode
Vacation Mode is used to lower the Space Heat (SH) and/
or DHW set points much like night setback. The set points
will remain lowered until Vacation Mode is disabled. Night
setback will not function when Vacation Mode is enabled.
Flame current support
To prevent nuisance shutdowns when the boiler is firing
at minimum rates, the control will increase the firing rate
when the flame signal drops too low.
64
Freeze protection
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the SMART SYSTEM control
module provides some protection for the boiler only -- not for
the system.
•
•
•
•
•
The SMART SYSTEM control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F (7°C):
Below 45°F (7°C), the boiler and system pumps
operate constantly.
Below 37°F (3°C), the boiler turns on.
Boiler and pumps turn off if boiler water
temperature rises above 45°F (7°C).
Lower temperatures may be programmed for systems
with anti-freeze solutions.
When system return temperatures
are maintained below the dew point,
condensation will form on the inside of the
boiler jacket causing some internal sheet
metal components to rust.
 CAUTION This feature of the SMART SYSTEM
control module does not eliminate the
possibility of freezing. The installation must
still use recognized design, installation and
maintenance practice to prevent freeze
potential for the boiler and system.
Low voltage blocking
The blower and gas valve require a minimum amount of
voltage in order to operate properly. If an ignition attempt is
made when the line voltage is temporarily low (such as during
a brownout), the control could enter a manual reset lockout.
To prevent this, the control monitors the voltage and blocks
any heat demands until the voltage returns to an acceptable
level.
NOTICE
Installation & Operation Manual
11
Operating information
(continued)
Monitor external limits
High limit operations
Connections are provided on the connection board for
a flow switch and a louver proving switch. The SMART
SYSTEM will shut off the burner and inhibit relighting
whenever either of these external limits open.
The FTXL is equipped with adjustable automatic reset and
manual reset high limits. The automatic reset high limit has a
maximum set point of 200°F and the manual reset high limit
has a maximum set point of 210°F.
Run-time and alarm outputs
When the outlet temperature exceeds 200°F, the automatic
high limit action occurs. The boiler shuts down until the outlet
water temperature cools below 190°F, and a 60 second timer
has expired. If the outlet temperature continues to increase, the
manual reset high limit action will occur at 210°F.
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
The control uses two timers to monitor the total hours of
burner operation. One timer monitors the time the boiler
is in the Space Heating Mode. The other timer monitors
the time the boiler is firing in the DHW Mode.
The control uses two (2) ignition counters to monitor
the amount of boiler cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when
either a set time frame has expired, or a set amount of
running hours or cycles has expired (all adjustable by the
installer). The display will show a Maintenance Required
screen. The installer’s name and phone number can be
programmed into the control. This information will appear
on the Maintenance Required screen. The service reminder
notification can be reset or disabled by the installer.
Error logging
The control will hold in memory the last 10 lockouts.
The date and time of the occurrence will be recorded as
well. Only the 10 most current occurrences will be held in
memory.
Boiler temperature regulation
Operating temperature (target)
The SMART SYSTEM control module senses water
temperature and regulates boiler firing and firing rate to
achieve a target temperature. The target temperature can
be set between 32°F (0°C) and 190°F (88°C).
•
Target temperature is fixed when the outdoor
sensor is not installed.
•
Target temperature is calculated as described
on this page under “Outdoor Reset Operation”
and “Target Temperature Boost” when the
outdoor sensor is connected.
High limit test procedure
NOTICE
Please note that the brackets ([]) denote
screen status.
1.
Turn ON the main power to the boiler by placing the
ON/OFF switch in the ON position.
2. From the Status Screen, press the NAVIGATION dial to
access the Set Points Screen.
3. Press the LEFT SELECT (LIMITS) key.
4. Select the manual reset high limit (MRHL) by rotating
the NAVIGATION dial counterclockwise, then press
the NAVIGATION dial.
5. Decrease the set point of the MRHL to below the current
outlet temperature (or to its minimum setting, whichever
is higher) by turning the NAVIGATION dial
counterclockwise.
