BRADFORD WHITE FTHW301 Wall Mounted Modulating Condensing Gas Boiler

Specifications

• Product Name: Wall-Mounted Modulating Condensing Gas Boiler
• Models: FTHW301 and FTHW399
• Includes Optional Floor Stand Accessory Information

Product Usage Instructions

1. Installation

It is crucial to have this product installed and serviced by a professional service technician qualified in hot water boiler and heater installation and maintenance. Improper installation and operation can lead to serious risks.

2. Safety Regulations

Follow all safety symbols, precautions, and proper use guidelines outlined in the manual to ensure safe operation.

3. Location and Clearances

Ensure proper location and clearances as specified in the manual for both wall mounting and floor stand application if using the optional accessory.

4. Zoning and Control Systems

Refer to the manual for detailed instructions on setting up zoning with zone valves, cascade systems, and separate control of space heating and DHW heating.

5. Error Codes and Troubleshooting

Familiarize yourself with the error code tables, fault tree analysis, diagnostics, and suggested corrective actions provided in the manual for troubleshooting purposes.

6. Maintenance

Regular maintenance is essential for optimal performance. Follow the annual startup & general maintenance procedures outlined, including daily, monthly, and every six months maintenance tasks.

7. Installation Check

Perform a quick view and final check lists to ensure all installation steps have been completed correctly. Pay special attention to freeze protection measures.

FAQs

• Q: Can I install the gas boiler myself?
  • A: No, it is strongly recommended to have the product installed by a professional service technician to ensure safety and proper operation.
• Q: What should I do if I encounter an error code?
  • A: Refer to the manual’s error code tables and fault tree analysis to identify the issue. Follow the suggested corrective actions or contact a qualified service technician for assistance if needed.

“`

Installation and Operation Instructions
Installation and Operation Instructions for

Document 1538

Wall-Mounted Modulating Condensing Gas Boiler (Includes Optional Floor Stand Accessory Information) Model FTHW301 and FTHW399
· 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.

The FT Series 301 / 399 Heating Only Boiler

Introduction

1.1 About this Installation Manual
For details on Combustion Air and Venting, (pages 17-29)
This manual provides the information necessary for the installation, operation, and maintenance of the FT 301/399 Wall or Floor Heating Only 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.
For details on Plumbing for Condensate, (page 51)

Page 3
For details on Plumbing for Central Heat
(page 40 to page 51)
For details on Gas Connections/Combustion
Setup (page 30 to page 36)
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.

Hi Voltage Terminals

Low Voltage Terminals

For details on Field Connections and Electrical Diagrams (page 40 to page 56)

Page 4

1.2 Included in the Box

Item

Description

Wall Mounted Heating Only
Boiler

Package, Outdoor Sensor
and Silicone tubing for air relief
on condensate trap, velcro strap and
condensate hose
Box, 30 psi Relief
Valve

Box, Air Vent

Box, Brass Adaptor
Package, Two ¾” plugs.
and Two 1-1/2″ caps)

Item
Installation and Operating
Manual
Package, Two Mesh Screens
3″ Dia.
Propane Conversion Kit with Orifice and
Instructions
Packages, Spare Parts. O-Rings and
Gaskets

Description

Condensate Trap

Wall Hanging Bracket and Isolation Pad

The FT Series 301 / 399 Heating Only Boiler

Product Characteristics

2.1 Model Number

Model Number / Rating Plate

The Model Number is shown on your Rating Plate

and consists of a series of letters and numbers (Nomenclature)

that further identifies the characteristics of your FTHW Heating Only Boiler.

