Bradford White BMFTCW-199 Brute FT Wall Mounted Combination Boilers (BMFTCW) Installation and Operation Instructions

Installation and Operation Instructions Document 1487

Installation and Operation

Instructions for

THE

FT

SERIES

Wall-Mounted, Modulating

Gas, Condensing, Combination Boiler

Model FTCW

199,000 BTU/h

•

Natural Gas (NG) - Factory Configuration

Propane Gas (LP) - Field-Convertible

FOR YOUR SAFETY:

This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.

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.

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a nearby 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 gas supplier.

AVERTISSEMENT

Assurez-vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables dans le à proximité de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE

GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dans le bâtiment où vous vous trovez.

• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le sservice des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.

Page 2

TABLE OF CONTENTS

SECTION 1 Introduction

1.1 About this Installation Manual ..............................

3

1.2 Included in the Box ..............................................

4

SECTION 2 Product Characteristics

2.1 Model Nomenclature (model number) .................

5

2.2 Specifications ......................................................

6

2.3 Dimensions .........................................................

8

2.4 Names of Components ......................................

10

2.5 Product Flow Paths and Characteristics ............

12

2.5.1 Central Heating flow.. .......................................

12

2.5.2 Domestic Hot Water flow. . ................................

12

4.16 Pressure Relief Valve ........................................

42

4.17 Disposal of Condensate

........................ 43

4.18 DHW Flow Restrictors ......................................

44

4.19 Electrical Wiring Connections .............. 45

4.20 DIP Switches .....................................................

46

4.21 Control Board, Electrical Diagram ....................

47

4.22 Ladder Diagram .................................................

48

4.23 Electrical Connections (table) ............................

49

SECTION 3 Safety Regulations

3.1 Safety Symbols ..................................................

13

3.2 Safety Precautions and Proper Use ..................

16

SECTION 5 Control Display and Operation

5.1 Control Dial and Buttons ....................................

51

5.2 LCD Overview ..................................................

52

5.3 Operating Mode .................................................

53

5.4 Status Display Mode ..........................................

54

5.5 DHW Set Point Change Mode ..........................

55

5.6 CH Set Point Change Mode ..............................

56

5.7 Storage Mode ....................................................

56

5.8 Installer Parameters ..........................................

57

5.9 Outdoor Reset Adjustment ................................

59

5.10 External Set Point Temperature Control ............

59

5.11 Error Mode .........................................................

60

SECTION 4 Installation

4.1 Location and Clearances ...................................

16

4.2 Wall Mount Bracket ............................................

17

4.3 Combustion Air

...................................... 18

4.3.1 Combustion Air from Room ...............................

18

4.3.2 Ducted Combustion Air ......................................

18

4.4 Venting (Exhaust) ................................... 20

4.5 General Location Guideline ...............................

21

4.6 Locations for Vent Pipe Terminator ....................

22

4.6.1 Direct Venting Clearances ................................

22

4.6.2 Venting Requirements in the

Commonwealth of Massachusetts .....................

23

4.7 Common Vent Test ............................................

24

4.8 Air Supply and Vent Connections ......................

25

4.8.1 Vent / Air Pipe Lengths ......................................

25

4.8.2 Indoor Combustion Air .......................................

26

4.9 Vent / Air Pipe Termination.................................

26

4.10 Gas Supply and Piping

.......................... 29

4.11 Gas Supply Pressure .........................................

32

4.12 Adjusting Combustion ........................................

33

4.13 High Altitude Installations. .................................

34

4.14 Natural Gas to Propane Conversion ..................

35

4.15 Plumbing Guidelines

............................. 39

4.15.1 External Plumbing and

Water Connection Guidelines ............................

39

4.15.2 Applicable Backflow Preventer ..........................

39

4.15.3 Diaphragm type Expansion tank ........................

39

4.15.4 Zoning with zone valves ....................................

40

4.15.5 Zoning with circulation pumps ...........................

41

SECTION 6 Error Codes

6.1 Error Code Tables .............................................

61

6.2 Fault Tree Analysis ...........................................

64

SECTION 7 Trouble Shooting

7.1 Diagnostics ........................................................

66

7.2 Suggested Corrective Actions ...........................

67

SECTION 8 Maintenance

8.1 Annual startup & general maintenance .............

70

8.2 Flushing the Combination Boiler ........................

72

8.3 Draining and Cleaning ......................................

73

8.4 Freeze Protection ..............................................

73

SECTION 9 Installation Check

9.1 Quick View .........................................................

74

9.2 Final Check Lists ...............................................

75

SECTION 10 Parts List and Illustrations

10.1 FT 140 ...............................................................

76

10.2 FT 199 ...............................................................

86

4

6

3/8”

12

3/4”

5/8”

17 3/8”

A

B

TOP VIEW

The FT Series Wall Mounted, Combination Boiler

SECTION 1 Introduction

1.1 About this

Installation Manual

This manual provides the information necessary for the installation, operation, and maintenance of the

FT Series Wall Mounted,

Combination Boiler .

All application and installation procedures must be read and reviewed completely before proceeding with the installation. Consult the factory, or your local factory representative, with any problems or questions regarding this equipment.

Experience has shown that most operating problems are caused by improper installation.

FRONT

VIEW

Page 3

For details on Combustion Air and Venting, See page 18 through to page 26

All installations must be made in accordance with

1) American National Standard Z223.1/

NFPA54-Latest Edition “National Fuel

Gas Code” or

2) CSA B149.1 “Natural Gas and

Propane Installation Code” and with the requirement of the local utility or other authorities having jurisdiction.

Such applicable requirements take precedence over the general instructions contained herein.

All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The

National Electrical Code ANSI/NFPA

No. 70-latest Edition, or 2) CSA STD.

C22.1 “Canadian Electrical Code - Part

1”. This appliance must be electrically grounded in accordance with these codes.

For details on Gas

Connections, See page 29 through to page 35

2 3/8”

5

8

3/4”

10

7/8”

14

3/4”

7/8”

C

BOTTOM VIEW

G

D

E

H

F

For details on Electrical

Connections,

See page 45 through to page 49

For details on Plumbing for Central

Heat, Domestic Hot Water and

Condensate, See page 39 through to page 44

L N G

MAIN POWER

L N G

CH/BOILER PUMP

L W C

0-10V

INPUT

T T O / S

Main

Power

External

CH Pump

Low Water

Cut Off

(jumpered)

0 - 10V

External

Input

8page (140)

zone relay panel

Page 4

1.2 Included in the Box

Item

Wall Mounted,

Combination Boiler

FTCW140 / 199

Description Qty

1

Installation Instructions and

User’s Manual

Condensate Hose

Wall Mount Bracket

2 types of Wall Anchors

Pressure Relief Valve

(CH LINE 3/4˝ 30psi)

Model: CASH ACME F-82

4

THE FT

THE FT

1

4

1

FT1894

1

1


1.2 Included in the Box (continued)

Items

3” Mesh Screens

Descriptions

Page 5

Qty

2

O-Ring and Gasket Kit 1

Outdoor Sensor with screws and anchors

4.5 GPM Flow Restrictor

(dark blue)

FTCW

140

*

FTCW

199

**

Propane Conversion Orifice

*

This additional 4.5 GPM (dark blue) is provided with the FTCW140 for use in higher inlet water temperature and/or well water applications to reduce internal pressure drop. A 3.2 GPM Flow

Restrictor (white) has been factory installed. See Section 4.18 on page 44

**

A 7.0 GPM restrictor (white / grey) is factory installed in the FTCW199.

Auto Fill Valve and Backflow Preventer Valves are NOT included (Field Supplied).

1

1

1

SECTION 2 Product Characteristics

2.1 Model Nomenclature (model number)

The Model Nomenclature is shown on your Rating Plate and consists of a series of letters and numbers ( Nomenclature

) that further identifies the characteristics of your FT Seriies

Combination Boiler.

1

M

2 3 4

F T C

SERIES

FT C Combination

5 6 7 8

W

CONFIG

W - Wall Hung

SIZE

MBTU/h

1 4 0

1 9 9

9

FUEL

N - Natural

P - Propane

10

A

ALTITUDE

A 0 -10,000 Feet

11

2

REVISION

2 Second

Model number

12

X

OPTIONS

X - Standard

13

N

PUMP

N - with Pump

Page 6

2.2 Specifications, 140

Model Name

Gas Input Rate

Hot Water Capacity

MAX

MIN

35°F Rise

45°F Rise

77°F Rise

Installation

Flue System

Vent Run / Vent Material

Orifice Size

Gas Supply Pressure

NG

LP

NG

LP

Gas type

Manifold Pressure

Vent size

Max Fire

Min Fire

Power Supply

Main Supply

Maximum Power

Consumption

Ignition System

Burner System

Gas Valve System

Minimum Flow Rate

Dimensions

Shipping Weight

Sub Heat Exchanger Water Capacity(DHW)

Main Controller / Control Panel

Domestic Hot Water Pressure, DHW

Central Heat Water Pressure, CH

Connection Sizes

Cold Water Inlet / Hot Water

Outlet

(CH) Space Heating Supply/Re turn

Gas Inlet

Casing

Materials

Heat Exchanger

Safety Devices

FTCW 140

140,000 Btu/h

14,000 Btu/h

7.1 GPM

5.5 GPM

3.2 GPM

Indoor / Wall hung type

Sealed Combustion Direct / Single Vent / Concentric

Vent

2˝(50ft), 3˝(100ft) Schedule 40 CPVC, PP, PVC

0.224” (6.2 mm)

0.185” (4.7 mm)

3.5˝ WC to 10.5˝ WC

8.0˝ WC to 13˝ WC

NG

2˝ or 3˝ VENT

-.130” WC (+/- 0.01)

LP

2˝ or 3˝ VENT

-.100” WC (+/- 0.01)

0.004” WC (+/- 0.001) 0.002” WC (+/- 0.001)

120V 60Hz / 4A

160W

Direct Electronic Ignition / Automatic Flame Sensing

Single Orifice Premixed Fuel Modulation

Combination modulating (Current proportional)

0.5 GPM

W17.25˝ - H29.0˝ - D15.5˝

111 lbs (50 kg)

Under 1 Gallon

NGTX-900CP / P-920C

Min 15 ~ Max 150 PSI

Min 15 ~ Max 30 PSI

3/4˝ NPT

1˝ NPT

3/4˝ NPT

Cold Rolled Carbon Steel

Primary Heat Exchanger : Stainless Steel

Sub Heat Exchanger : Stainless Steel

Optical Flame Sensor, Overheat Cut Off Device, Gas

Valve Operation Detector, Exhaust Temperature High

Limit Switch, Water Temperature High Limit Switch,

Low Water Cut Off, Air Pressure Sensor

The FT Series Wall Mounted, Combination Boiler Page 7

2.2 Specifications, 199

Model Name

Gas Input Rate

Hot Water Capacity

MAX

MIN

35°F Rise

45°F Rise

77°F Rise

Installation

Flue System

Orifice Size

Gas Supply Pressure

Vent Run

NG

LP

NG

LP

Gas type

Vent size

Manifold

Max Fire

Min Fire

Power Supply

Main Supply

Maximum Power

Consumption

Ignition System

Burner System

Gas Valve System

Minimum Flow Rate

Dimensions

Shipping Weight

Sub Heat Exchanger Water Capacity(DHW)

Main Controller / Control Panel

Domestic Hot Water Pressure, DHW

Central Heat Water Pressure, CH

Connection Sizes

Cold Water Inlet / Hot Water

Outlet

(CH) Space Heating Supply/

Return

Gas Inlet

Casing

Materials

Heat Exchanger

Safety Devices

FTCW 199

199,000 Btu/h

19,900 Btu/h

9.88 GPM

7.7 GPM

4.8 GPM

Indoor / Wall hung type

Sealed Combustion Direct / Single Vent / Concentric

Vent

2˝(50ft), 3˝(100ft) Schedule 40 CPVC, PP, PVC

NG

0.326” (8.3 mm)

0.250” (6.35 mm)

3.5˝ WC to 10.5˝ WC

8.0˝ WC to 13˝ WC

LP

2˝ VENT 3” VENT 3˝ VENT 3˝ VENT

-0.129

”WC -0.314

”WC -0.169

”WC -0.173

”WC

-0.015

”WC -0.015

”WC -0.015

”WC -0.015

”WC

120V 60Hz / 4A

160W

Direct Electronic Ignition / Automatic Flame Sensing

Single Orifice Premixed Fuel Modulation

Combination modulating (Current proportional)

0.5 GPM

W19.6” - H32.0” - D16.3”

130 lbs (59 kg)

Under 1 Gallon

NGTX-900CP / P-920C

Min 15 ~ Max 150 PSI

Min 15 ~ Max 30 PSI

3/4˝ NPT

1˝ NPT

3/4˝ NPT

Cold Rolled Carbon Steel

Primary Heat Exchanger : Stainless Steel

Sub Heat Exchanger : Stainless Steel

Optical Flame Sensor, Overheat Cut Off Device, Gas

Valve Operation Detector, Exhaust Temperature High

Limit Switch, Water Temperature High Limit Switch,

Low Water Cut Off, Air Pressure Sensor

Page 8

2.3 Dimensions FTCW

140

17 3/8”

4

6

3/8”

12

3/4”

5/8”

A

B

TOP VIEW

2 3/8”

5

8

10

7/8”

3/4”

14

3/4”

7/8”

C

BOTTOM VIEW

G

D

E

H

F

FRONT

VIEW

E

F

G

H

C

D

A

B

Description

Air Intake collar

Vent Pipe Collar

‘CH’ Supply

‘CH’ Return

‘DHW’ Outlet

‘DHW’ Inlet

Gas Inlet

Condensate Line

Diameter

3"

3"

1" NPT

1” NPT

3/4” NPT

3/4” NPT

1/2" NPT


2.3 Dimensions

199

9

19

15.0"

1/4”

3/4”

3 1/4”

B

A

TOP VIEW

2 1/2”

5

10

10

7/8”

3/4”

5/8”

16 5/8”

C

BOTTOM VIEW

G

H

D

F

E

Page 9

FRONT

VIEW

G

H

E

F

C

D

A

B

Description

Air Intake collar

Vent Pipe Collar

‘CH’ Supply

‘CH’ Return

‘DHW’ Outlet

‘DHW’ Inlet

Gas Inlet

Condensate Line

Diameter

3"

3"

1" NPT

3/4” NPT

3/4” NPT

3/4” NPT

1/2" NPT

Page 10

2.4 Names of Components

FTCW140

#

1

Name of Component

Air Vent (air eliminator)

8

9

6

7

2

3

4

5


Air Intake Collar

Air Gas Mixing Pipe

Gas Valve

DHW Water Tank

Main PCB

Manual Power Switch (ON / OFF)

Boiler Pump

10 'CH' Supply Connection

11 'CH' Return Connection

12 CH Pressure Gauge

13 DHW Outlet Connection

14 Gas Inlet Connection

15 DHW Inlet Connection (filter and flow restrictor)

16 Condensate Connection

# Name of Component

17 Condensate Trap

18 Blocked Condensate Switch

19 Mixing Valve

20 Terminal Block

21 Control Panel and Display

22 Heat Exchanger

23 Ignition Transformer

24 Flame Detecting Sensor

25 Burner Case

26 BLDC Fan (Blower)

27 Vent Pipe

28 Air Pressure Sensor

29 Vent Pipe Collar

30 Sight Glass

31 Low Water Cut Off

32 Overheat Temperature Sensor


2.4 Names of Components

FTCW199

Page 11

#

1

Name of Component

Air Vent (air eliminator)

8

9

6

7

4

5

2

3


Air Intake Collar

Gas Valve

Air Gas Mixing Pipe

DHW Water Tank

Main PCB

Manual Power Switch (ON / OFF)

Boiler Pump

10 'CH' Supply Connection

11 'CH' Return Connection

12 CH Pressure Gauge

13 DHW Outlet Connection

14 Gas Inlet Adapter

15 DHW Inlet Connection (filter and flow restrictor)

16 Condensate Connection

# Name of Component

17 Condensate Trap

18 Blocked Condensate Switch

19 Mixing Valve

20 Terminal Block

21 Control Panel and Display

22 Heat Exchanger

23 Ignition Transformer

24 Flame Detecting Sensor

25 Burner Case

26 BLDC Fan (Blower)

27 Vent Pipe

28 Air Pressure Sensor

29 Vent Pipe Collar

30 Sight Glass

31 Low Water Cut Off

32 Overheat Temperature Sensor

Page 12

2.5 Product Flow Paths and Characteristics

2.5.1

Central Heating flow. Combination Boiler Heating Mode.

Water in the heating pipe is used for space heating.

FTCW140

Note: The model 140 is shown in this illustration. The model 199 is identical in terms of flow path characteristics.

Combustion Air Vent

2.5.2 FTCW140

Domestic Hot Water Mode.

FTCW199

Cold water passes through the exchanger and is heated via a mini indirect tank. The domestic hot water

(DHW) is provided on demand.

Combustion Air Vent

Combustion Air Vent

FTCW199

Combustion Air Vent

CH Return

DHW Supply DHW Return

CH Supply CH Return

DHW Supply DHW Return


SECTION 3 Safety Regulations

3.1 Safety Symbols

WARNING

To avoid product damage, personal injury, or even possible death, carefully read, understand, and follow all the instructions in the Installation and

Operation manual before installation, operation and service the Boiler.

Manufacturer cannot anticipate every circumstance that might involve a potential hazard. Therefore, all possible incidents are not included in our warnings. Proper installation, operation, and service are your responsibility.

You must make sure that the operation and settings of the Boiler are safe for you and for others.

This manual provides Safety Symbols. When the user fails to adhere to the following requirement, it may cause death, serious injury, and substantial property damage.

For safety symbols, ‘DANGER’, ‘WARNING’,

CAUTION’ are indicated and the definitions for these terms are as follow:

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This signal word is limited to the most extreme situations.

WARNING

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

WARNING

FOR YOUR SAFETY READ BEFORE

OPERATING

If you do not follow these instructions exactly, a fire or explosion could result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

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

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

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Page 13

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

It is also used to alert against unsafe practices and hazards involving only property damage.

This appliance must be installed in accordance with local codes if any; if not, follow ANSI Z224.1/NFPA

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

Installation Code, as applicable.

WARNING

Cancer and Reproductive Harm. www.P65WARNINGS.CA.GOV.

as required by the state of California Proposition 65.

This appliance is certified for use at altitudes up to 4,500ft(1,370m) in accordance to the latest CSA/

CGA 2.17-M91 Gas-Fired Appliances for Use at

High Altitudes.

Page 14

3.2 Safety Precautions and Proper Use

DANGER

Vapors from flammable liquids will explode and catch on fire. These will cause death or severe burns.

Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the appliance.

Keep flammable products

Far away from boiler

In approved containers

Tightly closed

Out of children’s reach

Vapors

Cannot be seen

are heavier than air

spread on the floor

Can spread from other rooms to the main burner by air currents

Do not install the appliance where flammable products will be stored.

Read and follow boiler warnings and instructions thoroughly. If owner’s manual is missing, contact the retailer or manufacturer.

This combination boiler must be installed by a qualified plumber, a licensed gas fitter, and/or a professional service technician.