6. Press the RIGHT SELECT [SAVE] key.
7. Press the RIGHT SELECT [HOME] key. The new
parameter will upload to the control.
8. If the current outlet temperature is above the new MRHL
set point, the MRHL will function causing boiler lockout.
If this occurs, skip to Step 11.
9. If the current outlet temperature is below the new MRHL
set point, locate the pinhole (SERVICE button) below the
RESET button on the display board. Insert a thin probe
(such as a paper clip) into the hole and press the button
continuously for five (5) seconds to place the boiler into
Service Mode. In Service Mode, the boiler will fire at
ignition speed and will then modulate up to full fire.
10. Once the outlet temperature rises up to the MRHL set
point, the MRHL will function, causing the boiler to shut
down and lock out.
11. Repeat Steps 2 through 7 to adjust the MRHL to its normal
setting.
65
Installation & Operation Manual
11
Operating information
Low water cutoff protection
Sequence of the cascade
1.
To equalize the run time of all boilers on the Cascade, the firing
sequence will automatically be changed at set intervals.
2.
The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat
exchanger. If the flow rate is too low or the outlet
temperature too high, the control module modulates and
shuts the boiler down. This ensures boiler shutdown in
the event of low water or low flow conditions.
In addition, an electronic low water cutoff control is
provided.
Outdoor reset operation, if used
For the first 24 hours, the sequence will be changed once every
hour. The switching on/off sequence will be as follows:
TIME
SWITCHING ON SEQUENCE
Start
L-M1-M2-M3-M4-M5-M6-M7
1 hour
M1-M2-M3-M4-M5-M6-M7-L
2 hours
M2-M3-M4-M5-M6-M7-L-M1
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
See the FTXL Service Manual to change the settings.
Reset curve
The reset curves look at outdoor air temperature and adjust
the set points.
Cascade
When multiple boilers are installed, they can be wired
together in a cascade sequence. A maximum of eight boilers
can be controlled from a single control. In this application
one boiler would be designated as the Leader control and all
others would be designated as Member controls. Member
1 can be configured to take over control of the Cascade
should the Leader stop communicating with the Members.
The Leader control can be programmed to use Lead/Lag or
Efficiency Optimization control methods.
Once the Leader boiler receives a call for heat from a room
thermostat, BMS, Modbus, or BACnet the control will
determine what the set point will be. If outdoor air reset is
desired, connect the outdoor air sensor to the terminals on
the Low Voltage Connection Board on the Leader boiler. The
set point will be calculated based on the programmed reset
curve parameters. See the FTXL Service Manual to program
the reset curve. If outdoor air reset is not desired, do not
connect the outdoor air sensor. A fixed temperature set point
can be programmed into the control. See page 61 of this
manual to program the set point.
If the water temperature at the system supply sensor is less
than the set point + the turn-off offset - the off-on differential,
then the control will initiate a call for heat on the Cascade
(see the FTXL Service Manual for an explanation of the offset
and differential). The Leader will energize the lead boiler on
the Cascade. For a new startup this will be the Leader boiler.
66
After the first 24 hours, the sequence will change every night
at 2:00 a.m. If a boiler locks out or is used to heat an indirect
DHW tank, it will automatically be given the lowest priority
until 2:00 a.m.
DHW, Night Setback, and Ramp Delay operation with
cascade
For normal mode DHW operation any boiler(s) in the Cascade
can be selected to provide heat for a DHW call. Select a boiler to
be designated as the DHW boiler. Connect the DHW thermostat
or sensor to the terminals on the Low Voltage Connection
Board marked for the corresponding device. When the boiler
receives a DHW call, the Leader control will take that boiler
out of the Cascade sequence. If another boiler is available, the
Leader will start it up to take its place.
The DHW boiler will adjust its set point to the programmed
DHW boiler set point and will adjust its firing rate to maintain
this. Once the DHW call has been satisfied, the Leader control
will place that boiler back into the Cascade sequence.
Switching of the boiler between DHW operation and SH
operation when there is a call for both does not occur in Cascade
Mode.