123

4

FT

H

5

678

9

10

W

N

SERIES L/B FT

H – HEATING ONLY W – WALL MOUNTED

SIZE MBTU/h
301 399

FUEL N – NATURAL

OPTIONS X – BOILER ONLY F – BOILER WITH
FLOOR STAND

Page 5

2.2 Dimensions for FTHW301 and FTHW399 models

23.5″ 59.6 cm 22″ 55.9 cm 18.9″ 48 cm 13.3″ 33.8 cm 3.4″ 8.6 cm

20.7″ 52.5 cm

5.3″ 13.5 cm

A

B

25.4″ 64.5 cm
32.8″ 83 cm

11.5″ 29.3 cm 16.8″ 42.6 cm 20.7″ 52.5 cm

16.5″ 42 cm

C

D

E

Latches

TOP VIEW

22″ 55.9 cm 20.5″ 52 cm
1D8.e4s”cr4ip6.t8iocnm

Diameter

A

Air 3In.4t”ak8e.6Ccomllar

3″(*)

B

Vent Pipe Collar

3″(*)

C

Boiler Supply

1-1/2″ NPT

D

E

D

Boiler Return

1-1/2″ NPT

E

Gas Inlet

C1″ NPT

F

Condensate Line

1/2″ (no NPT)

G

PRV & Air Vent

3/4″ NPT and 1/2″ NPT

3.3″ 8.5 cm 29.3 cm 15.4″ 39 cm 16.5″ 42 cm

Handle Handle

50.8″ 129 cm

17.9″ 46 cm

*FLOOR STAND

19.5″ 50 cm

*Floor stand is available separately or ordered with the boiler.

Page 6

2.3 Specifications 2.3.1 Specifications, 301

Gas Input Rate

Model Name
MAX MIN Installation

Flue System

Vent Run

Orifice Size Gas Supply Pressure

NG LP NG LP Gas type

Manifold

Vent size Max Fire

Min Fire

Power Supply

Main Supply Maximum Power Consumption

Ignition System

Burner System Minimum Flow Rate
Dimensions

Shipping Weight

Water Capacity

Main Controller / Control Panel

Central Heat Water Pressure, CH

Connection Sizes (top and bottom)

Space Heating Supply / Return
Gas Inlet

Materials

Casing Heat Exchanger

Safety Devices

FTHW301NX

301,000 Btu/h

39,900 Btu/h

Indoor / Wall-mounted or floor (requires floor stand) boiler
Sealed Combustion Direct / Single Vent / Concentric Vent
3″(65 ft), 4″ (150 ft) Schedule 40 CPVC, PP, PVC, Stainless Steel, PP Flex 6.55 mm (0.258″) 5.40 mm (0.216″) 3.5 WC to 10.5 WC

8.0 WC to 13 WC

NG

LP

3 VENT

4″ VENT

3 VENT

4 VENT

-0.28 “WC -0.015 “WC

-0.28 “WC -0.28 “WC -0.015 “WC -0.015 “WC
120V 60Hz / 15A

-0.28 “WC -0.015 “WC

160W

Direct Electronic Ignition / Automatic Flame Sensing Single Orifice Premixed Fuel Modulation 5 GPM W 25.4″ – H 32.7″ – D 20.7″ 250 lbs (113 kg) 11.3 Gallons / 90 lbs (41 kg) NGTB-1000C / P-953EH Min 15 ~ Max 80 PSI

1-1/2 NPT

1 NPT Cold Rolled Carbon Steel

Primary Heat Exchanger : Stainless Steel
Flame rod, 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 301 / 399 Heating Only Boiler

Page 7

2.3.2 Specifications, 399

Gas Input Rate

Model Name
MAX MIN Installation Flue System

Vent Run

Orifice Size Gas Supply Pressure

NG LP NG LP Gas type

Manifold

Vent size Max Fire

Min Fire

Power Supply

Main Supply Maximum Power Consumption

Ignition System

Burner System Minimum Flow Rate
Dimensions

Shipping Weight

Water Capacity

Main Controller / Control Panel

Central Heat Water Pressure, CH

Connection Sizes (top and bottom)