Improper installation and/or operation will cause a potentially hazardous situation, such as serious injury or death. Also, it will void the warranty.

• The National Fuel Gas Code NFPA 54 / ANSI Z224.1

• National Electric Code ANSI/NEPA 70

• All applicable local, state, national and provincial codes, regulations and laws.

Proper care is your responsibility. Carefully read and understand the Operating Information in this manual before operating the Boiler.

Be aware of the location of the gas shut-off valve and operation method. Close the gas shut-off valve immediately if the appliance is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Boiler must be checked by a qualified technician before resuming operation.

DO NOT use this Boiler if any part has been under water. Immediately call a qualified technician for inspecting the Boiler and replacing any part of the control system and gas control which have been under water.

Do not power up the unit until the gas and water supply valves are fully opened. Make sure that the fresh air intake port and exhaust gas port are opened and functional.

DO NOT attempt to install, repair, or service this

Boiler by yourself.

Do not change any part of the Boiler.

Contact a qualified technician if the Boiler needs repair or maintenance.

Ask your gas supplier for a list of qualified service

providers.

DO NOT use spray paint, hair spray, or any other flammable spray near Boiler or near the exterior fresh air inlet port. DO NOT place any items in or around the exterior exhaust gas outlet port and/or fresh air inlet port. These could restrict or block the flow in or out of the vent system.

“Caution: While repairing control, all wires are labeled. You must connect the wires in accordance with the instruction.

Wiring errors can cause improper and dangerous

operation.

“Verify proper operation after servicing operation”

This consists of the gas ignition system components which are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

After installing the heater, safety devices must be tested.

This boiler is equipped with a blocked vent shutoff system.

If the error code ‘41’ occurs, follow the instructions

below.

- First, turn off the manual gas valve.

- Make sure that there is no foreign object in the vent passage or rodent screen.

- If you do not find any problem, do the following.

- Turn off the error state by pressing the power button of control panel.

- If the error occurs repeatedly, call your service technician or gas supplier.


Before Operation

1. Check the Gas Type (NG/LP) When using or moving the unit for the first time. Check if gas type matches with the gas type of the Boiler. Check whether the gas type which is supplied is NG

(Natural Gas) or LP (Propane) and also check the

Boiler gas type. The gas type is indicated on the rating plate on side of the Boiler.

2. Check the Power (120V 60Hz). Check that the appliance is connected properly.

3. Check the Cold Water

Inlet valve. Please keep the appliance water inlet valve open at all times. The appliance will not ignite when insufficient water or no water is in the heating pipes.

(valve: always open position) open

4. Check the Gas Valve. Check that the manual gas shut-off valve that supplies the FT is opened.

5. Check the area around the appliance and remove any combustible or flammable materials. Remove laundry or any other items that are on or near the boiler or vent pipe.

When in Operation

CAUTION

1. Caution for Gas leak

Frequently check for a gas leak at the gas connection portion with soapy water.

Steps to take if you have a Gas leak.

1. Shut down the boiler as soon as gas fumes are detected.

2. Close the intermediate gas valve.

3. Open windows for ventilation.

4. Call a qualified service technician for immediate repair.

WARNING

Do not use the appliance for any other purpose than for heating and hot water.

Do not store combustibles or flammable material such as gasoline near the appliance.

Do not store other items on or near this boiler.

Do not store combustible (flammable) materials such as papers.

Do not hang clothes on the vent pipe. This may start a fire.

2. Caution for Ventilation

Make sure that there is sufficient inflow and outflow of air ventilation while using the unit.

If the ventilation is improper, combustion quality may deteriorate inside the appliance and cause shortened life of the appliance.

3. Burn Warning

Be careful not to burn yourself on the flue or pipes. They become extremely hot during operation.

CAUTION

Scalding Risk: Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding.

Contact Manufacturer for recommended models.

Check with local codes.

__________________________________________

Carbon monoxide poisoning

If vent pipe fumes enter the room, it could cause poisoning by carbon monoxide gas. Check that the vent pipes are properly connected. Open windows for ventilation. Call a qualified service technician for immediate repair.

Gas leakage test.

Gas supply line must be inspected regularly.

Do not shut off the Boiler.

When you leave home for a long time, do not shut off

Boiler. The Boiler has a freeze protection function.

Do not wipe the appliance or control panel with wet cloth. Electric shock may occur, or internal parts may fail due to the exposure to moisture.

Do not disassemble the Boiler.

If repair is required, call your local qualified technician.

CAUTION

After repair of gas pipeline or gas regulator replacement, call a qualified contractor for inspection before starting it up.

__________________________________________

Page 16

SECTION 4 Installation

4.1 Location and Clearances

The FT must be mounted to a suitable wall by a qualified heating contractor under the guidelines of a boiler. The wall may be of concrete or wood. Suitable fasteners for concrete or wood must be used. Failure to wall mount this boiler using correct fasteners will affect the performance and life expectancy of the boiler and will void the warranty.

3

8

9

23

12

30

3

8

24

61

WARNING

Installations must comply with

• All the local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – The latest version.

• National Electrical Code.

• A National Standard of Canada CAN/CSA-B149.1

Check before placing the Combination boiler

• Always check the connected components which are near to the heater. The components are below.

Water piping position / Venting adapter / Gas supply piping / Electrical power / Condensate drain hose.

• Inspect area around Combination boiler. Remove any combustible materials, gasoline and other flammable liquids. Failure to keep Combination boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

• The Combination boiler which has gas control system components must be protected from any possible danger during operation and service.

• If new Combination boiler replaces an existing appliance, check and correct system problems, for example:

- Do not install if: System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

Provide clearances

• If the heater was installed in a narrow space or corner, please ensure that there is sufficient space for service and maintenance access. For regular maintenance, gas and water lines must be accessible.

The boiler must be installed on a wall that can bear its weight.

Minimum clearances to Combustibles.

Installation Clearances from Noncombustible and combustible surfaces.

TOP of appliance

BACK of appliance

9 in

(23 cm)

0 in

(1.5 cm)

FRONT of appliance

SIDE of appliance

24 in

(61 cm)

3 in

(7 cm)

BOTTOM of appliance

12 in

(30 cm)

Table 1. Minimum Clearances to Combustibles and for Service.

Suggested

Service

Clearance

18 in

(46 cm)

0 in

(1.5 cm)

40 in

(101 cm)

8 in

(20 cm)

24 in

(61 cm)

WARNING

CLEARANCES FOR SERVICE ACCESS

• If you do not provide the minimum clearances shown, it might not be possible to service the boiler without removing it from the space.

• Space must be provided with combustion / ventilation air openings correctly sized for all other appliances located in the same space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.


4.2 Wall Mount Bracket

• The installation height and location for your

FT depends on your installation scenario. With all clearances considered, and given adequate positioning for air supply and venting, you will need to determine the best position to mount the Wall Mount Bracket. The wall must be concrete, wood, or plywood over studs, and must be strong enough to hold the boiler!

• Start by familiarizing yourself to how the included Wall Mount Bracket hooks underneath the two Hangers that are attached to the back of the boiler. The ‘hooks’ of the Wall Mount Bracket will be 3” from the Top of the boiler once the boiler is hung.

Bolts (4)

• Position the Wall Mount Bracket at the location that it will go, being sure that it is level, and then drill 4 holes (0.47”dia) with a 1/2” drill bit, into the wall through the Bracket.

Anchors

(4)

Wall Mount

Bracket

*

• If mounting to a concrete wall, then use the concrete anchors.

If onto wood or 5/8” (16 mm) plywood, then use the wood screws. Do not hang the FT onto sheetrock unless it is possible to fasten directly into the structural studs. If the included anchors do not suit your installation, you must use

‘Field Supplied’ anchors that are appropriate for the wall’s construction.

Hangers (2)

(fastened to the back of unit)

Page 17

3" to Top

of Unit

Concrete,

Wood, or 5/8" Plywood

Wall Mount

Bracket

Hang the Boiler

• Lift the boiler up, align the Hangers on the back of the boiler with the hooks on the Wall Mount

Bracket, and hang the boiler onto the Wall Mount

Bracket. Do a visual inspection to make sure that the boiler is hanging properly onto the hooks of the Wall Mount Bracket.

• Fasten the bottom of the boiler to the wall using

2 suitable wall anchors (field supplied).

Page 18

4.3 Combustion Air

FT boilers must have provisions for combustion and ventilation air in accordance with the applicable requirements for Combustion Air Supply and Ventilation in the National Fuel Gas Code, ANSI Z223 1; or in

Canada, the Natural Gas and Propane Installation Code,

CSA B149.1. All applicable provisions of local building codes must also be adhered to.

A FT unit can take combustion air from the space in which it is installed, or the combustion air can be ducted directly to the unit. Ventilation air must be provided in either case.

4.3.1

Combustion Air from Room

In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow.

Where ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect.

Method 1

:

Two permanent openings, one commencing within 12” (300mm) of the top and one commencing within 12” (300mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4000 Btu/hr (550 square mm/kW) of total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (1100 square mm/kW) of total input rating of all equipment in the enclosure.

Method 2

:

One permanent opening, commencing within 12” (300mm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000

Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure. This opening must not be less than the sum of the areas of all vent connectors in the confined space.

Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above.

In Canada, consult local building and safety codes or, in absence of such requirements, follow CAN/CGA B149.1

4.3.2

Ducted Combustion Air

The combustion air can be taken through the wall, or through the roof. When taken from the wall, it must be taken from out-of-doors by means of the horizontal wall terminal. When taken from the roof, a field-supplied rain cap or an elbow arrangement must be used to prevent entry of rain water.

Use ABS, PVC, CPVC, polypropylene, or galvanized pipe for the combustion air intake. Route the intake to the boiler as directly as possible. Seal all joints.

Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. Maximum linear pipe length allowed is shown in Table 5 . Subtract

5 allowable linear ft. (1.5m) for every elbow used.

The connection for the intake air pipe is at the top of the unit.

In addition to air needed for combustion, air shall also be supplied for ventilation, including air required for comfort and proper working conditions for personnel.

MATERIAL

ABS

PVC, sch 40

CPVC, sch 40

COMBUSTION AIR INSTALLATION STANDARDS

UNITED STATES

ANSI/ASTM D1527

ANSI/ASTM D1785 or D2665

ANSI/ASTM F441

CANADA

Air pipe material must be chosen

CPVC, sch 40, ANSI/ASTM, Polypropylene

Polypropylene

Single wall galv. steel

UL1738, ULC S636.

26 gauge based upon the intended application of the boiler.

Table 2. Required Combustion Air Pipe Material.


NOTICE

The instructions for the installation of the venting system shall specify that the horizontal portions of the venting system shall be supported to prevent sagging; the methods of and intervals for support shall be specified. These instructions shall also specify that the venting system:

Category I, II and IV boilers must be installed so that horizontal sections have an upward slope away from the boiler of at least ¼ inch per foot (21 mm/m) to prevent accumulation of condensate; and

For Category II and IV boilers, where necessary, have means provided for drainage of condensate.

NOTICE

For long, trouble free operation, it is critical that the

FT unit has always access to clean combustion air, either drawn from an inside space (per section 4.3.1) or external (per section 4.3.2).

• Do NOT allow contaminated indoor air (either by internal dust, sheet rock, PVC or CPVC pipe debris dust or similar contamination) to be drawn in through the air intake connection. If the unit must operate under job site conditions, always ensure availability of fresh air and protect the unit accordingly.

• For ducted combustion air from the outdoors, follow the guidelines provided in Sections 4.6 through 4.8 and make sure that clean air is always available for combustion.

• During assembly of the air intake system, make sure that any PVC or CPVC pipe debris due to cutting pipe is fully removed and all connecting surfaces are smooth and free of contamination.

CAUTION

When an existing Cat I appliance is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances.

Under no circumstances should an improperly sized vent be used. An improperly sized vent may cause operational and safety problems, and could result in serious injury, death, or property damage.

AVIS

Les instructions d'installation du système d'évacuation doivent préciser que les sections horizontales doivent être supportées pour prévenir le fléchissement. Les méthodes et les intervalles de support doivent être spécifiés. Les instructions doivent aussi indiquer les renseignements suivants: les chaudières de catégories I, II et IV doivent présenter des tronçons horizontaux dont la pente montante est d'au moins ¼ po par pied (21 mm/m) entre la chaudière et l'évent; les chaudières de catégories II et IV doivent être installées de façon à empêcher l'accumulation de condensat; et si nécessaire, les chaudières de catégories II et IV doivent être pourvues de dispositifs d'évacuation du condensat.

CAUTION

The FT is standard as a Natural Gas Boiler and must be converted if propane is the desired gas, unless specifically manufactured for propane.

Adequate drainage

• The appliance should be installed not to damage the adjacent area. If such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not block combustion air flow.

Connecting the Water Supply

• To conserve water and energy, insulate all water piping—especially the hot and recirculation water lines. Never cover the drain or pressure relief valve.

Having a backflow preventer in the cold water supply line will prevent thermal expansion backflow. Contact the water supplier or local plumbing inspector for information about how to control this situation.

If overheating occurs or the gas supply fails to shut off, turn off the manual gas valve.

This installation must conform with below section

• “Air for Combustion and Ventilation” of the

National Fuel Gas Code, ANSI Z224.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and

Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

Page 20

4.4 Venting (Exhaust)

NOTICE

DO NOT COMMON VENT FT UNITS. FT units are never permitted to share a vent with

Category I appliances.

WARNING

All venting must be installed according to this manual and any other applicable local codes, including but not limited to, ANSI Z224.1/NFPA 54, CAN/CSA

B149.1 and ULC-S636. Failure to follow this manual and applicable codes may lead to property damage, severe injury, or death.

AVIS

NE PAS ÉVENT COMMUNE FT UNITÉS. FT unités ne sont jamais autorisés à partager un

évent Catégorie I avec les appareils.

The flue temperature of the FT changes dramatically with changes in operating water temperature. Therefore, it is necessary to assess the application of the boiler to determine the required certified vent class. If the FT is installed in an application where the ambient temperature is elevated, and/or installed in a closet/alcove,

CPVC, polypropylene, or stainless steel material is required. If the system temperatures are unknown at the time of installation, stainless, polypropylene or CPVC material is recommended.

The FT is a Category IV appliance and may be installed with PVC, CPVC or polypropylene that complies with ULC -S636, ANSI/ASTM D1785 F441

(see Table 3) or a stainless steel venting system that complies with UL 1738 Standard and ULC S636.

WARNING

Failure to use the appropriate vent material, installation techniques, glues/sealants could lead to vent failure causing property damage, personal injury or death.

WARNING

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) used in non-metallic venting systems is prohibited.

Non-metallic vent pipe (PVC, CPVC, polypropylene or other) shall NOT be insulated or covered. Insu lating or covering non-metallic venting may cause overheating which diminishes the integrity of the pipe.

INSTALLATIONS IN CANADA require the use of venting material certified to ULCS636. All Gas vents connected to the FT, plastic, stainless steel or otherwise must be certified to this ULC standard. Appropriate selection of vent material is very important for proper performance and safe operation of the FT.

The flue temperature of the FT changes dramatically with changes in operating water temperature. Therefore, it is necessary to assess the application of the boiler to determine the required certified vent class. If the FT is installed in an application where the outlet water temperature exceeds 145°F, and/or installed in a closet, class

IIB or higher vent material is required. If the system temperatures are unknown at the time of installation, class IIB or higher venting material is recommended.

IN CANADA all venting used must meet the following requirements:

1. ULC-S636 certified and marked

2. The first 3 feet of venting must be accessible for visual inspection.

3. All components used in the vent system must

MATERIAL

Stainless Steel

PVC, sch 40

CPVC, sch 40

Polypropylene

Table 3. Required Exhaust Vent Material.

INSTALLATION STANDARDS

UNITED STATES

UL 1738

ANSI/ASTM D1785

ANSI/ASTM F441

UL1738 or ULC-S636

CANADA

Venting must be ULC-S636 certified for use as venting material. The venting material must be chosen based upon the intended application of the boiler.

The FT Series Wall Mounted, Combination Boiler Page 21 be from a certified manufacturer.

4 . Vent system components must not be mixed with alternate manufacturers certified components and/or unlisted components.

5 . The venting must be installed according to the vent manufacturers installation instructions.

The unit’s vent can terminate through the roof, or through an outside wall.

Vent pipe must pitch upward, toward the vent terminal, not less than 1/4” per foot, so that condensate will run back to the FT to drain. Route vent pipe to the boiler as directly as possible.

Seal all joints and provide adequate hangers as required in the venting system manufacturer’s

Installation Instructions. Horizontal portions of the venting system must be supported to prevent sagging and may not have any low sections that could trap condensate. The unit must not support the weight of the vent pipe.

WARNING

Failure to vent this Boiler in accordance with these instructions could cause a fire, resulting in severe property damage, personal injury or death.

Do not interchange vent systems or materials unless it is specified.

The use of thermal insulation covering pipe and fittings is prohibited.

Do not apply an electric damper, draft hood or vent damper with this Boiler.

Do not locate vent termination where exposed to prevailing winds. Moisture and ice may fall on surface around vent termination. To prevent deterioration, surface must be in good repair

(sealed, painted, etc.).

4.5 General Location Guideline

1. Vent system installation must be in accordance with Local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z224.1 /NFPA

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

Installation Code.

2. The Boiler is designed to be installed as a Direct

Vent (sealed combustion) type. The air for combustion must be supplied directly from the outside to the burner. Also, the flue gases must be vented directly to the outdoors (through wall or roof).

3. Do not install venting system components on the exterior of building except as specifically required by these instructions

- Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.

- Maintain the correct clearance and orientation between the vent and air intake terminals.

The vent and air intake terminals must be at the same height and their center lines must be spaced apart 12˝ minimum.

- The bottom of the vent and air intake terminal must be at least 12˝ above the normal snow line. In no case should they be less than 12˝ above grade level.

- Do not install the vent terminal directly over windows or doors.

- Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools.

- For sidewall venting, the minimum horizontal distance between any adjacent individual Module

(Boiler) vent terminations is twelve (12) inches. It is better to be far more than 12 inches for avoiding frost damage to building surfaces where vent terminations are placed.

- The minimum horizontal distance between any adjacent individual module (boiler) roof vent end piece is one (1) foot.

The vent shall not terminate:

- over public walkways:

- near soffit vents, crawl space vents or other areas where condensate or vapor could create a nuisance or hazard, or cause property damage: or

- where condensate or vapour could cause damage or could be detrimental to the operation of regulators, relief valves or other equipment.