When DHW is programmed for Zone Mode, connect the DHW
thermostat or tank sensor to the Leader boiler. When a DHW
call is received, the Leader will modulate the entire Cascade to
bring the system supply temperature up to the DHW boiler set
point (if higher).
Night Setback operation of the boilers within the Cascade is
available. Programming of the Night Setback will be done
through the Leader boiler. Refer to the FTXL Service manual for
information regarding Night Setback.
Ramp Delay operation of the boilers as described in the FTXL
Service Manual is available when the boilers are part of a
Cascade system.
Installation & Operation Manual
11
Operating information
(continued)
Sequence of operation
OPERATION
DISPLAY
1. Upon a call for heat, the gas pressure switch(es) must be closed.
2. Once the gas pressure switch(es) are closed, the control turns
on the appropriate pumps (system and boiler pumps for space
heating, DHW pump for DHW). The flow switch and/or LWCO
must close.
3. The control turns on power to the louver relay. The louver
proving switch, and blocked drain switch must close.
4. The control starts the prepurge cycle by initiating the blower.
5. The control starts the trial for ignition by firing the spark
electrode and opening the gas valve.
6. If flame is not detected after the sparking ends, the control will
perform a postpurge, then start another prepurge cycle and try
to light the burner again. On the 500 and larger models, the control
will lock out if this second attempt also fails. On the 400 model,
the control will perform a total of 4 attempts before locking out.
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Installation & Operation Manual
11
Operating information
Sequence of operation
(continued)
OPERATION
7. If flame is detected, it holds the firing rate steady for a few
seconds to let the flame stabilize, then it begins to modulate the
firing rate based on a set point or some other command (such as
a 0-10V BMS signal).
8. If the space heating call for heat is active, and the tank thermostat
or sensor starts a DHW call for heat, the boiler will switch to the
DHW mode. If programmed for normal DHW operation (not as a
zone), the DHW pump will turn on first, then the boiler pump will
turn off (boiler and DHW pump operation briefly overlap to ensure
flow is maintained through the unit). This will divert the boiler’s
outlet water from the heating system and send it to the tank coil
instead. The control will then modulate to maintain the outlet
temperature to the DHW boiler set point.
9. If the boiler is not part of a Cascade, and both the space heating
and DHW calls for heat remain active long enough, the boiler will
switch back and forth between the two heating modes until one of
them is satisfied.
10. Once both calls for heat are satisfied, the control will turn off
the burner. The blower will continue to run during the postpurge
period.
11. Any pumps that are running will continue to run for their respective
pump delay times before turning off, unless programmed to
remain on continuously. A 60 second anti-cycle period will start,
which will delay any new call for heat until it times out.
12. In Standby, ready to start a new cycle.
68
DISPLAY
Installation & Operation Manual
11
Operating information
(continued)
FTXL control module
Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Figure 11-1 Control Panel
USB
DRIVE
PC
CONNECTION
RESET
SWITCH
LEFT
SELECT KEY
RIGHT
SELECT KEY
NAVIGATION
DIAL
IMG01093
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
Access modes
To save parameters and exit programming:
User
Press the RIGHT SELECT [SAVE] key and then
press the RIGHT SELECT [HOME] key.
The user can adjust space heating and tank target temperatures by
pressing the NAVIGATION dial when “SETPOINTS” is flashing at
the bottom of the display. The date and time, and the temperature
units can also be changed (see page 62).
Installer
Most parameters are available only to the installer, accessible by
entering the installer password, see the FTXL Service Manual.
Saving parameters (reference the Parameter Table in the FTXL
Service Manual)
NOTICE
Please note that the brackets ([]) denote screen
status.
To enter a parameter and continue programming:
Press the RIGHT SELECT [SAVE] key 1 time to
return to the parameter listings; press again to return
to the menu listings. Remember to press the RIGHT
SELECT [HOME] key when finished programming
in order to save the changes made.
See the FTXL Service Manual for a detailed
description of parameters and access modes.