Page 22

4.6 Locations for Vent Pipe Terminator

Canadian Installations1

A = Clearance above grade, veranda, porch, deck, or balcony

B = Clearance to window or door that may be opened

1 2 i n ( 3 0 c m )

● 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW)

● 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and

≤ 100,000 Btuh (30 kW)

● 36 in (91 cm) for appliances >100,000 Btuh (30 kW)

See Note 4

See Note 4

C = C l e a r a n c e t o p e r m a n e n lt y c l o s e d w i n d o w

D = Vertical clearance to ventilated soffit located above the terminal within a horizontal

E = distance of 2 ft (61 cm) from the center line of the terminal

C l e a r a n c e t o u n v e n t li a t e d s o ff ti

F =

G =

C

C l l e e a r a r a n c e a n c e t o o u t s i d e c o r n e r t o i n s i d e c o r n e r

H = Clearance to each side of centerline extended above meter / regulator assy

I = C l e a r a n c e t o s e r v i c e r e g u l a t o r v e n t o u

J = Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance lt e t

K = Clearance to a mechanical air supply inlet

L = Clearance above paved sidewalk or paved driveway located on public property

See Note 4

See Note 4

See Note 4

3 ft (91 cm) within a height of 15 ft (4.6 m)

3 tf ( 9 1 c m )


● 12 in (30cm) for appliances > 10,000 Btuh (3 kW) and

≤ 100,000 Btuh (30 kW)


6 tf ( 1 .

8 3 m )

7 tf ( 2 .

1 3 m ) †

1 2 i n ( 3 0 c m ) ‡

U.S. Installations2

1 2 i n ( 3 0 c m )


● 9 in (23 cm) for appliances > 10,000 Btuh (3 kW) and

≤ 50,000 Btuh (15 kW)

● 12 in (30 cm) for appliances >50,000 Btuh (15 kW)

See Note 5

See Note 5

See Note 5

See Note 5

See Note 5

See Note 5

See Note 5


● 9 in (23cm) for appliances > 10,000 Btuh (3 kW) and

≤ 50,000 Btuh (15 kW)

● 12 in (30 cm) for appliances > 50,000 Btuh (15 kW)

3 tf tf

(

(

9

2 .

1

1 c

3 m m

)

) a b o v e i f w

10 ft (3 m) horizontally

7 f o r m e c h a ti h n i i n c a l d r a f t s y s t e m s ( C a t e g o r y appliances). Vents for Category II and IV appliances

I cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard*

See Note 5 M = Clearance under veranda, porch, deck, or balcony

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

* The manufacturer shall specify a minimum clearance or state "Not applicable" in the table and/or instructions.

Notes:

openings shall not be less than those values specified in the National Fule Gas Code, ANSI Z223.1/NFPA 54,

and/or the Natural Gas and Propane Installation Code, CSA B149.1; ii) Information on preventing blockage by snow; and

4) For clearances not specified in CAN/CSA-B149, clearance is in accordance with local installation codes and the requirements of the gas supplier.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single

family dwellings and serves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

Notes:

1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.

2) In accordance with the current ANSI Z223.1/NFPA 54, Natural Fuel Gas Code.

3) If locally adopted installation codes specify clearances different than those illustrated, then

the most stringent clearance shall prevail.

*When vent terminal is less than 10 feet (3m) horizontally from a forced air inlet, the terminal must be at least 3 feet (0.9m) above the air inlet.

(US only)

Table 4. Direct Vent Clearances


4.6.1

Venting Requirements in the

Commonwealth of Massachusetts

In Massachusetts the following items are required if the side-wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches. From Massachusetts Rules and regulations 248 CMR 5.08

1. Installation of Carbon Monoxide Detectors

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

a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of the subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty

(30) days to comply with the above requirements, provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm be installed.

2. Approved Carbon Monoxide Detectors. Each carbon monoxide detector shall comply with NFPA

720 and be ANSI/UL 2034 listed and IAS certified.

3. Signage. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print no less than one-half (1/2) inch in size: “GAS

VENT DIRECTLY BELOW, KEEP CLEAR OF ALL

OBSTRUCTIONS”.

4. Inspection The state or local gas inspector of the side-wall horizontally vented gas fueled appliance shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1-4.

Page 24

4.7 Common Vent Test

NOTE: This section does not describe a method for common venting FT units. It describes what must be done when an existing unit is removed from a common vent system.

NOTICE

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.

1. Seal any Not Used openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. 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.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance will operate continuously.

5. Operate the main burner for 5 minutes then, determine if the cut-draw overflows to the discharge opening. Use the flame of a match or a candle or the smoke of a cigarette, a cigar or a pipe

6. Once it has been determined, according to the method indicated above, that each device connected to the drainage system is placed in the open air in an adequate manner.

Install the doors and windows, fans, the registers of chimneys and gas appliances to their original position

7. Any malfunction of the venting system should be corrected so that the installation conforms to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 and (or) the installation codes CAN/

CSA-B149.1. If the size of a section of the evacuation system must be changed, the system should be modified to comply with the minimum values of the relevant tables of appendix F of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and

(or) the installation codes CAN/CSA-B149.1

AVIS

Au moment du retrait d'une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d'évacuation commun et qui fonctionne alors que d'autres appareils toujours raccordés au système d'évacuation ne fonctionnent pas:

1. Sceller toutes les ouvertures non utilisées du système d'évacuation.

2. Inspecter de façon visuelle le système d'évacuation pour déterminer la grosseur et l'inclinaison horizontale qui conviennent et s'assurer que le système est exempt d'obstruction, d'étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l'espace où les appareils toujours raccordés au système d'évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d'évacuation commun et tous les ventilateurs d'extraction comme les hottes de cuisinière et les ventilateurs des salles de bain.

S'assurer que ces ventilateurs fonctionnent à la vitesse maximale.

Ne pas faire fonctionner les ventilateurs d'été. Fermer les registres des cheminées.

4. Mettre l'appareil inspecté en marche. Suivre les instructions d'allumage. Régler le thermostat de façon que l'appareil fonctionne de façon continue.

5. Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l'ouverture de décharge.

Utiliser la flamme d'une allumette ou d'une chandelle ou la fumée d'une cigarette, d'un cigare ou d'une pipe.

6. Une fois qu'il a été déterminé, selon la méthode indiquée cidessus, que chaque appareil raccordé au système d'évacuation est mis à l'air libre de façon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

7. Tout mauvais fonctionnement du système d'évacuation commun devrait être corrigé de façon que l'installation soit conforme au

National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d'installation CAN/CSA-B149.1. Si la grosseur d'une section du système d'évacuation doit être modifiée, le système devrait

être modifié pour respecter les valeurs minimales des tableaux pertinents de l'appendice F du National Fuel Gas Code, ANSI

Z223.1/NFPA 54 et (ou) les codes d'installation CAN/CSA-B149.1

NOTICE

DO NOT COMMON VENT FT UNITS. FT units are never permitted to share a vent with

Category I appliances.

AVIS

NE PAS ÉVENT COMMUNE FT UNITÉS. FT unités ne sont jamais autorisés à partager un évent

Catégorie I avec les appareils.

Use this table for Doc. 1483

MFTHW 100/140/199 NG & LP

Deductions per 90° Elbow


Max. # of Total Elbows on

Air Intake & Exhaust Vent

2" Combustion Air & Vent Pipe

Min.

Combustion Air

Min. Vent

Pipe

Max. Combustion

Air & Vent Pipe

Pipe

0 FT

8 FT (2.4 M)

4 FT (1.2 M)


Min.

Combustion

Air Pipe

Min. Vent

Pipe

Max. Combustion

Air & Vent Pipe

* (0 M) 3 FT (1 M) 50 FT (15 M) 0 FT * (0 M) 3 FT (1 M) 100 FT (30 M)

5 FT (1.5 M)

2.5 FT (.75 M)

4 6

*appliance needs to vent outdoors using approved vent caps and following all guidelines as noted in our IO manual.

Proper protection against debris in the air intake (through using a downward spout and/or screen) to avoid debris pick-up / falling into the appliance is required.


4.8 Air Supply and Vent Connections

4.8.1

Vent / Air Pipe Lengths

Use this table for Doc. 1487

MFTCW 140/199 NG & LP


Min.

Combustion Air

Pipe

Min. Vent

Pipe

Max. Combustion

Air & Vent Pipe


Min.

Combustion

Air Pipe

Min. Vent

Pipe

Max. Combustion

Air & Vent Pipe

0 FT * (0 M) 3 FT (1 M) 50 FT (15 M) 0 FT * (0 M) 3 FT (1 M) 100 FT (30 M)

8 FT (2.4 M) 5 FT (1.5 M) Deductions per 90° Elbow


Max. # of Total Elbows on

Air Intake & Exhaust Vent

4 FT (1.2 M)

4

2.5 FT (.75 M)

6

Table 5. Maximum Vent / Air Pipe Lengths for either 3” or 2 “ Pipes

* Appliance needs to vent outdoors using approved vent caps and following all guidelines as noted in the

Installation Manual.

Proper protection against debris in the air intake (through using a downward spout

NOTES: length of the air intake and exhaust vent piping.

• A total of 4 elbows matches the total number of elbows allowed for 2” venting.

Example: 2” venting system desired.

Air intake piping: Two 90 elbows and 15 ft of straight pipe: 2 x 8 ft + 15 ft = 31 ft (okay)

Exhaust vent piping: Two 90 elbows and 20 ft of straight pipe: 2 x 8 ft + 20 ft = 36 ft (okay)

NOTE: Proper protection against debris in the air intake (through using a downward spout and/or screen) to avoid debris pick-up / falling into the appliance is required.

4.7.2 Direct Venting

The FT boiler uses 3˝ or 2˝ diameter exhaust and 3˝ or

2˝diameter intake air ducts. To ensure the draw of air directly from and exhaust of air directly to the outside of the building, create an airtight seal from the boiler collar to the vent termination.

(For installations in Canada) field-supplied plastic vent piping must comply with CAN/CSA B149.1 (latest edition) and be certified by the Standard For Type BH

Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues of the certified vent system must be from a single system manufacturer and must not be intermixed with another system manufacturer’s parts.

Tightening — Boiler Collar (Socket) to Vent Pipe &

Inlet Pipe

- Clean and dry your selected PVC, CPVC vent pipe and boiler collar (socket).

- You can select to the size of vent pipe(2˝ & 3˝), according to the installation conditions.

- Push the pipe into the collar (socket) until it touches the bottom of the socket fitting.

- For 2” installations, install a field supplied 3” to 2” adaptor.

Adaptor must be installed in vertical section of piping only.

3” pipe

2” pipe connected, using an adapter

3” to 2” adapter is NOT included.

Page 26

4.8.2

Indoor Combustion Air

Read and Follow Sections 4.3 Guidelines First.

1. Insert the termination end cap into the intake air duct.

2. Provide two openings to allow for circulation of combustion air as specified by ANSI Z224.1/NFPA 54.

In Canada refer to CAN/CSA B-149.1

NOTE: The FT needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

Model

Maximum Input (BTU/H)

Indoor make up air is provided, a minimum free area of 1 in 2 per 1,000 BTU/H

FTCW140

140,000

140 in 2 13 1/4˝

(W) x 13 1/4˝ (H)

4.9 Vent / Air Pipe Termination

Vent Air Terminations:

After connecting terminals install vent screens on both the vent and air inlet.

Two 3” vent screens are included with each unit.

Additional replacement screens are available for purchase.

2” Vent Screen P/N - FT1508

3” Vent Screen P/N - FT1730

FTCW199

199,000

199 in 2 13 1/4˝

(W) x 13 1/4˝ (H)

Vertical Vent Termination

• Direct Vent - Vertical Terminations with Sloped Roof

Vent Screens are required


Horizontal Vent Termination

• Direct Vent - Sidewall Termination

Page 27

4.9 Vent / Air Pipe Termination (continued)

Exhaust

12” MIN

Apart


1” MIN

12” MIN

Exhaust

Exhaust Screen

Exterior Wall

90 o Elbow

A

NOTE: The Exhaust must be equal to or above the

Combustion Intake while at a Minimum of 12” apart.

FRONT VIEW

NOTE: Must be 12”

Minimum distance above highest anticipated snow level or grade, whichever is greater (TYP).

Air Intake Screen

SIDE VIEW

Exterior Wall

Exhaust Exhaust

Exhaust Screen

B

12” MIN

12”

MIN

Combustion

Intake

FRONT VIEW


12” MIN

90 o Elbow

NOTE: Must be 12”


Air Intake Screen

SIDE VIEW

Exhaust

Exhaust

Screen

Exterior Wall

1” MIN

Sill

Exhaust

12” MIN

12”

MIN

12” MIN

Vent

Screens are required

1” MIN

Sill

C FRONT VIEW

NOTE: Must be 12”


SIDE VIEW

• Direct Vent - Optional Side wall Terminations


Page 28


Concentric Vent Termination

• Direct Vent - Optional Horizontal and Vertical Concentric Vent

Exterior Wall

(2” or 3”)

NOTE: Concentric Vent Terminations cannot be less than 12” apart in multi-unit installations or in cascading operations. Consult local codes and the manufacturer’s guidelines for acceptable separation distances.

Side Wall Kit

(2” or 3”)

4. Concentric Vent Termination

12” Minimum clearance above highest anticipated

Side Wall Kit

(2” or 3”)



Exterior Wall

Exhaust

Exhaust

Exhaust



4" (100mm)


4" (100mm)

Combustion Air

12” Minimum clearance above highest anticipated snow level or grade, whichever is greater.

Strap

Vent

Combustion Air 1" (25mm) to

4" (100mm) snow level or grade, whichever is greater.

Vent

12” Minimum clearance above highest anticipated snow level or grade, whichever is greater.


12” (30cm) Minimum clearance above highest anticipate

snow level.


snow level.


snow level.

Vent

Combustion Air

Vent

Combustion Air

Vent

Combustion Air


4.10 Gas Supply and Piping

Gas piping should be supported by suitable hangers or floor stands, not the appliance.

Review the following instructions before proceeding with the installation.

1. Verify that the appliance is fitted for the proper type of gas by checking the rating plate. FT will function properly at elevations up to 10,000 feet

(3050 m). Refer to Section 4.12 for High Altitude

Settings.

2. For minimum and maximum supply pressures, see

Table 9 on page 32

3. Refer to Table 6, Table 7, and Table 8 to size piping.

4. Run gas supply line in accordance with all applicable codes.

5. Locate and install manual shutoff valves in accordance with state and local requirements.

6. A sediment trap must be provided upstream of the gas controls.

7. All threaded joints should be coated with piping compound resistant to action of liquefied petroleum gas.

8. The appliance and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45kPa).

9. The unit must be isolated from the gas supply system by closing it’s individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 PSIG (3.45kPa).

10. The appliance and it’s gas connection must be leak tested before placing it in operation.

11. Purge all air from gas lines.

WARNING:

Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life.

NOTE : The FT appliance and all other gas appliances sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure.

The pressure can be measured at the supply pressure port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line.

SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY

UNDILUTED PROPANE

NOMINAL PIPE SIZE

@

11" W.C. INLET AND 0.5" W.C. PRESSURE DROP

SIZE 1/2" 3/4" 1"

LENGTH MAXIMUM CAPACITY IN THOUSANDS OF BTU PER HOUR

20

40

60

80

200 418 787

137 287 541

-

-

231 434

197 372

100 - 175 330

NOTES: 1. Follow all local and national propane gas codes for line sizing and equipment requirements. 2. Verify that inlet gas pressure remains between

4 and 13 inches of water column before and during operation.

Source: ANSI Z223.1-80 National Fuel Gas Code.

Table 6. Nominal Pipe Size, Propane

SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY NATURAL GAS

NOMINAL PIPE SIZE

@

0.30" W.C. PRESSURE DROP

LENGTH 3/4" 1"

FT CUBIC FEET OF GAS PER HOUR

20

40

60

80

190 350

130 245

105 195

90 170

100

Table 7. Nominal Pipe Size, Natural Gas

CAUTION

PRV (included) must be installed immediately at the top of boiler outlet to PRV, with no valves between.

Refer to Section 4.15

__________________________________________

ATTENTION

PRV (inclus) doit être installé immédiatement en haut de la chaudière sortie de PRV, sans les vannes entre.

Se reporter à la Section 4.15

__________________________________________

EQUIVALENT LENGTHS OF STRAIGHT PIPE FOR TYPICAL SCH 40 FITTINGS

NOMINAL PIPE SIZE

FITTING 1/2" 3/4"

LINEAR FEET

1"

90° ELBOW 3.6 4.4 5.2

TEE 4.2 5.3 6.6

Table 8. Equivalent Pipe Lengths

Page 30

4.10 Gas Supply and Piping (cont)

The gas connection fitting is,

3/4” male NPT on FTCW140 models

3/4” male NPT on FTCW199 models

The supply line must be sized for the maximum output of the combination boiler model being installed. If there are additional gas appliances from the main supply line, you must measure sizes of the supply line according to the

COMBINED total maximum BTUH draw for the appliances as if they were all operating at the same time.

Measure the length of the gas supply line from the gas meter to the Combination boiler.

Use the tables in this manual or refer to the gas line manufacturers sizing information to determine the correct supply pipe size.

The gas shut-off valve in the gas supply line should be installed close to the unit.

To facilitate any future maintenance, it is also recommended that an approved gas union fitting be installed in the supply line between the shut-off valve and the 3/4˝ male NPT connection on the

Combination boiler.

1) Install an approved gas line pipe to gas line connection under the Combination boiler.

Include manual shut off valve and gas union connection, as shown.

2) Test gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards for the combination boiler.

3) Leak test the gas line pipe before placing the unit in operation. Use approved leak detector liquid solutions only to check for leaks.

Do Not Operate the combination boiler until all connections have been completed, checked for leaks, and the heat exchanger is filled with water.

CLOSED POSTION

UNION

FITTING

MANUAL SHUT OFF VALVE

GAS PIPE

Gas Line Valve Detail


Suggested Natural Gas (NG) Layout

NOTE: Total gas supply capacity must not be less than the total demand capacity of the connected appliances.

Page 31

Other Appliances

Gas Regulator

(Supply Press 12˝ )

Gas Meter

Sediment

Trap

Suggested Propane Gas (LP) Layout

NOTE: Total gas supply capacity must not be less than the total demand capacity of the connected appliances.

Gas Regulator

(Supply Press 12˝ )

Gas Meter

Sediment

Trap

Other Appliances

The combination boiler must be installed downstream of the gas meter for adequate gas supply.

The gas piping must not be less than 1/2” for FTCW140 models and 3/4” female NPT on FTCW199 models.

Page 32

4.11 Gas Supply Pressure

Refer to the illustration.

Offset Adjustment.

Do Not Adjust without using a combustion analyzer to verify adjustment. Adjust ONLY when in MIN Fire and when using a combustion analyser.

See Section 4.12 for step by step details.

Gas Outlet / Manifold Pressure Port

Inlet Gas Pressure Port

FTCW 140

FTCW 199

Gas Outlet / Manifold Pressure Port

Inlet Gas Pressure Port

Offset Adjustment.

Do Not Adjust without using a combustion analyser to verify adjustment. Adjust

ONLY when in MIN Fire and when using a combustion analyser.

See Section 4.12 for step by step details.

LP Gas Natural Gas

The Maximum and Minimum gas line pressures must be at

Max Fire operation.

Maximum Pressure 13.0" WC Maximum Pressure 10.5" WC

Minimum Pressure 8.0" WC Minimum Pressure 3.5" WC

CAUTION

Table 9. Gas Pressures

The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa).

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

Loosen the pressure port screws before you check the gas inlet pressure.


4.12 Adjusting Combustion

1. Using a Phillips screwdriver, remove the 4 screws on the front cover and remove cover.

2. Turn ON the GAS and WATER supply to the FT.

3. Turn ON the FT.

4. Ensure your FT is set for the correct altitude. The default setting is for altitudes of 0~1,999 ft above sea level. If your FT is installed at an altitude of 2,000 ft,or greater the correct altitude setting should be set according to Section 4.13 of the FT

Install and Operating Manual (document #1487) before you continuing tuning this unit.

5. Connect a manometer to the manifold pressure port. For dual port manometers, use the positive pressure side. Check for proper manifold gas pressure. Refer to table below.

6. Establish a call for heat. You may need to disconnect the outdoor reset if you are making this gas conversion during warm weather.

7. Setup your combustion analyser and place the sensor into the combustion test port

8. Per Section 4.14 for Max Fire, change dip switch 6 to ON and 7 to OFF. The unit will cycle up to MAX fire.

9. WAIT for your combustion analyser to stabilize.

This may take up to 3 minutes depending on your combustion analyser. Then check the CO 2 measurement for MAX Fire. Refer to Table 10 for acceptable MAX fire combustion readings Do

NOT attempt to adjust CO2 at MAX Fire.

ONLY adjust CO2 in MIN Fire operation .

Page 33

10. For MIN Fire, change dip switch 6 to OFF and 7 to

ON. The unit will cycle down to MIN Fire.

11. WAIT for your combustion analyser to stabilize.

Then check the CO 2 measurement for MIN fire. Refer to Table 10 for acceptable MIN fire combustion readings

12. Open the Gas Valve Adjustment Port by removing the cap screw with a # T15 wrench.

13. Then use the # T15 wrench to make a minor adjustment (1/8 turn) to either increase or decrease CO2. See 4.11 on page 32

14. It may be necessary to go back and forth between

HI Fire and LOW Fire several times (and adjusting only at LOW Fire), before CO2 at both are within acceptable levels. Be sure to put the adjustment port cap screw back onto the valve when done.

15 Once the CO2 and manifold pressure measurements for both MIN and MAX Fire are acceptable Table Table 10, set DIP switches 6 and

7 to the OFF position for Nominal Fire (normal operation).

16. Remove your combustion analyser from the Test

Port and be sure to thread the Test Port plug back into position.

17. Re-connect outdoor reset if it was disconnected, put the boiler cover back on and assemble/tighten the 4 screws that hold the cover in place.

Document 4288D

Installer is required to verify combustion settings as part of the installation process.

CO should not exceed 200 ppm.

Standard Factory Setting is for

MAX Fire. 9.0% CO2 @ 0-2,000 ft altitude (Natural Gas).

CO

2

value

FTCW (ALL Sizes)

( and all altitudes)

Table C

CO2 Values

MAX FIRE

MIN FIRE

Natural Gas (NG)

2˝ VENT 3˝ VENT

8.5 - 10.5%

8 - 10%

Propane Gas (LP)

2˝ VENT 3˝ VENT

9.5 - 11%

9 - 10.5 %

Manifold pressure

FTCW140

FTCW199

MAX FIRE

MIN FIRE

MAX FIRE

MIN FIRE

Table D

‘NG’ type combustibility

2"/3" VENT

-0.216

" WC

0.002

" WC

-0.314

"WC

-0.015

"WC

‘LP’ type combustibility

2"/3" VENT

-0.216

" WC

0.079

" WC

-0.173

"WC

-0.015

"WC

21.

It may be necessary to go back and forth between HI Fire and LOW Fire several times (and making adjustments only at LOW Fire), before CO2 at both are within acceptable levels. Be sure to put the adjustment port cap screw back onto the valve when done.

22.

Once the CO2 and manifold pressure measurements for both MIN and MAX Fire are acceptable per

Table C, set DIP switches 6 and 7 to the OFF position for Nominal Fire (normal operation).

23.

Write in the correct Conversion Date and the Technicians Name to the included gas conversion sticker. See Figure F. Then apply that sticker adjacent to the rating plate.

24. Remove your combustion analyser from the Test Port and be sure to thread the Test Port plug back into position.

25. Re-connect outdoor reset if it was disconnected, put the boiler cover back on and assemble/tighten the 4 screws that hold the cover in place.

Figure F (Conversion label)

This unit was converted on ____/____/___to _____gas with kit #____________by______________________

(name and company __________________________ accountable)_________________________________

___________________________________________

Cette unité a été converti ____/____/____ten ______gaz en utilisant le kit numéro _____ par______________

(nom et société_________________________________ responsable)___________________________________

_____________________________________________

800.900.9276 • Fax 800.559.1583 (Customer Service, Service Advisors)

20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355 (Applications Engineering)

1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • pg 4 of 4 www.Laars.com

Manifold

pressure

FTCW140

MAX

FIRE

MIN

FIRE

NG'

type

combustibility LP'

type

combustibility

2''/3''

VENT

‐

0.130''WC

0.004''WC

2''/3''

VENT

‐

0.100''WC

0.002''WC

Page 34

Adjusting Combustion (continued)

Manifold

FTCW140

pressure

MAX

FIRE

MIN

FIRE

NG'

type

combustibility

2''/3''

VENT

‐

0.130''WC

0.004''WC

LP'

type

combustibility

2''/3''

VENT

‐

0.100''WC

0.002''WC

Manifold

FTCW199

pressure

NG' type combustibility

2" VENT 3" VENT

LP' combustibility

2" VENT 3" VENT

MAX

FIRE

‐ 0.129" WC ‐ 0.314

WC ‐ 0.169" WC ‐ 0.173" WC

MIN

FIRE

‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC

Table 11. Manifold Pressures

Manifold

FTCW199

pressure


2" VENT 3" VENT

LP' combustibility

2" VENT 3" VENT

MAX

FIRE

‐ 0.129" WC ‐ 0.314

WC ‐ 0.169" WC ‐ 0.173" WC

MIN

FIRE

‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC

4.13 High Altitude Installations. 2,000’ to 10,000’

The FT is shipped with a default factory setting for installation at an altitude of 0 to 2000’ (approx). For maximum efficiencies at higher altitudes (2,000’ to 10,000’), the FT does have an adjustment in the

Installer Parameters Mode.

Follow these instructions if your installation is at 2,000’ - 10,000’. 36page

1. With the Power turned OFF, press the 'Modes button' for 5 seconds to get into the Installer

Parameters Mode.

2. Turn the dial (E) until ‘

28:HA

’ appears.

3. Press the dial (E).

4. Set the high altitude value by turning the dial.

1

2

4

#

0

Altitude of Installation

0~1999 ft (0~609 m)

2,000~4,499 ft (610~1,645 m)

4,500~7,699 ft (1,646~2,346 m)

7,700~10,000 ft (2,347~3,048 m)

Refer to table.

5. Press the dial again (E) to save the setting.

6. Press the ‘Modes button’ for one second, to

Save the number and to go back to initial status.

37page

36page


4.14 Natural Gas to Propane Conversion

Kit # RXXXXX

The FT Series, wall combi, condensing boiler is confi gured for Natural Gas (NG) from the factory.

A Natural Gas to Propane Conversion Kit is included with every FT. The gas conversion kit will show you how to convert your FT boiler to propane gas. If your

FT does not have the bag containing the conversion kit, a replacement kit can be obtained. Contact the manufacturer and request a replacement conversion kit.

NOTICE

If your installation altitude is greater than 2000 ft, check that the ‘High Altitude’ Installer Setting has been adjusted to suit your installation altitude. Refer to Section 4.12 of the

Installation and Operation Instructions (Document 1318).

WARNING

This gas conversion kit shall be installed by a qualifi ed service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of fi re or explosion or to prevent property damage, personal injury or death. The qualifi ed service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specifi ed in the manufacturer’s instructions supplied with the kit.Installation must conform to local codes and the latest edition of the National Fuel

Gas Code, ANSI Z223.1 and CAN-B149.1. Failure to follow instructions could result in serious injury or property damage. The qualifi ed agency performing this work assumes responsibility for gas conversion.

CAUTION

This combination boiler has already been set to burn natural gas, but can be converted to burn LP gas. Before placing the combination boiler into operation, verify that the type of gas supplied to your combination boiler.

37page

ON / OFF

Document 4388

Steps 1 thru 12

1. Turn OFF the FT. The ON / OFF button is located at the bottom left of the Control Display

.

2. Turn OFF the GAS and WATER supply to the FT

(valves are located on the plumbing pipes.)

3. Using a Phillips screwdriver, remove the 4 screws on the front cover. See Figure A.

4. Locate the Gas Inlet Pipe at the top left of the unit as shown in Figure A, and loosen the Brass Fittings at both ends of the Gas Inlet Pipe.

5. Completely unthread the brass fi tting on the blower end of the Gas Inlet Pipe and then carefully swing the Gas

Inlet Pipe to the left or right, just enough so that it is out of the way. See Figure B.

6. Remove the existing natural gas nozzle or orifi ce. If your unit is a 199, note that the fl at side of the orifi ce is towards the blower. Save the packing for re-use. See

Figure C.

Model

FTCW140

FTCW199

Table A. Gas Conversion Parts

Natural Gas (NG) part #

FT2027

FT1780

Propane Gas (LP) part #

FT2028

FT1802

Orifi ces




Page 36

Figure A

Gas Valve

Combustion

Test Port

Figure B

Document 4388

Figure C

Gas Valve

FTCW 140

FTCW 199

Figure B

Gas Valve

ORIFICE

PACKING

Figure C

ORIFICE

PACKING

WARNING AVERTISSEMENT

This conversion shall be installed by a qualified service agency in accordance with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fi re, an explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualifi ed service agency is responsible for the proper and complete installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer's instruction supplied with the kit. Installation must conform to local codes and the latest edition of the

National Fuel Gas Code, ANSI Z223.1 and CAN-B149.1.

Failure to follow instructions could result in serious injury or property damage. The qualifi ed agency performing this work assumes responsibility for gas conversion.

800.900.9276 •

Ce conversion doit être installé par un organisme de service conformément aux instructions du fabricant et tous les codes et les exigences de l’autorité compétente. Si les informations contenues dans ces instructions n’est pas suivi à la lettre, un incendie, une explosion ou de la production de monoxyde de carbone mais résultat causant des dommages matériels, des blessures ou des pertes de vie. Le service est responsable pour la bonne et complète l’installation de ce kit. L’installation n’est pas correcte et complète jusqu’à ce que le fonctionnement de l’appareil converti est vérifi ée comme spécifi é dans le manuel d’instruction fourni avec le kit.L'installation doit être conforme aux codes locaux et la dernière édition du National Code de gaz combustible, ANSI Z223.1 et peut-B149.1. Non-respect des instructions peut entraîner des blessures graves ou des dommages matériels. L'organisme qualifi é eff ectuant ce travail suppose la responsabilité de conversion au gaz.




ON

MIN Fire

MAX Fire

NG Natural

3” Vent Size

OFF

Normal Operation

Normal Operation

LP Propane

2” Vent Size

Page 37

Document 4388

MBH 140 199

Table B DIP Switch Settings

7. Install the new LP (propane) nozzle or orifi ce.

Re-use the packing from previous.

8. Return the Gas Inlet Pipe to its original position and tighten both brass fi ttings.

9. Per Table B, set DIP Switch 5 to OFF for LP

Propane.

10. Turn ON the GAS and WATER supply to the FT

11. Now start the unit and adjust combustion as described in Section 4.12

12. Upon completion of set up, write in the correct

Conversion Date and the Technicians Name to the included gas conversion sticker. See Figure F.

Then apply that sticker adjacent to the rating plate.

Shown is a

Model 140 with 3" Venting and using

Natural Gas

Figure D

Gas Valve

Adjustment Port

-

+

FTCW

140

Figures E

Gas Valve

Adjustment Port

-

800.900.9276 • Fax 800.559.1583

20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355

1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 •

FTCW

199

905.238.0100 • pg 3 of 4 www.Laars.com

Manifold

pressure

FTCW140

MAX

FIRE

MIN

FIRE

NG'

type

combustibility LP'

type

combustibility

2''/3''

VENT

‐

0.130''WC

0.004''WC

2''/3''

VENT

‐

0.100''WC

0.002''WC

Page 38

The FT Series, Wall Combi, Gas Conversion Kit

4.14 Natural Gas to Propane Conversion (continued)

NOTE: Installer is required to verify combustion settings as part of the installation process.

CO should not exceed 200 ppm.

CO

2

value

FTCW (ALL Sizes)

( and all altitudes)

Table C

MAX FIRE

MIN FIRE

Natural Gas (NG)

2˝ VENT 3˝ VENT

8.5 - 10.5%

8 - 10%

Document 4388

Propane Gas (LP)

2˝ VENT 3˝ VENT

9.5 - 11%

9 - 10.5 %

Manifold

pressure

FTCW140

MAX

FIRE

MIN

FIRE

NG'

type

combustibility

2''/3''

VENT

‐

0.130''WC

0.004''WC

LP'

type

combustibility

2''/3''

VENT

‐

0.100''WC

0.002''WC

Manifold

FTCW199

pressure


2" VENT 3" VENT

LP' combustibility

2" VENT 3" VENT

MAX

FIRE

‐ 0.129" WC ‐ 0.314

WC ‐ 0.169" WC ‐ 0.173" WC

MIN

FIRE

‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC

Table D

NOTE: Values in the range of -.001 to -.35 Inches WC are indicative of proper set-up. If your values are outside this range, call technical support.

Manifold

FTCW199

pressure


2" VENT 3" VENT

LP' combustibility

2" VENT 3" VENT

MAX

FIRE

‐ 0.129" WC ‐ 0.314

WC ‐ 0.169" WC ‐ 0.173" WC

MIN

FIRE

‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC ‐ 0.015" WC

This unit was converted on ____/____/___to _____gas with kit #____________by______________________

(name and company __________________________ accountable)_________________________________

___________________________________________

Cette unité a été converti ____/____/____ten ______gaz en utilisant le kit numéro _____ par______________

(nom et société_________________________________ responsable)___________________________________

_____________________________________________

Figure F (Conversion label)





4.15 Plumbing Guidelines

4.15.1

External Plumbing and Water

Connection Guidelines

- Ensure pipe material meets local codes and industry standards.

- The pipe end must be clean and free of debris.

- Do not apply torch heat within 12˝ of the bottom connections of the unit.

- The DHW inlet and outlet connections are 3/4”.

The CH supply and return connections are 1”. The system piping must be a min. of 1-1/4” (see Sections

4.15.4 & 4.15.5 for details).

- Isolation valves (shutoff valve) will be used.

- All piping should be insulated.

4.15.2

Applicable Backflow Preventer

- Apply a backflow preventer valve in the DHW supply inlet (water Inlet) to the unit as required by local codes.

4.15.3

Diaphragm type Expansion tank

- The air in a diaphragm-type expansion tank is separated from the water by a flexible rubber membrane. When the tank is installed in and connected to the piping of the system, water enters the other side of the tank chamber and presses down on the diaphragm.

- You should always install an ‘Automatic Air Vent on the top of the air separator to remove

residual air from the system.

- Automatic air vent has been installed on the inside of the boiler.

- If the boiler is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, it will control thermal expansion.

CAUTION

Use at least the MINIMUM pipe size for the entire boiler loop piping (connecting boiler to and from the primary/secondary connection). Use only primary/secondary piping as shown. Failure to follow these guidelines could result in system problems.

CH pipe minimum size : 1 1/4˝

DWH pipe minimum size : 3/4˝

CAUTION

For guidelines in the use of Glycol Products.

Please refer to Section 8.4 on page 73

CAUTION

Scalding Risk: Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding.

Contact Manufacturer for recommended models.

Check with local codes.

__________________________________________

Page 40

Plumbing Guidelines (continued)

4.15.4

Zoning with zone valves

- In a valve based system, there is one circulator pump at the boiler and each heating zone has a zone valve which opens when the zone demands.

- Each thermostat is wired directly to the corresponding zone valve. Contacts in the zone valves provide a proper signal to the boiler when the valve is opened.

SECONDARY LOOP

(SPACE HEATING)

SECONDARY LOOP

(SPACE HEATING)

Auto Fill Valve and Backflow

Preventer Valves are

NOT included (Field

Supplied).

Do not exceed

12"

See

Note

Do not exceed

12"

See

Note

P

Differential

Pressure By-Pass

Expansion tank

Expansion tank

(Diaphragm-type)

Automatic air vent

Air separator

Circulation pump

Check valve

Drain valve valve

Backflow preventer


Anti-scald rated

Mixing Valve

1 1/4 ”

Min

Piping

1

1/4

”

Min

Piping

CH

CH

SUPPLY

Make-Up Water

Make-Up Water

DHW INLET

DHW INLET

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. The minimum pipe size of DHW piping should be 3/4” diameter.

5. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

6. Install a check valve on the return line to the boiler.

7. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding. Contact Manufacturer for recommended models. Check with local codes.

P

P


4.15.5 Zoning with circulation

pumps

- In a pump based system, each heating zone of has its own circulator pump which runs when the zone demands.

- Each zone thermostat goes to a controller which controls the pumps.

SECONDARY LOOP

(SPACE HEATING)

(SPACE HEATING)

(SPACE HEATING)

Auto Fill Valve and Backflow

NOT included (Field

Supplied).

Preventer Valves are

Do not exceed

12"

See

Note

Note

Do not exceed

12"

See

Note

Expansion tank

(Diaphragm-type)

1

Min

Expansion tank

(Diaphragm-type)

1/4 ”

Piping

”

Piping

1

1/4

”

Min

Piping

Air separator

Circulation pump

Circulation pump

Check valve

Check valve

Drain valve

Drain valve

Gate valve

Gate valve

Backflow preventer


Anti-scald rated

Mixing Valve

Anti-scald rated

Mixing Valve

CH

SUPPLY

CH

SUPPLY

Make-Up Water

Make-Up Water

Make-Up Water

DHW INLET

DHW INLET

DHW INLET

DHW OUTLET

CH RETURN

1. This piping diagram is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be 12” (or 4 pipe dia) center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. The minimum pipe size of DHW piping should be 3/4” diameter.

5. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

6. Install a check valve on the return line to the boiler.

7. Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding. Contact Manufacturer for recommended models. Check with local codes.

Page 41

Page 42

4.16 Pressure Relief Valve

External pressure relief valves must be installed.

Observe the following. Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in personal injury, death or substantial property damage.

WARNING

Do not operate this appliance before the pressure relief valve supplied is installed with sufficient relieving capacity in accordance with the ASME

Rating Plate on the boiler.

This hot water boiler is provided with 30 psi safety relief valve that complies with the ANSI/ASME Boiler and

Pressure Vessel Code, Section IV (“Heating Boilers).

(Model : CASE ACME F-82)

This safety relief valve (30 psi) is shipped loose for field installation.

An approved ASME HV Pressure Relief Valve must be installed on the DHW supply line as close to the unit as possible. Valve size 3/4”, maximum 150 psi. Not included with boiler.

For safety, the relief valve(s) must be installed into it’s designed location and not be removed or plugged.

Failure to comply with the guidelines on installing the pressure relief valves and discharge piping can result in personal injury, death or substantial property damage.