69
Installation & Operation Manual
11
Operating information
Figure 11-2 Status Display Screen
A
B
(BOILER
STATUS)
(CALL FOR
HEAT)
C
(OPERATIONAL
INFORMATION)
D
F
(LEFT SELECT
KEY)
(RIGHT SELECT KEY)
E
(NAVIGATION DIAL)
Status Display Screens
NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.
Section
Display
Description
STANDBY
The unit has not received a call for heat from a remote thermostat nor
has it received a call for heat from a DHW thermostat.
START
A
(Boiler Status
Bar)
The unit has begun a burn cycle and is checking all safety circuits.
PREPURGE
The unit has initiated a prepurge period on a call for heat.
IGNITION
The unit has begun a spark period to ignite the main burner.
%
The unit has fired and is running at the displayed percentage.
POSTPURGE
The call for heat has been satisfied and the unit runs the fan for an
additional postpurge period to clear the combustion chamber and
vent system of residual flue products.
SHUTDOWN
The unit has been placed in the OFF position.
SETPOINT MET
The controlled temperature has exceeded its set point and its offset.
BLOCKED
The unit has detected a condition that has temporarily interrupted
the current call for heat.
Room Thermostat 1 has a call for heat.
Room Thermostat 2 has a call for heat.
B
(Call for Heat
Indicators)
Room Thermostat 3 has a call for heat.
The tank thermostat or sensor has a call for heat.
Indicates which room thermostat demand has priority.
The unit is being controlled by a 0 - 10V BMS signal.
The member unit is supplying heat while in Cascade Mode.
70
Installation & Operation Manual
11
Operating information
(continued)
Status Display Screens (cont’d)
NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.
Section
Display
DETAILS SCREEN 1
DETAILS SCREEN 2
Description
a.
b.
c.
d.
e.
f.
a.
b.
c.
d.
e.
f.
g.
C
(Operational
Information)
SYSTEM TEMP
TANK TEMP
OUTDOOR TEMP
INLET TEMP
OUTLET TEMP
DHW RECIRC TEMP - The temperature read by the DHW
recirculation sensor (if connected).
DELTA T
FLUE TEMP
FLAME CURRENT
FAN SPEED
LOOP 1 TEMP - The temperature of Loop 1 reported by the
MTLC control.
LOOP 2 TEMP - The temperature of Loop 2 reported by the
MTLC control.
LOOP 3 TEMP - The temperature of Loop 3 reported by the
MTLC control.
I/O SCREEN
a. GAS PRESS SW - The state of the gas pressure switch.
b. FLOW SW - The state of the flow switch.
c. LOUVER RELAY - The state of the louver relay output.
d. LOUVER SW - The state of the louver proving switch.
e. BLOCKED DRAIN - The state of the blocked drain switch.
f. GAS VALVE - The state of the gas valve output.
BMS SCREEN
a. 0 - 10V BMS IN
b. 0 - 10V RATE OUT
c. BMS ADDRESS
d. BMS CONTROL?
e. SYS PUMP SPEED
f. BLR PUMP OUT
HISTORY SCREEN
LAST 10 FAULTS
a. SH RUN TIME - Total time running for Space Heat (SH).
b. SH CYCLES - Total Space Heat (SH) demand cycles.
c. DHW RUN TIME - Total time running for DHW.
d. DHW CYCLES - Total DHW demand cycles.
e. POWER TIME - Total time powered ON.
f. IGNITIONS - Total number of successful ignitions.
g. IGN ATTEMPTS - Total number of ignition attempts.
a.
b.
c.
d.
FAULT NO.
FAULT
DATE
TIME
71
Installation & Operation Manual
11
Operating information
Status Display Screens (cont’d)
NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys.
Section
C
(Operational
Information
cont.)
Display
CASCADE STATUS
NIGHT SETBACK
D
(LEFT SELECT
key function)
USB
E
(NAVIGATION
dial function)
MODIFY
F
(RIGHT SELECT
key function)
72
Description
a. CASCADE STATUS
b. CASCADE POWER
c. PRESENT
a. TRIGGER 1 - Next Space Heat (SH) night setback trigger.
b. TRIGGER 2 - Next DHW night setback trigger.