Direct the discharge piping of the pressure relief valve so that hot water will not splash on anyone or any nearby equipment. Attach the discharge line to the pressure relief valve and run the end of the line within

6-12″ (150 - 300mm) of the floor.

WARNING

DO NOT install a CH pipe line relief valve with a pressure higher than 30 psi and a DHW pressure relief valve with a pressure rating above 150 psi.

This is the maximum allowable relief valve setting for the combination boiler.

Test the operation of the valve after filling and pressurizing system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve. Ensure that the discharge capacity of the pressure relief valve is equal to or greater than the maximum pressure rating of the combination boiler.

Ensure that the maximum BTU/H rating on the pressure relief valve is equal to or greater than the maximum input BTU/H rating of the combination boiler.

Pressure Relief Valve must be installed on the provided CH Pressure Relief valve tapping at the top of the Combi & DHW outlet line as close to the unit as possible. (CH supply line: maximum 30psi, DHW outlet line : maximum 150psi). No other valves should be placed between the pressure relief valve and the appliance.

This appliance has a high-temperature shut off switch built in as a standard safety feature .Therefore a

“pressure only” relief valve is required.

3/4” 30psi Relief Valve


4.17 Disposal of Condensate

High efficiency gas condensing Boilers create condensation when operating. Condensation has acidic (pH) of approximately 4-5.

Condensate must be drained in accordance with all local regulations. Follow your local code with regards to the disposal of condensation.

One of 3 disposal methods must be followed

1. to floor drain

2. to neutralizer (optional kit)

3. to condensate pump (field supplied)

If a neutralizer is installed, periodic replacement of the lime stone (or neutralizing agent) will be required. The rate of depletion of the lime stone varies upon usage of the boiler. During the first year of operation, please check the neutralizer every few months for depletion.

Apply only corrosion-resistant materials for the condensate drain lines such as 1/2˝ PVC, CPVC,

Polypropylene pipe or included plastic hose.

Condensate

Trap

Condensate drain pipe

NOTICE

Category II & IV boilers must be installed with a means provided for the drainage of condensate.

AVIS

les chaudières de catégories II et IV doivent être installées avec un moyen de drainage du condensat.

1

2 3

Page 43

(View is as if side panel were removed)

CAUTION

Condensate is mildly acidic (pH=5), and may harm some floor drains and/or pipes, particularly those that are metal. Ensure that the drain, drainpipe, and anything that will come in contact with the condensate can withstand the acidity, or neutralize the condensate before disposal. Damage caused by failure to install a neutralizer kit or to adequately treat condensate will not be the manufacturer’s responsibility.

Contact Manufacturer to order

Neutralizer Kit# A2123601

_________________________________________

Various condensate disposal methods

Page 44

4.18 DHW Flow Restrictor

Flow Restrictors are factory installed. Rated at 3.2

GPM for the model 140 and 7.0 GPM for the model

199, both of these factory installed restrictors are white in color. For the 140, an additional flow restrictor, rated at 4.5 GPM, is blue in color and is packaged with the Product Accessories. See Section 1.

If 3.2 GPM is not sufficient for your model 140 installation, replace the factory installed white flow restrictor with the blue flow restrictor by following these instructions.

To replace the Flow Restrictor.

1. Being sure that the unit is completely shut off and drained, locate the DHW inlet adapter on the bottom of the appliance.

2. Pull the two pins to release the DHW inlet filter. See

Illustration. The flow restrictor is attached to the top of the filter assembly.

3. Remove the installed white flow restrictor and replace it with the blue flow restrictor included with the Product Accessories.

4. Reinstall the DHW inlet filter.

5. Re-insert the two pins.

6. Refill and restart your FT as per the Installation

Instructions.

WARNING

If the appliance has been filled and operational, then the gas, water and power must be completely shut off, and the unit must be drained before proceeding with this instruction. See

Section 8 of this installation book.

Failure to do so could result in substantial property damage, sever personal injury, or death.

Flow Restrictor

Shown is the 140. The 199 is very similar.


4.19 Electrical Wiring Connections

FTCW140 and FTCW199

Page 45

Manual Switch

L N G

MAIN POWER

L N G

CH/BOILER PUMP

Terminal Blocks

L W C

0-10V

INPUT

T T O / S

Main

Power

External

CH Pump

Low Water

Cut Off

(jumpered)

0 - 10V

External

Input

Thermostat

Connection or end switch of multizone relay panel

Outdoor

Sensor

WARNING

I nstall wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electrical Code, NFPA 70, and/or CSA C22.1

Electrical Code-Part 1 in Canada.

ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard.

Failure to do so can cause severe personal injury or death.

This appliance must be electrically grounded. Ensure the electrical receptacle that the combination boiler will be plugged into, is properly grounded; if wiring directly.

Do not attach the ground wire to either the gas or the water piping as plastic pipe or dielectric unions may isolate the Combination boiler electrically.

The wiring diagrams contained in this manual are for reference purposes only.

Refer to these diagrams and diagrams from external controls used with this appliance. Read, understand, and follow all wiring instructions.

Do not disconnect the power supply when the unit is in normal operation. Damage caused by freezing is not covered under the warranty.

Manual(Rocker) switch maximum allowable current for each circulator is 1.6 amps at 125VAC.

( Housing : Nylon #66 UL 94V-2 , Rocker : Nylon #66 UL 94V-2, Terminal : Copper Alloy )

Terminal block (External power connector) : DFT-20A-10P (20 amps at 300VAC)

Page 46

4.19 Electrical Wiring Connections (continued)

Line Voltage Terminals

L N G

MAIN POWER

L N G

CH/BOILER PUMP

Low Voltage Terminals

L W C O

0-10V

INPUT

T T O / S

120V/15A

Service

(14 Gauge Wire)

Low Water

Cutoff

(Factory Jumper Installed)

External

Circulator

Pump

(14 Gauge Wire)

The FT Series, Wall Combi, Gas Conversion Kit

4.20 DIP Switches

ON

MIN Fire

MAX Fire

NG Natural

3” Vent Size

OFF

Normal Operation

Normal Operation

LP Propane

2” Vent Size

Outdoor

Sensor

(18 Gauge Wire)

Thermostat or

Endswitch

(18 Gauge Wire)

Document 4388

MBH 140 199

Table B DIP Switch Settings

Shown is a

Model 140 with 3" Venting and using

Natural Gas

System Control Setting

Figure D

2.4V

Maximum 10s, minimum 1s

Safety Time (igniting time) (Ts)

8. Return the Gas Inlet Pipe to its original position

3s

10s

+

<3s

60s

Pump2 post circulating time (T1pv)

10. Turn ON the GAS and WATER supply to the FT

60s

<6s

<6s

11. Now start the unit and adjust combustion as described in Section 4.12

12. Upon completion of set up, write in the correct

Conversion Date and the Technicians Name to the included gas conversion sticker. See Figure F.

Then apply that sticker adjacent to the rating plate.

-

FTCW

140

Figures E

Gas Valve

Adjustment Port

-

800.900.9276 • Fax 800.559.1583

20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355

1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 •

FTCW

199

905.238.0100 • Fax 905.366.0130

www.Laars.com


4.21 Control Board, Electrical Diagram

Page 47

Control Board

Page 48

4.22 Ladder Diagram

Air Pressure Sensor

F/B

level


4.23 Electrical Connections, (table)

Connector

#, Location, Type

CN9

65001WS-12

CN6

LW6A4-03

CN1

SMW250-5D

CN4

LWD1140-06D

CN8

SMW250-04D

CN11

LWD1140-16

PIN Label

7

8

7

15

8

5

13

6

14

3

11

4

12

1

8

2

10

3

4

1

2

5

6

3

4

1

2

2

3

3

1

9-12

1

16

4

5

1

2

3

6

RS-485

FAN

MCU ISP

HWL

LWL

HD

TH

APS

EL

BL

HL

-

-

L

CP1

IT

L(HT)

GV

N

N

CP3/3Way

Description

GROUND

Power Supply Line

Not Used

Igniter

Pump : CH

Gas Valve

-

Power Supply Neutral

AC Power COM Line

3 Way Valve

RS485 +

GND

RS485 -

Not Used

GND

VDD

Fan power(start coil)

Fan power(end coil)

Fan speed feedback signal

GND

ISP /Reset port

ISP TOOL0 Data port

VCC

Not Used

Low Water Level Leakage Sensor

Central Heating Demand

Connect to the Display

Control(Thermostat)

Jump

Jump

Burner Limit

Condensate Block

Page 49

HT SELV

HT (120V~)

HT (120V~)

HT (120V~)

HT (120V~)

HT (120V~)

HT (120V~)

-

HT (120V~)

HT (120V~)

HT (120V~)

HT (120V~)

SELV (5V)

SELV (5V)

SELV (5V)

-

SELV (30V)

SELV (14V)

SELV (30V)

SELV (30V)

SELV (14V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (12V~)

SELV (12V~)

SELV (5V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

Page 50

Electrical Connections , (table) (continued)

Connector

#, Location, Type PIN Label

CN7

LWD1140-14

CN14

SMW250-09D

13

7

14

1

2

11

5

12

6

5

6

3

4

7

3

10

4

2

9

1

8

F.S

OP.S

DH.S

I.S

BG.S

ST.S

SP.S

DHM

CN3

SMW250-06D

CN5

SMW250-10D

8

2

3

4

5

6

1

2

9

1

APS

SENSOR

FLUX1

RPM

Description

Flame Detect Sensor

Operating water temperature sensor

DHW temperature sensor

Return temperature sensor

Venting (Exhaust) temperature sensor SELV (5V)

Not Used

Over-Heat temperature sensor

GND

DHM Stepper motor position

VDD

DHM Stepper motor coil X phase

DHM Stepper motor coil Y phase

VDD

DHM Stepper motor coil /X phase

DHM power IWM Stepper motor coil /Y phase

Unuse

VCC

GND

Voltage Input

VCC

Water Flow Sensor

GND

FAN RPM Check

GND

HT SELV

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

SELV (14V)

-

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)

SELV (5V)


53page

SECTION 5 Control Display and Operation

5.1 Control Dial and Buttons

Page 51

C

D

E

Buttons

A

B

B

A

E

C

D

The Control Display

The Control Display has a Control Dial (E), 4 buttons (A, B, C, D), and a Liquid

Crystal Display (with 72 back-lit segments). This section of this manual gives instruction on how to navigate into the many functions of the FT and to change temperature set points, set system variables and controller parameters.

Status Light

(constant green when operating normally)

Display

Power

Function

Turns Control Display ON / OFF

Status Display Mode (With display power on)

Modes

Installer Mode (WIth display power off)

Hot

Water

Central

Heat

Scroll /

Select

DHW Set point LOW Range

95 - 120°F (35 - 49°C)

CH set point mode (boiler only)

Method

Press/Tap

Function Method

Press/Hold (5 Seconds)

Press/Hold (5 Seconds)

Press/Tap (To return home, tap Scroll/Select)

Press/Tap (To return home, tap Scroll/Select)

Return to Menu (from

Status Display Mode)

Return to off display off mode (from installer mode)

DHW set point HIGH

Range 121-140°F (49.5-

60°C) (from DHW set point LOW RANGE)

Toggle (°C/°F) (from CH set point mode)

Press/Tap

Press/Tap

Press/Hold (5 Sec onds), (To return home, tap Scroll/

Select)

Press/Hold (5

Seconds)

Turn to scroll (clockwise or counterclockwise),

Tap to select

Press/Tap

• Temperature Specifications

Operating ambient Temperature Range : -10 to 60°C.

Operating Relative Humidity up to: 90% at 40°C.

Shipping & Storage Temperature Range of : -20 to 80°C.

Page 52

5.2 LCD Overview

CH

Central

Heat

Summer

Mode

(warm weather shutdown)

Outside

Temp Mode or 0-10V

Anti-Freeze

Mode

Domestic Hot Water Mode

Storage

Heating

Numeric Display

Lock Communicating

Pump

Status and

Installer

Modes

Flame

Signal

CH mode

Anti-freeze mode

Storage Heating mode

Lock mode

Communication

Summer mode

Status and Installer mode

Flame signal

Pump icon

Numeric Display

DHW mode

Outside temp or 0-10 V mode

Central Heat mode icon can be adjusted

Anti-freeze mode icon

Stored Water Being Heated, can be adjusted

Buttons-locked mode icon

Communication icon

Only DHW Mode, can be adjusted (warm weather shutdown)

The Status Mode or the Installer Mode is Active (all parameters)

Flame Signal icon

Water pump operation (CH or DHW) icon

Number and character display, to display all parameters

Combination boiler Set Point, can be adjusted

Operating by outside temperature or 0-10V

The LCD will illuminate when a user action is detected (a button is pressed) and will turn back off after 20 seconds.

* NOTE: The display will not allow changes when the lock mode is activated.

To exit the Lock mode, press the button.

WARNING

Do no use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that may have been under water.


5.3 Operating Mode

Operating Mode

55page

, the Control Display entering into the ‘Operating Mode. It will then display the following information.

Page 53

Indicate

Current Operating Temperature

Temperature sign Celsius or Fahrenheit letter

Display and Controller are communicating

If flame detected

If pump is operating

Outdoor sensor or 0-10V

56page

Example

110°F

°C or °F

B

A

E

C

D

55page

Page 54

5.4 Status Display Mode

56page

B

A

E

C

D

Digital Display Status Display Parameter

O:ot Outdoor temperature

Description

Current Outdoor temperature

A: Li or A: GA Flow unit b: It

Current flow value(Li: L/m, GA: GPM)

CH Return Water Temperature Current Return Water Sensor Temperature

C: Fr d: Lc

E: oP

F: dH

H: Eh

I : St

J: oH

L: rt

1: PH

2: rh

3: rH

4: It

5: IH

Fan rpm

Lock mode

OP temperature

DHW temperature

Exhaust temperature

N/A

Overheat temperature

Supply power time

Burner

Operation

Time

Burner operation time

Burner operation time

Current fan rpm value

Lock mode ON/OFF

Current OP temperature

Current DHW temperature

Current Exhaust temperature

Not Used (Default is 0)

Current Overheat temperature

Supply power time x 100 hour

Burner operation time x 1 hour

Burner operation time x 1,000 hour

Ignition cycles Ignition cycles x 10 times

Ignition cycles Ignition cycles x 10,000 times

1st Icon

P: Ou

Displays output condition for internal primary pump and three way valve.

- Off

Not Used

2nd Icon 3rd Icon

Internal CH

Pump

3 Way Valve

- On

To view any of the above listed Status Parameters,

Press and Hold Button B to get into the Status Display Mode.

Rotate Dial E until you find the Parameter that you wish to view. Tap Dial E to enter that Parameter.

Adjust to the setting that you require and then press (tap) Dial E to save and to Exit.


5.5 DHW Set Point Change Mode

DHW Set Point Change Modes

The display shows the following information when changing water heating temperature set points.

Changing between Celsius and Fahrenheit

When the button D is pressed (for more than 5 seconds), temperature unit will toggle between °C and °F.

B

A

B

A

57page

57page

E

E

C

D

C

D

Page 55

B

A

E

C

D

Indicate

Current DHW set point temperature


B

A

If display is communicating with the main controller normally, the communication icon will be indicated.

When DHW set point range is high : from 121°F (49.5°C) to 140°F (60.0°C)

When changing DHW set point, the DHW icon will flash

E Example

120°F

°C or °F

H . 140°F

S24

C

D

* Default DHW set point is 120°F (49°C)

• DHW 95-120°F (35 - 49°C) LOW range (Default)

-To change LOW range, press the C Button. The DHW icon and current DHW LOW will flash (a flashing value means it can be changed).

-Turn dial E clockwise to increase and counterclockwise to decrease until desired temperature is reached.

-Press dial E to save set point changes.

• DHW 121 - 140°F (49.5 - 60°C) HIGH range

-To change HIGH range, press and HOLD the C button for more than 5 seconds. The DHW icon and current DHW HIGH will flash (a flashing value means it can be changed).

-Turn dial E clockwise to increase and counterclockwise to decrease until desired temperature is reached.

-Press dial E to save set point changes and to Exit.

DANGER

Scalding may occur within 5 seconds at a setting of 140°F (60°C). Water temperatures over 125°F can cause severe burns, or death from scalding. Children, disabled, and elderly are at highest risk of being scalded. Read all instructions before setting temperature at appliance. Feel water before bathing or showering.

Manufacturer strongly recommends the use of an anti-scald mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding.

Contact Manufacturer for recommended models. Check with local codes.

Page 56

5.6 CH Set Point Change Mode

58page

Changing between Celsius and Fahrenheit

When the button D is pressed (for more than

5 seconds), temperature unit will toggle between

°C and °F.

B

A

E

Indicate




If flame detected

If pump is operating

When changing CH Set point, the CH Icon will flash

Example

°C or °F

Default CH set point is 130°F (54°C)

CH set point range is 130 - 180°F (54.4 ~ 82.0°C)

B

B

E

A E

To change CH Set point,

press the D button. The CH Icon and current

CH Set point will flash.

Turn the E dial clockwise to increase, and counterclockwise to decrease CH set point, until desired temperature is reached.

Press E dial to save changes and to Exit.

C

D

C

D

C

D

5.7 Storage Mode

B

A

E

C

D

Indicate




If flame detected

Storage mode indication

If Pump is operating

Example

110°F

°C or °F

To activate heat storage function,

First turn OFF the power to the Control Display.

Then Press and Hold Button B to get into the Installer Mode.

Rota te Dial E until you find 5:St Tap Dial E to enter Storage Mode. Storage Mode indicates that the boiler is maintaining the water temperature in the internal storage tank. When Storage Mode is active, the display will appear as shown.

Turn the E dial clockwise to activate and counterclockwise to deactivate the Heat storage function. Default: ON.

Press E dial to save changes and to Exit.

Page 57

5.8 Installer Parameters

B

A

E

C

D

WARNING

For low temperature heating applications, adjust P16 and possibly P17 to desired value(s).

Proper high temperature protection might be required when the combination boiler transitions from DHW production to low temperature heating. Contact

Technical Services for assistance in changing settings.

These changes are to be made only by a qualified technician.

To c hange any of the Installer Parameters,

Start by turning OFF the Power to the Display Control.

Then, with the power OFF, Press and HOLD (more than 5 seconds) the Button B

Installer Mode. to get into the

Rotate Dial E until you find the Installer Parameter (full list on facing page) that you wish to change.

Tap Dial E to enter that Parameter.

Adjust to the setting that you require and then press (tap) Dial E to save and to Exit.

Finish by pressing button B

Page 58

18:dH

19:cb

20:db

21:PP

22:Po

23:PF

24:SF

5.8 Installer Parameters (continued)

Index

1: EH

2: cE

3: In

4: Fu

5: St

6: OH

7: OL

8: FH

9: FL

10: dr

11: dI

12: bt

Parameter

History entry

Clear Error History

System initialize

Flow unit

Heat storage function

Maximum Outdoor

Temperature

Minimum Outdoor

Temperature

Max fan

Min fan

Delete running time

Delete igniting times

Outside Unit Function

Delay Time (boost time)

Description

History fault code (E0~E9)

Clearing of error History buffer

System initialize to default gallon / liter Default gallons

Heat storage function On/Off Default On

Range: (Minimum Outdoor Temperature + 9°F) to 110°F

Default -1°C (30°F) ->Default 20°C (68°F)

Range: -4°F to (Maximum Outdoor Temperature -9°F) Default -1°C (30°F)

Adjusts Maximum Fan Speed

Range: -30 - +30 Default 00

Adjusts Minimum Fan Speed

Range: -30 -+30 Default 00

Delete running time Default NO

Delete igniting times Default NO

When heating in the outside unit function for the first time, there will be a delay.

(0~120 min, Default 0)

13: Ft

14: bo

Delay time for heating burner operation

Setting temperature of burner ON.

Burner does not operate during the delay time when the burner is turned off due to the temperature during heating operation. (0~20 min, Default 1 min)

Heating temperature setting during heating operation –

Operate in burner ON temperature setting Range:

-12.7°C(9°F)~-2.7°C(27°F), Default -9°C (15°F)

15: OF

16:cH

17:cL

25:So

26:dt

27:PE

28: HA

29: AP

30: dP

Setting for Heating

Maximum Temperature

Setting for Heating

Minimum Temperature

Setting for Hot Water

Maximum Temperature

Range: 9°F less than Minimum Temperature to 180°F, Default 180F

12.7°C less than Minimum Temperature to 82°C, Default 82°C

Range: 86°F to 9 degrees °F less than Maximum Temperature,

Default Setting to 54°C (130°F)

49°C(120°F)~60°C(140°F), Default 60°C(140°F)

Heating Combustion Rate 50%~100%, Default 100%

Hot Water Combustion Rate 50%~100%, Default 100%

Pump Post-Purge Time (Heating Pump) 1min ~ 60min, Default 40min

Pump on Time (Heating Pump Repeat ON Time) 1 min ~60 min, Default 5 min

(Heating Pump Repeat Off Time) 0min ~60 min, Default 0 min Pump off Time

Heat storage off

Temperature

Heat storage on

Temperature.

Delay time when switching from DHW mode to CH mode

Internal CH Pump Post-

Purge Time,

T/T Satisfied

60°C(140°F)~75°C(167°F), Default (67°C)150°F

(off Temperature-Setting Temperature) -12.7°C(9°F)~2.2°C(36°F),

Default (-2.7°C) 27°F

Range: 0 – 2 minutes,Default 2min

Allows the user to set the appliance pump post purge time once the appliance CH set point and thermostat are satisfied. Range: 1-5 minutes,Default 1min

(Normal)0<1<2<4 (High) Default 0 High Altitude setting

Internal CH Pump and

3-way valve Pump Test

Mode

Internal CH Pump and

3-way valve Pump Test

Mode

DHW Timeout Feature

This function sets the time to run both the Internal CH and 3-way valve pumps to purge air from the system. Range: 1 – 30 minutes , Default 5min

Turn this function on to activate Internal CH and 3-way valve pump testing.

Only works in installation mode. Turns off when in normal mode.

Range: 0 - 12 hours, ‘0’ OFF, Default: 4 hours

Default OFF


5.9 Outdoor Reset Adjustment

Outdoor Reset varies the control set point based on the outdoor temperature. The reset function works as shown in Figure ‘CH Outdoor Reset’. When the outdoor air temperature reaches 6:OH “high outdoor temperature set point”, the control point setting is adjusted to 17:cL “low boiler temperature set point”.

When the outdoor air temperature reaches 7:OL “low outdoor temperature set point” the control set point is adjusted to 16:cH “high boiler temperature”.

Default outdoor reset set point is 100°F (38°C)

The Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sensor or 0-10 Volt is not connected to the appliance.

To check the CH Target Temperature while using

Outdoor Temperature Mode, press the button while the appliance is operational and the display panel is powered on.

Operating condition

CH Outdoor Reset

Note: In this example, the Summer Mode (Warm

Weather Shut-down) is set to 80F°

Page 59

Connect to terminal strip as outlined 4.17 Electrical Connections.

NOTE: 0 - 10VDC terminals may not be used for both outdoor reset and 0 - 10VDC temperature set point simultaneously.

5.10 External Set Point Temperature Control

A signal from a building management system may be connected to the appliance to enable remote control.

This signal should be a 0-10 volt DC signal. When this input is enabled, a building control system can be used to control the set point temperature of the appliance.

The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the appliance will be in standby mode, not firing.

When the signal rises above 1.5 volts, the appliance will ignite. As the signal continues to rise towards its maximum of 10 volts, the appliance will increase in set point temperature. Adjust 16:cH and 17:cL to set MIN and MAX boiler water temperatures respectively.

Connect a building management system or other auxiliary control signal to the terminals marked for this purpose on the appliance terminal block (shown in Piping Diagrams, this manual). Caution should be used to ensure that the 0-10 VOLT + connection does not become connected to ground.

Connect to terminal strip as outlined 4.17 Electrical Connections.

NOTE: 0 - 10VDC terminals may not be used for both outdoor reset and 0 - 10VDC temp set point simultaneously.

Page 60

5.11 Error Mode

62page

B

A

E

C

D

Indicate

Error ‘ Er : ’ will flash

Error Code


Example

Er:11

Er:11

NOTE: When communication between the Control Display and the main controller is lost, the

will not be displayed.

Flashing


SECTION 6 Error Codes

Error

Code

Error Code Descrip tion

6.1 Error Code Tables

Possible Remedies

10

11

16

20

28

29

32

33

Flame has Extin guished 8 (Eight)

Times

Ignition has Failed 10

(Ten) Times

Operating Temperature

Sensor detects Water

Temperature Greater than 203°F (95°C)

Condensate – Closed is Normal, Open is

Fault (Condensate

Drain Trap)

Overheat Sensor Open or Short

Loose connection at

PCB board

DHW Sensor Open or

Short

CH Temperature Sen sor Open or Short

Press the Power button to clear the Error Code.

If Error happens again:

1. Monitor the gas pressure to the appliance while in operation. Ensure pressure is be tween 3.5” to 10.5” WC (Nat. Gas) and 8” to 13” WC (Propane).

2. Check gas valve wire. Ensure connection is secure.

3. Check flame detection sensor. Ensure connections are secure. Normal operating set tings are more than 2.5DC before ignition, less than 2.5DC after ignition.

4. Check exhaust and intake terminations for blockages. Also verify that intake, intake boot, blower and burner housing is free of blockages and debris.

5. Assure that the flame is stable when lit. Confirm Flame stability by manually forcing the boiler into Low Fire (see section 4.20) - Burner should not cycle on and off in low fire.

If burner cycles on/off during low fire operation adjust fuel/air mixture and confirm CO2 values are within range for model and fuel type.

6. If the problem persists, contact technical support.



1. Monitor the gas pressure to the appliance while in operation. Ensure pressure is be tween 3.5” to 10.5” WC (Nat. Gas) and 8” to 13” WC (Propane).

2. Check gas valve wire. Ensure connection is secure.

3. Check flame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

4. Check igniter transformer for proper connection.

5. Clean the spark igniter with steel wool to remove oxides. Ensure proper separation (3-4 mm).

6. Replace the spark igniter if damaged.

7. Assure that the flame is stable when lit.



If boiler is not piped Primary/Secondary it is likely the internal boiler pump is not able to move enough water thru heat exchanger.


1. Check if dip switch Max Fire setting is ON. Switches 6 and 7 should be OFF for normal operation.

2. Check if CH inlet pipe is blocked. Ensure there is enough water flowing to the appliance.

3. Check Operating Temperature sensor at CH heat exchanger outlet. If resistance is zero, replace the sensor.

4. Verify operation of internal boiler pump by checking rotation of pump shaft. (Manu ally spin pump shaft by removing round cap at back of the pump and insert a flat head screwdriver).



1. Check Condensate and main controller connections. Ensure all are secure.

2. Check Condensate sensor resistance. If resistance is zero, replace the switch.

3. Check Condensate hose. Ensure it is connected and in good condition.

4. Check condensate line and termination for blockages.

5. Check Vent Pipe for blockages.

6. If the condensate is “hard piped” in the field, install a vent in this piping at a point higher than the condensate trap.


This Error Code will go away when CH temperature decreases.


1. Check overheat temperature sensor. Ensure connections are secure.

2. Check overheat sensor resistance. If resistance is zero, replace the sensor.


1. Check upper left plug on PCB board. Reconnect blue jumper wire part of this plug.

2. Press the Power button to clear the Error code.

Error occurs when the blue wire inside the KI-I9CCWL plug (upper left corner of PCB board) is shorted to ground or has a poor contact.

This Error Code will go away when outlet DHW temperature decreases.


1. Check DHW outlet temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.


This Error Code will go away when CH temperature decreases.


1. Check CH temperature sensor. Ensure connections are secure.

2. Check CH sensor resistance. If resistance is zero, replace the sensor.


Recover methods

Hard

Lock

Hard

Lock

Hard

Lock

Hard

Lock

Soft Lock

Hard

Lock

Soft Lock

Soft Lock

Page 62

SECTION 6. Error Codes

(continued)

Error

Code

35

36

37

38

40

41

42

43

44

45

61

Error Code Description

Venting (Exhaust) Sensor

Open or Short

Abnormal Supply Voltage

Abnormal Supply Frequency

Error Appears When Control

Stores Data, but Data is not

Saved

Possible Remedies

Recover methods

This Error Code will go away when exhaust temperature decreases.


1. Check Venting (exhaust) temperature sensor. Ensure connections are secure.


3. Check vent pipes for blockage.


Supply voltage is too low to operate. This Error Code will go away when supply voltage returns to normal operating range.


1. Ensure appliance is properly wired to a power source meeting the requirements on the rating plate.

2. If problem persists, contact technical support.

Supply frequency is too high to operate. This Error Code will go away when supply frequency returns to normal operating range.


1. Ensure appliance is properly wired to a power source meeting the requirements on the rating plate.

2. If problem persists, contact technical support.


If the problem persists. contact technical support.

Soft Lock

Soft Lock

Soft Lock

Hard Lock

Gas Leakage is Detected for

Greater than 5 seconds, or three times within 10 minutes

Fan Speed too High with

Flame On

LWCO Jumper disconnected

Burner Overheat Switch Open

Air Pressure Sensor (APS)

Fault

Air Pressure Sensor (APS)

Open

Fan Speed Feedback Signal

Abnormal

IMPORTANT: If you smell gas, STOP! Follow the instructions on page 2, this manual, and call a qualified service technician or the fuel gas utility.



1. Check the appliance cover. Ensure it is secure.

2. Check gas connections for leakage with a soapy solution. Fix any leaks.

3. Check condition of the burner assembly.




1. Check the vent connections for blockages.

2. Check the burner assembly.

3. Check fan operation. If fan appears to be operating normally but RPMs are too high, replace the fan.

4. Check intake and exhaust for blockages, debris, proper installation and placement. Check and record SFN (revision # of printed circuit board during startup for future reference).




1. Ensure the LWCO jumper wire is properly connected.




1. Check burner overheat switch connections. Ensure connections are secure.

2. Check switch resistance. If resistance is zero, replace the switch.


Press the power button to reset

If error happens again:

1. Check the vent pipe for blockages.

2. Check the air intake pipe for blockages.

3. inspect the Venturi and fan motor, the air intake screen at the fan connection (for the 140 only) or the burner itself for any debris that could have been drawn in by the fan thru the air intake.

4. If error do not clear, replace the APS


Check the aps connection.

1.If APS is closed and connections are secure, check APS connection.

2. If the problem is not happen, replace the APS


This Error Code will go away when the condition is remedied.


1. Check the connections to the fan. Ensure all are secure.

2. Check intake and exhaust for blockages and debris.

3. If the fan does not rotate during the ignition sequence, check for AC8V~26.5V power at the fan connection. If AC8V~26.5V power is present at the control, replace the fan. If the blower does not have AC8V~26.5V power, check power at the control. If

AC8V~26.5V power is not present at the control, replace the control.


Hard Lock

Hard Lock

Soft Lock

Hard Lock

Hard Lock

Soft Lock

Soft Lock


Error

Code

66

68

70

72

76

77

80

81

85

94

Error Code Description

Mixing Valve Initial Value

Error

(Mixing Valve Cannot Return to Initial Position)

Mixing Valve Operation Error

(Mixing Valve Stuck in Initial

Position)

Register, Ram, Rom, I/O

Port, AD Abnormal, Important

EPROM Data or Safe Data

Abnormal

Flame Signal Detected before

Ignition

Poor Communication

Outdoor sensor error

Low Water Level Sensor

(Low Water Level Detected

Four (4) Consecutive times)

Low Water Level Circuit

Freeze Protection

(Appliance has detected water temperature below

34°F(1°C)

Exhaust Sensor detects Vent

Temperature is Greater than

190oF (88oC)

Possible Remedies

Recover methods



1. Turn power OFF and ON at the main power switch internal to the appliance.

2. Check wiring connections to mixing valve. Ensure all are secure.

3. Replace mixing valve.





2. Check wiring connections to mixing valve. Ensure all are secure.

3. Replace mixing valve.








1. Check the appliance cover. Ensure it is secure. Flame detection sensor can detect an external light source.

2. Look thru boiler sight glass and check for glowing after burner shutdown. If you see glowing, do step 3.

3. Check burner plate by removing blower and boiler top plate and remove any debris from top of burner plate. Debris can come from PCV shavings during intake installation and/or from nearby dryer vents and landscapers causing debris being pulled in thru the air intake. Debris can glow after burner shutdown.

4. Check flame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.




1. Check connections from main control to display panel.

2. If the problem persists, replace the display and/or c ontact technical support.



2. Check outdoor sensor resistance. If resistance is zero, replace the sensor.




1. Ensure all valves are open to the appliance and there are no leaks.

2. Ensure all air has been purged from the system.

3. Check wiring connections to low water level sensor. Ensure all are secure.

4. Check low water level sensor resistance. If resistance is zero, replace the sensor.




1. Ensure all valves are open to the appliance and there are no leaks.




This Error Code will go away when the freezing condition is remedied.


1. Ensure appliance is located in a mechanical room protected from freezing conditions.

2. Ensure all valves are open to the appliance, there are no leaks.






1. Check if dip switch Max Fire setting is ON. Switches 6 and 7 should be OFF for normal operation.

2. Check exhaust temperature sensor. Ensure connections are secure.


4. Check exhaust vent for blockage.


Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Soft Lock

Page 64

6.2 Fault Tree Analysis

1. Flame detection


6.2 Fault Tree Analysis (cont)

2. Gas Detection

Page 65

3. ‘Storage’, ‘DHW’, ‘OP’, ‘CH overheat’, ‘Exhaust heat’ Sensor detects

Error code

E32

E33

E35 contents

DHW NTC open or short

OP NTC open or short

Exhaust NTC open or short

Page 66

SECTION 7 Trouble Shooting

7.1 Diagnostics

Question Answer

Make sure that the ON/OFF button on the Control Panel has been turned ON.

Burner does not ignite when the hot water is opened.

Water is not hot enough.

Water is too hot.

Hot water temperature fluctuates at the opened tap.

If the monitor on the Control Panel is blank, make sure the power cord is plugged and 4A fuses on the main controller in the units are good.

Make sure that there is water supplied to the unit. The unit activates once the inlet water flow is over 0 gpm.

Make sure the cold and hot water lines are not plumbed in reverse side.

Make sure that the cold water and gas supply lines are opened.

Make sure that the water lines are not frozen.

Check that the setting temperature on the unit is not too low

Make sure that the filter in the cold water supply line is not clogged with debris.

Make sure that the gas supply type is correct.

Check the supply and manifold gas pressures are in accordance with specifications.

Make sure that the water flow sensor with three wires has been properly connected on the top of heat exchanger.

Make sure that the setting temperature on the unit is not too hot.

Make sure that the filter in the cold water supply line is not clogged with debris.


Make sure that the filter in the cold water supply line is clean.


Check the supply gas pressure is sufficient.

The blower is still oper ating after the combustion stops.

This is normal because the blower keeps operating for 1 minute to vent

(exhaust) the flue gas from the chamber once the combustion has stopped.

Temperature Rise too Quickly tion.

DHW flow is initiated

Abnormal sounds come from unit during opera-

Heater doesn’t fire when

CH Temp drops lower than expected before unit re-fires

Occurs when supply water temperature in heat exchanger rises faster than

2°F per second during the first two minutes the burner is on. Automatically resets after a few minute delay or using manual reset on control panel. See message displayed TEMPERATURE SENSOR and follow procedure for loose connections.

A leak of combustion gas between sealed chamber and exhaust tube inside the unit. Call a qualified service technician for evaluation.

Improper venting termination, make sure that the venting termination com plies with specification.

Check the supply gas pressure is sufficient. Insufficient gas pressure will cause unstable burner flame and noise.

Potentially the domestic water flow is too low. Min allowable is 0.75 gpm.

Check in Manual Mode OTO AGA

Change Parameter 14:bo to 10 degrees F (5.5 degrees C)


7.2 Suggested Corrective Actions

This controller is able to record information about the boiler’s condition at the time of the five previous faults or errors. Refer to the Section ‘5.10 Error Mode’ of this manual.

Display

Nothing shown on display control panel and blower running at full speed.

Condition

Control is not receiving power.

Diagnostic

Check wiring for short circuit or incorrect wiring.

Check transformer connection to the control per wiring diagram. Check for 12V output of transformer.

Check service switch and/or circuit breaker to boiler turned is on.

Corrective Action(s)

Correct wiring per wiring diagram including connection of transformer to the control.

Replace transformer if it is receiving

120V, but not outputting 12Vac.

Turn on service switch to power boiler.

Nothing is shown in display control panel and no other boiler components are operating.

Control is not receiving 120V power.

Nothing is shown on control panel, but boiler is operating.

Occurs when the communication is lost from the control to the display.

Is there 120 Volts at the service switch?

Is the ON/OFF

POWER

SWITCH (inside boiler case) turned on?

Check for 120 volts at the line voltage terminal block located inside the boiler case.

Troubleshoot and correct the power supply to the manual switch.

Turn ON the manual power switch inside the boiler case.

Correct wiring inside the boiler case using the wiring diagram in this manual.

Inspect the fuse.

Replace if necessary.

Check for loose connections and proper pin alignment/ engagement on the

Control's plug.

Cycle power off and on using boiler power switch and check for operation.

Replace the fuse with proper part found in the replacement part section of this manual. If fuse blows again recheck wiring per diagram.

Check for continuity on the wire harness from the display to the control.

See repair parts section for proper replacement part.

Replace with new display module.

See repair parts section for proper replacement part.

Page 68

7.2 Suggested Corrective Actions (continued)

Fault

TEMPERATURE

SENSOR

FLAME FAULT

BLOWER FAULT

IGNITION

FAULT

GAS VALVE

FAULT

Condition

Occurs when a temperature sensor has electrically shorted

(SHORT) or has become disconnected

(OPEN).

Occurs when flame is detected when there should be no flame.

Blower unable to reach required speed or does not reach 0

RPM when turned off.

Even if boiler went through

8 ignition attempts, but cannot detect flame

The Control has detected a problem with it gas valve output circuit.

Diagnostic

Reset using manual reset screen on control panel. (Power button)

Reset using manual reset screen on control panel.