Press the LEFT SELECT key to access the USB and Installer menu.
Pressing the NAVIGATION dial will allow the installer to change the
text.
SHDN
Press the RIGHT SELECT key to turn the boiler OFF.
ON
Press the RIGHT SELECT key to turn the boiler ON.
NO
Press the RIGHT SELECT key to cancel the shutdown operation.
SAVE
Press the RIGHT SELECT key to save the current change.
HOME
Press the RIGHT SELECT key to return to the Status Screen and
upload parameter changes.
Installation & Operation Manual
12
Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
Service technician
(see the following pages for instructions)
Owner maintenance
(see the FTXL User’s Information Manual for
instructions)
General:
• Address reported problems
• Inspect interior; clean and vacuum if
necessary;
• Check boiler area
Daily
• Check pressure/temperature
gauge
• Clean condensate trap and fill with fresh
water
ANNUAL START-UP
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check vent piping
• Check system water pressure/system
piping/expansion tank
• Check air piping
• Check control settings
Monthly
• Check ignition and flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check air and vent termination
screens
• Check relief valve
• Check wiring and connections
• Check condensate drain system
• Perform start-up checkout and
performance verification per Section 10.
• Check air vents
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
Periodically
• Reset button (low water cutoff)
• Clean the heat exchanger if flue
temperature is more than 54°F (30°C)
above return water temperature.
If combustion or performance
indicate need:
• Test low water cutoff
Every
6 months
• Clean heat exchanger
• Check boiler piping (gas and
water) for leaks
• Operate relief valve
• Remove and clean burner using
compressed air only
• Clean the blower wheel
End
of season
months
• Shut boiler down (unless boiler
used for domestic hot water)
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Installation & Operation Manual
12
Maintenance
 WARNING
Follow the Service and maintenance procedures given throughout this manual and in component literature
shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler
or system. Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
 WARNING The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the boiler designated in Table 12A and explained on the following pages must be performed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
 WARNING
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
Address reported problems
Figure 12-1 Condensate Trap
1. Inspect any problems reported by the owner and correct
before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of this manual. If any of these are
present in the boiler intake air vicinity, they must be
removed. If they cannot be removed, reinstall the air and
vent lines per this manual and the FTXL Service Manual.
Inspect boiler interior
1. Lift the top bezel (prop the bezel up for service) and
inspect the interior of the boiler.
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
1. Inspect the condensate drain line, vent line, condensate
PVC fittings, and condensate trap.
Flush condensate trap with water
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (FIG. 12-1).
2.
Locate the plastic ball inside the float tube. Verify there
is nothing under the ball causing it to not seat properly.
3.
Fill with fresh water until the water begins to pour out of
the drain.
4.
Replace the top cover and the screws removed in Step 1.
74
FROM CONDENSATE
VENT ON BOILER
TO FLOOR DRAIN
OR NEUTRALIZER KIT
1” PVC / CPVC CONNECTION
FROM CONDENSATE
DRAIN ON BOILER
Check all piping for leaks
 WARNING
Eliminate all system or boiler leaks.
Continual fresh makeup water will reduce
boiler life. Minerals can build up in sections,
reducing heat transfer, overheating heat
exchanger, and causing heat exchanger
failure. Leaking water may also cause severe
property damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 7 Gas Connections.
Installation & Operation Manual
12
Maintenance
(continued)
Flue vent system and air piping
1.
Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe
is connected and properly sealed.
2.
Verify that boiler vent discharge and air intake are clean
and free of obstructions.
 WARNING
 WARNING
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions
may corrode the valve or its components
over time, rendering the valve inoperative.
Such conditions are not detectable unless
the valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection agency
– not by the owner. Failure to re-inspect the
boiler relief valve as directed could result in
unsafe pressure buildup, which can result in
severe personal injury, death, or substantial
property damage.