(Power button)


(Power button)

Power off and on.


(Power button)

Corrective Action(s)

Check all the temperature readings of the boiler on the DIAGNOSTICS -

TEMPERATURES menu to determine if any sensors are currently displayed as SHORT or OPEN.

Check wire harness for loose connections and pin engagement at sensor Connection and Control module.

If problem persists after checking items above replace Control. Refer to repair parts section for kit number.

Burner may be operating too hot due to incorrect combustion. Inspect flame and conduct combustion test.

Check for flame at burner via flame current with burner off. Turn boiler off and watch flame through observation port. If flame continues after shutdown replace gas valve.

Check wire harness for loose connections and pin engagement at blower.

Connections.

Boiler in standby mode and blower not running. If BLOWER SPEED is not 0

RPM then replace blower.

If blower does not rotate during ignition sequence check for 120V power at blower connection. If 120Vac power at blower motor and it doesn't start replace blower. Check power at

Control. If 120Vac is not present at

Control when boiler is powered replace

Control.

Dirty burner and/or heat exchanger will cause high back pressure and poor ignition.

Visual inspection of flue ways often will not be able to diagnose condition.

Check incoming gas pressure with boiler off and at Max fire. Adjust within limits on rating label.

Check for flue pipe and intake pipe restrictions or blockage

Check burner fasteners and gaskets

Check air intake pipe and proper propane orifice

Check wire harness connections between gas valve and Control.

If lockout re-occurs replace Control.


this page intentionally left blank.

Page 70

SECTION 8 Maintenance

8.1 Annual startup & general maintenance

Regular Maintenance

- This Manual should be placed in a safe and dry location near the Combination boiler. Maintenance instructions should be carried out by the following guidelines.

Maintenance procedures [ Daily ]

- Check the power source .

Make sure that the power cord is correctly connected. The main power line is connected to the manual switch box inside a combination boiler.

(Power line through the strain relief in the bottom of the combination boiler casing and fix it.)

- Check the status of the control panel

Check status of the power supply. Please check for any debris on the button.

- Check that the boiler casing is closed.

Check if there is any problem with the Combination boiler casing and the two upper and lower screws are tightened well. Combination boiler casing must be closed while it is running.

WARNING

To prevent potential severe personal injury, death or substantial property damage, remove all contaminates or contaminated materials immediately from the area around the boiler.

If exposed to contaminated materials, call a qualified service technician to inspect the boiler for possible damage from acid corrosion.

WARNING

DO NOT store combustible materials, gasoline or any other flammable vapors or liquids near the Boiler. Remove them immediately or store them other places.

Maintenance procedures [ Monthly ]

- Check the vent pipe.

Visually inspect the flue gas vent piping for detecting any signs of blockage, leakage or deterioration of the piping. Please contact a qualified service technician immediately if you find any problem.

- Check the air inlet pipe.

Visually inspect the air inlet to be sure it is unobstructed. Inspect entire length of air piping for ensuring that piping is intact and all joints are properly sealed. Call your qualified service technician if you notice any problems.

- Check the relief valve.

Inspect the Combination boiler relief valve and the relief valve discharge pipe for any signs of weeping or leakage. If the relief valve often weeps, immediately contact your qualified service technician for inspecting the Combination boiler and system.

- Check the condensate outlet.

While the Combination boiler is running, check the discharge end of the condensate drain tubing.

Make sure that no flue gas is escaping from the condensate drain tubing.

If flue gas is continuously escaping, it is a serious problem. Call your qualified service technician for inspecting the Combination boiler and condensate line. Also, refill the condensate trap if problem persists regularly.

- Check the vent terminal screen vent (rodent screen).

If you encounter a problem of combustion specifications, visually inspect the terminal screen.

And then replace it with spare parts or clean the screens.


- Check the air vent

If the air vent valve seems to work freely without leaking, replace cap “A” by twisting all the way on.

Loosen cap “A” one turn to allow vent to operate.

If vent does not operate correctly, replace the vent.

Maintenance procedures [Every 6 Months]

- Check the boiler piping (gas and water)

Visually inspect for leaks around internal water piping. Also inspect external water piping, circulators, relief valve and fittings. Immediately call a qualified service technician to repair any leaks. Leaks must be fixed by a qualified service technician immediately.

Failure to comply with this instruction could result in severe personal injury, death or substantial property damage.

- Check the pressure relief valve

WARNING

Leaks must be fixed by a qualified service technician immediately. Failure to comply with this instruction could result in severe personal injury, death or sub stantial property damage. This discharge line must be installed by a qualified heating installer or a service technician.

Before proceeding, verify that relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of scalding from hot water. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain. If the valve weeps, lift the seat again to attempt to clean the valve seat. If the valve continues to weep, contact your qualified service technician for inspecting the valve and system. If water does not flow from the valve even though you have lifted the lever completely, the valve or discharge line may be blocked. Shut down the Combination boiler immediately. Call your qualified service technician to inspect the combination boiler and system.

- Check the burner state

You can clean the exterior of burner. However, if you need to clean the inside of the burner stage, you should call a qualified service technician.

Page 72

8.2 Flushing the Combination Boiler

Flushing the Heat Exchanger is a complicated procedure that should only be done by an authorized technician or licensed professional. Keep in mind that improper maintenance can void your warranty.

V3

V1

V4 V2

1. Disconnect electric power to the combination boiler.

2. Close the shutoff valves on both hot water outlet and cold water inlet lines. (V1 & V2)

3. Connect hose “D1” to the valve “V3” and place the free end in the bucket. Connect hose “D3” to the circulation pump outlet and the cold water inlet line at the valve “V4”. Connect hose “D2” to the circulation pump inlet and place the free end in the bucket.

4. Pour the cleaning solution into the bucket. Place the drain hose

(D1) and the hose (D2) to the pump inlet into the cleaning solution.

5. Open service valves (V3 & V4) on the hot water outlet and cold water inlet lines.

6. Turn on the circulation pump (Operate the pump and allow the cleaning solution to circulate through the combination boiler for at least 1 hour at a rate of 4 gallons per minute.)

7. Rinse the cleaning solution from the combination boiler as follows:

- Remove the free end of the drain hose (D1) from the bucket.

- Close service valve, (V4), and open shut off valve,

(V2).

Do not open shut off valve, (V1).

- Allow water to flow through the combination boiler for

D1 5 minutes.

- Close shut off valve (V2).

8. Ensure service valves are closed (V3 and V4) and shut off

valves are open (V1 and V2).

D3

9. Disconnect all hoses.

D1

D2

10. Remove the cold water inlet filter from the combination boiler and clean out any residues.

11. Reinsert the filter and ensure the filter cap is securely tightened.

12. Connect electrical power to the combination boiler.

D3


8.3 Draining and Cleaning

Page 73

Flow

Restrictor

DHW Cold Water

Inlet Filter

CH Return Filter

Flow

Restrictor

DHW Cold Water

Inlet Filter

CH Return Filter

FTCW 140 FTCW 199

1. Place a bucket under the appliance to collect the residual water inside the combination boiler.

2. Press the Power button on the front control panel to turn OFF the electrical power to the combination boiler.

3. Turn off the gas valve.

4. Close water supply valve on the inlet to the appliance. If there is no valve, turn off main water valve.

5. Open the hot water faucets completely.

6. Remove the CH (Central Heat) return filter by removing the metal pin and then pulling the filter downward.

7. Remove the Cold Water Inlet filter by removing the two small pins and then pulling the filter downward at an angle. If your system is using a flow restrictor, be sure that the flow restrictor is also cleaned and placed back into the system during re-assembly.

8. Clean them with a toothbrush and clean running water.

9. To refill the combination boiler, reassemble the filters back into the combination boiler and reverse steps 7 back to 1.

8.4 Freeze Protection

FT Series Boilers are certified for indoor use only, and are not design-certified for placement outdoors.

Proper precautions for freeze protection are recommended for boiler installations in areas where the danger of freezing exists.

Power outage, interruption of gas supply, failure of system components, activation of safety devices, etc., may prevent a boiler from firing. Any time a boiler is subjected to freezing conditions, and the boiler is not able to fire, and/or the water is not able to circulate, there is a risk of freezing in the boiler or in the pipes in the system.

When water freezes, it expands which may result in bursting of pipes, or damage to the boiler, which could result in leaking or flooding conditions.

NOTICE

Different glycol products may provide varying degrees of protection. Glycol products must be maintained properly in a heating system, or they may become ineffective. Consult the glycol specifications, or the glycol manufacturer, for information about specific products, maintenance of solutions, and set up according to your particular conditions.

NOTICE

Not all pumps are capable of maintaining the reduced temperature rise required with glycol concentrations greater than 35%.

Page 74

Freeze Protection (continued)

WARNING

Do NOT use automotive antifreeze or ethylene glycol. Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets, seals, and metallic components used in hydronic systems. A correct glycol concentration and inhibitor level is critical.

Some items to consider are

• Consider the effects of reduced heat transfer and an increase in head pressure against the system circulator. For example: A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.

• Glycol mixtures should not exceed 50%. A 50% mixture of glycol will result in a BTU output loss of

30% with a 50% increase in head against the system circulator. Glycol concentrations above 40% by volume can lead to short cycling of the burner.

No change on venting material is required when using glycol in the system.

• The glycol solution should be tested as recommended by the glycol manufacturer but not less than annually.

Some items of concern are pH additive breakdown, inhibitor reduction, etc.

• Glycol/antifreeze solutions expand more than water; therefore, system design must take this into account.

For example: a 50% by volume solution expands

4.8% in volume for a temperature increase from 32◦F to 180◦F, while water expands 3% over the same temperature rise.

CAUTION

It is highly recommended to follow the manufacturers recommended concentrations, expansion requirements, and maintenance recommendations. You must carefully calculate the additional friction loss in the system as

__________________________________________

NOTICE

Do not exceed a 40% glycol concentration by volume as it may result in short cycling of the burner.

SECTION 9 Installation Check

9.1 Quick View

Before Installing

- Make sure that there is enough space for installing

Water and gas line.

Verify vent/air termination is located as required.

- All models need for propane Conversion which requires a separate gas conversion manual.

Install Water Piping

- Boiler loop piping must be sized to the minimums listed in the Boiler manual. Using smaller piping will cause performance problems.(page 34)

Install Vent & Air Piping

- Slide the air inlet pipe and vent pipe into the Boiler pipe connector.

- Make sure the terminations are placed as required in the manual and that air intakes are at least 12 inches above normal snow line.

- Refer to the material check list in this guide for a list of items needed.

Install Condensate Piping / Tubing & Components

- Fill out the material check list in this guide to ensure you have the tubing or PVC pipe and all components needed for the condensate piping.

- Connect internal components that are supplied with the Boiler.

Install Gas Piping

- Install a union and shutoff valve.

Wire the Boiler

- Connect power wiring and control wiring per boiler manual wiring diagram.(Section 4.19)

Start up, Adjust & Test

- Follow the Boiler manual instructions to clean the system if needed, then fill and check water chemistry.


9.2 Final Check Lists

Final check : Installation Conditions.

• Is the Boiler properly mounted on the wall?

• Is there space for a drain which is close to the

Boiler?

• Are there any combustible materials near the Boiler and vent pipe?

• Is the air supply sufficient for proper operation of the Boiler?

• Are the proper service clearances maintained?

• Is the distance between the Boiler and point of vent termination minimized?

• Is the proper distance from windows, doors, and other intake vents maintained?

Final check : Gas pipe installation

• Is the gas supply line equipped with a manual shut off valve?

• Is the gas supply line a minimum of 3/4˝ inner diameter?

• Is the gas supply line length and diameter adequate to deliver the required BTU’s?

• Has the gas supply line pressure been measured?

• Does the supply gas type match the type indicated on the boiler rating plate?

Final check: Air/Vent pipe installation

• Has the Boiler been vented with 3˝ or 2” PVC,

CPVC, Polypropylene or BH Special

Gas Vent (S636 PVC, CPVC) for Category IV appliances in accordance with this manual and/or your local code?

• Is the vent termination at least 12˝ above the exterior grade?

• Is the total vent length within the maximum vent length restriction?

• Have you checked the air/vent piping for leaks?

• Have you properly supported the vent termination?

• Are all vent runs properly supported?

• Is the vent sloped upward toward the vent termination at a rate of 1/4˝ per foot (2% grade)?

Final check : Condensate drain installation

• Have you installed a condensate drain line from the

Boiler to a drain or laundry tub?

Final check : Setting the DIP switches

• Are all DIP switches correctly set on the main board?

Final check : Connecting the power supply

• Please check that the power is 120V AC.

• Have you checked the polarity of the electrical connection?

Final check : Pressure relief valve

• Have you properly installed an approved pressure relief valve on the boiler?

• If applicable, has the DHW pressure relief valve been properly installed. This will be dependent on local codes.

Final check : Burner flames

• The burner flame must be checked periodically for a constant proper blue color.

• If the flame does not appear normal, the burner may need to be cleaned.

• If the burner needs to be cleaned, it must be performed by a qualified service technician.

Sight Glass

Blue flame

Page 76

SECTION 10 Parts List and Illustrations

FTCW 140

Casing Assembly


FTCW 140

Casing140- (New)

Casing Parts

No.

28

29

30

30-1

31

32

33

33-1

34

35

36

37

24

25

26

27

20

21

22

23

16

16-1

16-2

16-3

16-4

17

18

19

O-6

15

15-1

15-2

15-3

15-4

15-5

15-6

Description

Part

Number

O-Ring P6

Exhaust vent duct assembly

Stainless band (Ø100)

Packing

3 inch Exhaust vent duct

O-Ring P75

O-Ring P7

Exhaust testing cap

Air inlet duct assembly


Packing

3 inch Air inlet vent duct

O-Ring P75

Air vent

Air vent rubber packing

Gasket bracket

Control bracket

Power switch

Terminal block (6P)

Terminal block (8P)

Front cover

Display panel cover

Pressure gauge

Pressure gauge bracket

Intake/Exhaust sealing pad

Wall hung bracket (top)

Casing assembly

Wall hung bracket (bottom)

FT2092

FT2000

FT1603

FT1604

FT2001

FT1609

FT1601

FT1606

FT2002

FT1603

FT1604

FT2003

FT1609

FT1321

FT1013

FT1797

Safety valve rubber pad

Air pressure sensor (80)

PCB Control (NGTX-900CP)

Ignition transformer

FT1921

FT1804

FT1899

ST1006

Control sub-bracket

Display Control

FT2004

FT2005

Bracket FT2006

Condensate blockage, Air pressure switch FT1022

FT1922

FT1020

FT1827

FT2007

FT2008

FT2009

FT1025

FT2010

FT1771

FT1924

FT2105

FT1936

Ass’y ss’s’y ’y y

Page 77

Page 78

FTCW 140

CH Assembly


FTCW 140

Page 79

CH Block & DHW Block Ass’y (New)

‘B3’DHW Block Ass’y

53

53-1

P-5

P-6

54

54-1

P-6

O-25

52-1

52-2

P-5

O-22

O-22A

O-25

C-2

C-3

C-2

C-4

C-5

50

51

51-1

P-5

52

B2

49

49-1

49-2

49-3

O-20

O-22

O-22A

C-3

B3

40

40-1

P-4

O-18

CH Hydro block assembly

Return block assembly

Return block

Block cap

CH Filter

O-Ring P20

O-Ring P22

O-Ring P22A

Piping clip

R Clip

U Clip

CH Return, Supply connector

CH Return Pipe assembly

CH Return pipe

3/4" Packing

3way valve assembly

3way valve

CH Return sensor

3/4" Packing

O-Ring P22

O-Ring P22A

O-Ring P25

Piping clip

Pump clip

CH Supply pipe assembly

CH Supply pipe

3/4" Packing

1" Packing

Pump assembly

Pump

1" Packing

O-Ring P25

Pump clip

DHW Hydro block assembly

DHW Outlet Pipe assembly

DHW Outlet pipe

1/2" Packing

O-Ring P18

FT1220

FT1219

FT1646

FT1644

FT1515

FT1516

FT1107

FT1108

FT2109

FT1527

FT1646

FT1691

FT2110

FT1222

FT1691

FT1516

FT1100

FT2106

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1217

FT1215

FT2107

FT1218

FT1646

FT2108

FT1108

FT1200

FT2111

FT1109

FT1645

FT1687

C-1

46

46-1

O-16

C-1

47

47-1

47-2

44-1

O-15

O-16

C-1

45

45-1

O-16

O-18

C-2

42

43

43-1

P-4

O-18

C-1

44

C-1

41

41-1

41-2

O-15

O-18

O-22A

C-1

47-3

47-4

O-16

O-20

C-1

C-4

48

Flow sensor clip

DHW Outer block assembly

DHW Outer block

DHW Temperature Sensor

O-Ring P15

O-Ring P18

O-Ring P22A

Flow sensor clip

Piping clip

DHW Nipple

DHW Inlet Pipe assembly

DHW Inlet pipe

1/2" Packing

O-Ring P18

Flow sensor clip

Mixing valve assembly

Mixing valve

O-Ring P15

O-Ring P16

Flow sensor clip

Flow sensor assembly

Flow sensor

O-Ring P16

O-Ring P18

Flow sensor clip

DHW Inlet block assembly

DHW Inlet block

O-Ring P16

Flow sensor clip

DHW Filter body assembly

DHW Filter body

Flow restrictor(5L)

DHW Filter mesh

Block cap

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

FT1116

FT1685

FT1643

FT1208

FT2115

FT1115

FT1643

FT1687

FT1208

FT2116

FT1522

FT1643

FT1208

FT2117

FT1549

FT1119

FT1208

FT2112

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT2113

FT1114

FT1645

FT1687

FT1208

FT2114

FT1120

FT1121

FT1643

FT1513

FT1208

FT1524

FT1122

Page 80

FTCW 140

DHW Assembly

CH Block & DHW Block Ass’y (New)

‘B2’ CH Block Ass’y ‘B3’DHW Block Ass’y

CH Block & DHW Block

C-2

C-4

C-5

50

51

51-1

P-5

52

B2

49

49-1

49-2

49-3

O-20

O-22

O-22A

52-1

52-2

P-5

O-22

O-22A

O-25

C-2

C-3

Ass’y (New)



Return block

Block cap

CH Filter

O-Ring P20

O-Ring P22

O-Ring P22A

Piping clip

R Clip

U Clip



CH Return pipe

3/4" Packing

3way valve assembly

3way valve

CH Return sensor

3/4" Packing

O-Ring P22

O-Ring P22A

O-Ring P25

Piping clip

Pump clip


CH

53

53-1

P-5

P-6

40

40-1

P-4

O-18

P-5

P-6

54

54-1

P-6

O-25

C-3

B3

C-3

B3

40

40-1

P-4

O-18

P-5

O-22

O-22A

52-1

52-2

P-5

O-22

O-22A

O-25

C-2

C-3

C-5

50

51

51-1

P-5

52

52-1

52-2

49-1

49-2

49-3

O-20

O-22

O-22A

C-2

C-4

C-2

C-4

C-5

50

51

51-1

P-5

52

B2

49

49-1

49-2

49-3

O-20

O-22

O-22A

Block &

FTCW 140

DHW

Return block

Block cap

CH Filter



Return block

Block cap

CH Filter

O-Ring P20

O-Ring P22

O-Ring P22A

Piping clip

R Clip

U Clip



CH Return pipe

3/4" Packing

3way valve assembly

3/4" Packing

O-Ring P22

O-Ring P22A

3way valve

CH Return sensor

3/4" Packing

O-Ring P22

O-Ring P22A

O-Ring P25

Piping clip

Pump clip

3/4" Packing

1" Packing

Pump assembly

Pump

1" Packing

O-Ring P25

Pump clip



DHW Outlet pipe

1/2" Packing

O-Ring P18



DHW Outlet pipe

1/2" Packing

O-Ring P18

Block

FT1108

FT1200

FT2111

FT1109

FT1645

FT1687

FT1108

FT1200

FT2111

FT1109

FT1645

FT1687

FT1220

FT1219

FT2109

FT1527

FT1646

FT1691

FT1108

FT2110

FT2109

FT1527

FT1646

FT1691

FT1100

FT2106

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1220

FT1219

FT1646

FT1644

FT1515

FT1516

FT1107

FT1108

FT1100

FT2106

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1217

FT1215

FT2107

FT1218

FT1646

FT2108

P-5

P-6

Ass’y (New)

DHW Parts

B3

40

40-1

P-4

O-18

C-1

46

46-1

47-4

O-16

O-20

C-1

C-4

48

47-3

47-4

O-16

O-20

C-1

C-4

48

46

46-1

O-16

C-1

47

47-1

47-2

47-3

O-15

O-16

C-1

45

45-1

O-16

O-18

C-1

44-1

O-15

O-16

C-1

45

45-1

O-16

O-18

42

43

43-1

P-4

O-18

C-1

44

44-1

41

41-1

41-2

O-15

O-18

O-22A

C-1

C-2

C-2

42

43

43-1

P-4

O-18

C-1

44

C-1

41

41-1

41-2

O-15

O-18

O-22A

C-1

3/4" Packing

1" Packing

Pump assembly

Pump

1" Packing

O-Ring P25

Pump clip



DHW Outlet pipe

1/2" Packing

O-Ring P18

Flow sensor clip


DHW Outer block


O-Ring P15

O-Ring P18

O-Ring P22A

Flow sensor clip

Piping clip

DHW Nipple


DHW Inlet pipe

O-Ring P16

Flow sensor clip


Mixing valve

O-Ring P15

O-Ring P16

Flow sensor clip

DHW Inlet block

O-Ring P16


DHW Filter body

Flow restrictor(5L)

DHW Filter mesh

Block cap

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

FT1220

FT1219

FT1646

FT1644

FT1515

FT1516

FT1107

FT1108

FT2109

FT1527

FT1646

FT1691

FT2110

FT1222

FT1691

FT1516

FT1108

FT1200

FT2111

FT1109

FT1645

FT1687

FT1116

FT1685

FT1208

FT2116

FT1522

FT1643

FT1687

FT1208

FT1208

FT2116

FT1522

FT1643

FT1120

FT1121

FT1643

FT1513

FT1208

FT1524

FT1208

FT2112

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT1116

FT1685

FT1643

FT1208

FT2115

FT1115

FT1643

FT1687

FT1208

FT2112

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT2113

FT1114

FT1645

FT1687

FT1208

FT2114

FT1100

FT2106

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1217

FT1215

FT2107

FT1218

FT1646

FT2108

FT1643

FT1513

FT1208

FT1524

FT1122

C-1

46

46-1

O-16

C-1

47

47-1

47-2

44-1

O-15

O-16

C-1

45

45-1

O-16

O-18

C-2

42

43

43-1

P-4

O-18

C-1

44

C-1

41

41-1

41-2

O-15

O-18

O-22A

C-1

47-3

47-4

O-16

O-20

C-1

C-4

48

Flow sensor clip


DHW Outer block


O-Ring P15

O-Ring P18

O-Ring P22A

Flow sensor clip

Piping clip

DHW Nipple


DHW Inlet pipe

1/2" Packing

O-Ring P18

Flow sensor clip


Mixing valve

O-Ring P15

O-Ring P16

Flow sensor clip


Flow sensor

O-Ring P16

O-Ring P18

Flow sensor clip

DHW Inlet block

O-Ring P16

Flow sensor clip


DHW Filter body

Flow restrictor(5L)

DHW Filter mesh

Block cap

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

FT1116

FT1685

FT1643

FT1208

FT2115

FT1115

FT1643

FT1687

FT1208

FT2116

FT1522

FT1643

FT1208

FT2117

FT1549

FT1119

FT1208

FT2112

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT2113

FT1114

FT1645

FT1687

FT1208

FT2114

FT1120

FT1121

FT1643

FT1513

FT1208

FT1524

FT1122

Page 82

FTCW 140

Heat Exchanger & Tank

Assembly


FTCW 140

Heat Exchanger & Tank (New)

Heat Exchanger & Tank Parts

71

72

73

73-1

73-2

73-3

74

O-22

66-7

67

68

69

70

70-1

P-5

P-6

66-2

66-3

66-4

66-5

66-5a

66-5b

66-5c

66-6

64

64-1

64-2

64-3

64-4

65

66

66-1

Exhaust pipe assembly

Exhaust pipe

FT2011

FT2094

EX-Adaptor FT1784

Exhaust overheat sensor

Exhaust pipe packing (lower)

Heat Exchanger assembly

Burner assembly

Overheat sensor

Burner upper case

Burner packing

Burner

Ignition rod assembly

FT1307

FT2012

FT2013

FT2014

Ignition rod

Ignition rod gasket

Ignitor ceramic paper

Burner downside case

Refractory


DHW Tank bracket

DHW Tank

CH Supply upper pipe assembly

CH Supply upper pipe

3/4" Packing

1" Packing

Temperature sensor

Low level sensor

Flame detector sensor assembly

Flame detector sensor bracket

Flame detector sensor

Flame detector sensor cover

Condensate trap assembly

O-Ring P22

FT1310

FT1926

FT1927

FT2015

FT2118

FT2016

FT1316

FT2017

FT1928

FT1665

FT1528

FT1530

FT1323

FT2119

FT1322

FT1646

FT1691

FT1324

FT1325

FT2120

FT1669

FT1327

FT1069

FT1783

FT1644

Page 83

Page 84

FTCW 140

Blower and Gas Valve Assembly

86

87

87-1

P-7

88

88-1

P-7

89

83-3

83-4

83-5

84

84-1

84-2

84-3

84-4

82

82-1

82-2

82-3

82-4

83

83-1

83-2

85

85-1

85-2

85-3

85-4

85-5

P-7

Fan guide assembly

Fan guide

Damper body assembly

Fan rubber packing #2

Fan rubber packing (1.6t)

Fan assembly

Fan

Fan sealing O-Ring

AGM Venturi (Ø23)

AGM O-Ring

AGM Body

Air intake hose (140K) assembly

Air intake hose (140K)


Nylon Barb Y Fitting


Gas valve assembly

Gas valve outlet adaptor

Gas valve O-Ring

Gas valve

Gas valve inlet adaptor

Gas valve bracket

1/2" Spiral packing

Nozzle NG (Ø6.2)

Nozzle LP (Ø4.7)

Gas pipe (upper) assembly

Gas pipe (upper)

1/2" Spiral packing

Gas pipe (down) assembly

Gas pipe (down)

1/2" Spiral packing

Gas inlet adaptor

FT1413

FT1919

FT1727

FT1416

FT1538

FT1539

FT1710

FT2027

FT2028

FT2123

FT2029

FT1710

FT2124

FT1419

FT1710

FT1893

FT2121

FT2018

FT2019

FT2020

FT1082

FT2021

FT1406

ST1038

FT2022

FT2023

FT2024

FT2122

FT2026

FT1603

FT1918

FT2025

Page 85

FTCW 140

Blower and Gas Valve Parts

100

101

102

104

105

106

107

114

115

Pressure relief valve

Outdoor temperature sensor

Bird screen 3"

Spare parts kit

Condensate hose

Restrictor (12L)

Wall hung bracket

Wire harness

Gas conversion kit

FT1500

FT1501

FT1730

FT2030

ST1070

FT1506

FT1894

FT1903

FT2091

Page 86

FTCW 199

Casing Assembly


FTCW 199

No.

16

16-1

16-2

16-3

16-4

17

18

19

O-6

15

15_1

15_2

15-3

15-4

15-5

15-6

20

21

22

23

23-1

24

25

26

27

34

35

36

37

28

29

30

30-1

31

32

33

33-1

Description

O-Ring P6

Exhaust vent duct assembly


Packing

3 inch Exhaust vent duct

O-Ring P75

O-Ring P7

Exhaust testing cap

Air inlet duct assembly


Packing

3 inch Air inlet vent duct

O-Ring P75

Air vent

Air vent rubber packing

Gasket bracket

Safety valve rubber pad

Air pressure sensor (80)

Control bracket

Ignition transformer

Ignition Transformer bracket

Control sub-bracket

FT1013

FT1797

FT1921

FT1804

FT1751

FT2031

FT2032

FT2033

Display Control FT2005

Bracket FT1795

Part

Number

FT2092

FT2000

FT1603

FT1604

FT2001

FT1609

FT1601

FT1606

FT2002

FT1603

FT1604

FT2003

FT1609

FT1321

Condensate blockage, Air pressure switch FT1022

PCB Control (NGTX-900CP)

Power switch

Terminal block (6P)

Terminal block (8P)

Front cover

Display panel cover

Pressure gauge

Pressure gauge bracket

Intake/exhaust sealing pad

Wall hung bracket (top)

Casing assembly

Wall hung bracket (bottom)

FT1899

FT1020

FT1827

FT2007

FT2034

FT2009

FT1025

FT2065

FT1771

FT1924

FT2093

FT1936

Page 87

Page 88

FTCW 199

CH Assembly


FTCW 199

Page 89

CH

Block

&

DHW

Block

Ass’y

(New)

No.

C-3

53

53-1

P-5

P-6

54

54-1

P-6

O-25

C-3

52-1

52-2

P-5

O-22

O-22

O-22A

O-25

C-2

C-2

C-4

C-5

50

51

51-1

P-5

52

B2

49

49-1

49-2

49-3

O-20

O-22

O-22A

Description

CH Hydro block assembly


Return block

Block cap

CH Filter

O-Ring P20

O-Ring P22

O-Ring P22A

Piping clip

R Clip

U Clip


Ch Return Pipe assembly

CH Return pipe

3/4" Packing

3-way valve assembly

3-way valve

CH Return sensor

3/4" Packing

O-Ring P22

O-Ring P22

O-Ring P22A

O-Ring P25

Piping clip

Pump clip


CH Supply pipe

3/4" Packing

1" Packing

Pump assembly

Pump

1" Packing

O-Ring P25

Pump clip

Part Number

FT1220

FT1219

FT1646

FT1644

FT1644

FT1515

FT1516

FT1107

FT1108

FT2072

FT1808

FT1646

FT1691

FT2073

FT1798

FT1691

FT1516

FT1108

FT1937

FT2069

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1217

FT1215

FT2070

FT1807

FT1646

FT2071

No.

C-1

45

45-1

O-16

O-18

C-1

47

47-1

43-1

P-5

O-18

C-1

44

44-1

O-15

O-16

47-2

47-3

47-4

O-16

O-20

C-1

C-4

48

41-2

O-15

O-18

O-22A

C-1

C-2

42

43

B3

40

40-1

P-5

O-18

C-1

41

41-1

Description

DHW Hydro block assembly


DHW Outlet Pipe

3/4" Packing

O-Ring P18

Flow sensor clip


DHW Outer block

DHW Temperature sensor

O-Ring P15

O-Ring P18

O-Ring P22A

Flow sensor clip

Piping clip

DHW Nipple

DHW Inlet pipe assembly

DHW Inlet pipe

3/4" Packing

O-Ring P18

Flow sensor clip


Mixing valve

O-Ring P15

O-Ring P16

Flow sensor clip


Flow sensor

O-Ring P16

O-Ring P18

Flow sensor clip


DHW Filter body

Flow restrictor

DHW Filter Mesh

Block cap

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

Part Number

FT1806

FT1646

FT1687

FT1208

FT2077

FT1116

FT1685

FT1643

FT1208

FT2078

FT1115

FT1643

FT1687

FT1208

FT2080

FT1549

FT1938

FT2074

FT1805

FT1646

FT1687

FT1208

FT2075

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT2076

FT1822

FT1120

FT1121

FT1643

FT1513

FT1208

FT1524

FT1122

Page 90

FTCW 199

DHW Assembly


FTCW 199

CH

Block

&

DHW

Block

Ass’y

(New)

No.

C-3

53

53-1

P-5

P-6

54

54-1

P-6

O-25

C-3

52-1

52-2

P-5

O-22

O-22

O-22A

O-25

C-2

C-2

C-4

C-5

50

51

51-1

P-5

52

B2

49

49-1

49-2

49-3

O-20

O-22

O-22A

Description

CH Hydro block assembly


Return block

Block cap

CH Filter

O-Ring P20

O-Ring P22

O-Ring P22A

Piping clip

R Clip

U Clip


Ch Return Pipe assembly

CH Return pipe

3/4" Packing

3-way valve assembly

3-way valve

CH Return sensor

3/4" Packing

O-Ring P22

O-Ring P22

O-Ring P22A

O-Ring P25

Piping clip

Pump clip


CH Supply pipe

3/4" Packing

1" Packing

Pump assembly

Pump

1" Packing

O-Ring P25

Pump clip

Part Number

FT1220

FT1219

FT1646

FT1644

FT1644

FT1515

FT1516

FT1107

FT1108

FT2072

FT1808

FT1646

FT1691

FT2073

FT1798

FT1691

FT1516

FT1108

FT1937

FT2069

FT1523

FT1121

FT1216

FT1513

FT1644

FT1515

FT1107

FT1524

FT1217

FT1215

FT2070

FT1807

FT1646

FT2071

No.

C-1

45

45-1

O-16

O-18

C-1

47

47-1

43-1

P-5

O-18

C-1

44

44-1

O-15

O-16

47-2

47-3

47-4

O-16

O-20

C-1

C-4

48

41-2

O-15

O-18

O-22A

C-1

C-2

42

43

B3

40

40-1

P-5

O-18

C-1

41

41-1

Description

DHW Hydro block assembly


DHW Outlet Pipe

3/4" Packing

O-Ring P18

Flow sensor clip


DHW Outer block

DHW Temperature sensor

O-Ring P15

O-Ring P18

O-Ring P22A

Flow sensor clip

Piping clip

DHW Nipple

DHW Inlet pipe assembly

DHW Inlet pipe

3/4" Packing

O-Ring P18

Flow sensor clip


Mixing valve

O-Ring P15

O-Ring P16

Flow sensor clip


Flow sensor

O-Ring P16

O-Ring P18

Flow sensor clip


DHW Filter body

Flow restrictor

DHW Filter Mesh

Block cap

O-Ring P16

O-Ring P20

Flow sensor clip

R Clip

DHW Connector

Part Number

FT1806

FT1646

FT1687

FT1208

FT2077

FT1116

FT1685

FT1643

FT1208

FT2078

FT1115

FT1643

FT1687

FT1208

FT2080

FT1549

FT1938

FT2074

FT1805

FT1646

FT1687

FT1208

FT2075

FT1518

FT1112

FT1685

FT1687

FT1515

FT1208

FT1107

FT1111

FT2076

FT1822

FT1120

FT1121

FT1643

FT1513

FT1208

FT1524

FT1122

Page 91

Page 92

FTCW 199

Heat Exchanger & Tank Assembly

No.

72

73

74

74-1

74-2

74-3

75

O-22

67-7

68

69

70

71

71-1

P-5

P-6

67-2

67-3

67-4

67-4a

67-4b

67-4c

67-5

67-6

65

65-1

65-2

65-3

65-4

66

67

67-1

Heat Exchanger & Tank (New

FTCW 199

Heat Exchanger & Tank Parts

Description

Part

Number

Exhaust pipe assembly

Exhaust pipe

FT2081

FT2125

EX-Adaptor FT1784

Exhaust overheat sensor

Exhaust pipe packing (lower)

Heat Exchanger assembly

Burner assembly

Burner upper case

Burner packing

Burner

Ignition rod assembly

Ignition rod

FT1307

FT2036

FT2037

FT2038

Ignition rod gasket

Ignitor Ceramic Paper

Overheat sensor

Burner downside case

Refractory


DHW Tank bracket

DHW Tank

CH Supply upper pipe assembly

CH Supply upper pipe

3/4" Packing

1" Packing

Temperature sensor

Low level sensor

Flame detector sensor assembly

Flame detector sensor bracket

Flame detector sensor

Flame detector sensor cover

Condensate trap assembly

O-Ring P22

FT1760

FT1824

FT2039

FT2126

FT2040

FT1316

FT2017

FT1310

FT2041

FT2042

FT1813

FT1793

FT1794

FT2084

FT1809

FT1646

FT1691

FT1324

FT1325

FT2085

FT1669

FT1327

FT1069

FT1783

FT1644

Page 93

Page 94

FTCW 199

Blower and Gas Valve Assembly

No.

83-3

83-4

83-5

84

84-1

84-2

84-3

84-4

82

82-1

82-2

82-3

82-4

83

83-1

83-2

85

85-1

85-2

85-3

85-4

P-7

86

87

87-1

P-7

88

88-1

P-7

89


Fan & Gas Valve _ Feature (Ne

Blower and Gas Valve Parts

Description

Part

Number

Fan guide assembly

Fan guide

Damper body assembly

Fan rubber packing #2

Fan guide packing

Fan assembly

Fan

Fan sealing O-Ring

AGM Venturi

AGM O-Ring

AGM Body

Air intake hose assembly

Air intake hose


Nylon Barb Y Fitting


Gas valve assembly

Gas valve outlet adaptor

Gas valve O-ring

Gas valve

Gas valve bracket

1/2" Spiral packing

Nozzle (natural)

Nozzle (propane) - 6.35MM

Gas pipe (upper) assembly

Gas pipe (upper)

1/2" Spiral packing

Gas pipe(down) assembly

Gas pipe (down)

1/2" Spiral packing

Optional items

FT1778

FT1919

FT1727

FT1416

FT1779

FT1710

FT1780

FT1802

FT2089

FT1810

FT1710

FT2090

FT1811

FT1710

FT1893

FT2087

FT2043

FT2044

FT2020

FT1772

FT1916

FT1406

ST1038

FT1917

FT1774

FT1775

FT2088

FT1812

FT1603

FT1918

FT1777

No.

100

101

102

104

105

106

107

108

Description

Pressure relief valve

Outdoor temperature sensor

Bird screen 3"

Spare Parts Kit

Condensate hose

Wall hung bracket

Wire harness

Gas conversion kit

Optional Items

Part

Number

FT1500

FT1501

FT1730

FT2030

ST1070

FT1894

FT1904

FT2091

Page 95

Notes:


For Product and

Service V IDEOS

Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement.

Customer Service and Product Support: 800.900.9276 • Fax 800.559.1583

20 Industrial Way, Rochester, NH, USA 03867

20-10 Document 1487

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