 WARNING
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be
taken to avoid contact with hot water and
to avoid water damage. Before operating
lever, check to see that a discharge line is
connected to this valve directing the flow
of hot water from the valve to a proper
place of disposal. Otherwise severe personal
injury may result. If no water flows, valve
is inoperative. Shut down the boiler until a
new relief valve has been installed.
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder
type. See Section 6 - Hydronic Piping for suggested best
location of expansion tanks and air eliminators.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 6 - Hydronic Piping before
proceeding further.
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief
valve. Ensure that the reason for relief valve weeping is
the valve and not over-pressurization of the system due to
expansion tank waterlogging or undersizing.
75
Installation & Operation Manual
12
Maintenance
Inspect ignition and flame sense
electrodes
1. Remove the ignition and flame sense electrodes from the
boiler heat exchanger access cover.
Figure 12-2 Burner Assembly - Model 400 - 850
FAN TOP PLATE
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
BURNER
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
GASKET
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
GASKET
HEX TOP PLATE
FIBER BOARD
2. Verify all wiring is in good condition and securely
attached.
3. Check ground continuity of wiring using continuity
meter.
4. Replace ground wires if ground continuity is not
satisfactory.
HEAT EXCHANGER
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
Check control settings
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the FTXL Service Manual. Adjust settings if necessary.
See Section 1 of the FTXL Service Manual for adjustment
procedures.
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 10 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
Check burner flame
1. Inspect flame through observation window.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove
the burner and clean it thoroughly using a vacuum
cleaner or compressed air. Do not use compressed air to
clean burner if performed inside a building.
3. Remove the burner, reference FIG. 12-2.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 12-2).
76
IMG01072
Installation & Operation Manual
12
Maintenance
(continued)
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the flame
sense electrode.
7. Disconnect the condensate hose from the condensate trap
and route to drain.
8. Use a vacuum cleaner to remove any accumulation on the
boiler heating surfaces. Do not use any solvent.
9. Using a clean cloth dampened with warm water, wipe out
the combustion chamber. Rinse out debris with a low
pressure water supply.
10. Allow the heat exchanger to thoroughly dry.
3. See Section 3 - Troubleshooting in the FTXL Service
Manual for other procedures to deal with low flame
signal.
11. Reinstall the condensate hose, heat exchanger top plate,
burner, fan plate, fan, venturi, and bezel (FIG. 12-2).
Review with owner
12. Perform a combustion analysis by following the instructions
in Section 10 - Start-up - Check Flame and Combustion, on
pages 59 and 61 of this manual.
1. Review the FTXL User’s Information Manual with the
owner.
13. Resume operation.
2. Emphasize the need to perform the maintenance schedule
specified in the FTXL User’s Information Manual (and in
this manual as well).
3. Remind the owner of the need to call a licensed contractor
should the boiler or system exhibit any unusual behavior.
4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual start-up at the
beginning of the next heating season.
Cleaning boiler heat exchanger
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in Section 10 - Startup.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fluid
in system, do not drain.
2. Allow time for the boiler to cool to room temperature if it
has been firing.
3. Remove the bezel from the unit.
4.
Remove the screw securing the fan and venturi from the
fan plate and set aside.
5.
Remove the nuts securing the fan plate and burner from
the heat exchanger plate and set aside (FIG. 12-2).
6.
Loosen the heat exchanger bolts to remove the heat
exchanger top plate (FIG. 12-2).
 WARNING The boiler contains ceramic fiber materials.
Use care when handling these materials per
instructions in the FTXL Service Manual.
Failure to comply could result in severe
personal injury.
77
Installation & Operation Manual
13
Diagrams
Figure 13-1 Wiring Diagram
78
Installation & Operation Manual
13
Diagrams
(continued)
Figure 13-2 Ladder Diagram
79
Revision Notes: Revision A (ECO #C15743) initial release.
Revision B (ECO #C16066) reflects updates made to the room air kit on
page 19 along with updates made to the wiring and ladder diagrams.
Revision C (ECO C17014) reflects the standardization of pressure drop
information on pages 49 and 50 as well as the the addition of the system
supply sensor note on page 53.
.
FTXL-I-O Rev C
01/15
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