Space Heating Supply / Return
Gas Inlet

Materials

Casing Heat Exchanger

Safety Devices

FTHW399NX

399,000 Btu/h

39,900 Btu/h

Indoor / wall-mounted or Floor (requires floor stand) Sealed Combustion Direct / Single Vent / Concentric
Vent 3″(65 ft), 4″ (150 ft) Schedule 40 CPVC, PP, PVC,
Stainless Steel, PP Flex 6.70 mm (0.264″) 5.40 mm (0.216″)
3.5 WC to 10.5 WC

8.0 WC to 13 WC

NG

LP

3 VENT

4″ VENT

3 VENT

4 VENT

-0.48″ WC -0.015″ WC

-0.48″ WC

-0.48″ WC -0.48″ WC

-0.015″ WC -0.015″ WC -0.015″ WC

120V 60Hz / 15A

160W

Direct Electronic Ignition / Automatic Flame Sensing Single Orifice Premixed Fuel Modulation 5 GPM W 25.4″ – H 32.7″ – D 20.7″ 260 lbs (118 kg) 10 Gallons / 80 lbs (36 kg) NGTB-1000C / P-953EH Min 15 ~ Max 80 PSI

1-1/2 NPT

1 NPT Cold Rolled Carbon Steel

Primary Heat Exchanger : Stainless Steel
Flame rod, 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
2.4 Names of Components

2

6

5

4

3

36 37

35 34 33 32
31 30 29 28

27 26
25 24

2 23

22

21 8 7

Item # Description

1 Boiler Return Connection

17 8

2 Boiler Supply Connection 3 Vent Pipe Collar 4 Combustion Test Port

5 Air Intake Collar

6 Air Intake Screen

9

7 Gas Inlet Connector

8 Supply Gas Pressure Test Port

9 Blower

10

10 Air/Gas Venturi

11 Air Intake Attenuator

12 Gas Valve

13 Internal Exhaust Pipe 11
14 Sensor, Flue Gas Temperature 12
15 Low Voltage Terminal

16 Low Voltage Terminal

13 17 24V Transformer

14 18 Air Pressure Switch

15 16

19 Sensor, Return Water Temperature

20 Pressure Gauge Probe

17 21 Condensate Pan

18

19

22 Main PCB (NGTB-1000C)

20 23 Front Door Latches (4)

24 120V Terminal Block

25 Pressure Gauge

26 Control Panel and Display

27 Heat Exchanger

28 Sensor, Overheat Shut-Off Switch

29 Sensor, Supply Water Temperature 1
30 Sensor, Low Water Cut-Off (LWCO)

31 Thermal Fuse

32 Sensor, Flame Detecting

33 Sight Glass

34 Igniter

35 Ignition Transformer

36 Sensor, CO2 Flue Gas Recirculation

37 Air Intake Deflector

The FT Series 301 / 399 Heating Only Boiler

Page 9

2.5 Product Flow Paths and Characteristics 2.5.1 Central Heating flow. Boiler Heating Mode.
This boiler has top and bottom return and supply water connections. Place the combo brass adaptor fitting on the upper left supply connection. Use at least one of the CH return and CH supply connections. Cap off any other connections using the 2 1-1/2” caps provided.
Note that the boiler has top and bottom gas connections. Each unit come from a factory with the capped top connection. If the top gas connection is desired, remove its cap using a 2 wrench method and install it on the bottom gas connection (lower right).

CH Supply

Combustion Air
GAS INPUT

Vent
CH Return

CH Supply

GAS INPUT

CH Return

Condensate Drain connection

Page 10

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.
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.
WARNING Cancer and Reproductive Harm. www.P65WARNINGS.CA.GOV.
as required by the state of California Proposition 65.

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.
This appliance must be installed in accordance with local codes if any; if not, follow ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, Natural Gas and Propane Installation Code, as applicable.
This appliance is certified for use at altitudes up to 10,000 ft (3,150 m) in accordance to the latest CSA 2.17 Gas-Fired Appliances for Use at High Altitudes.

The FT Series 301 / 399 Heating Only Boiler 3.2 Safety Precautions and Proper Use

Page 11

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 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 Z223.1 · 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 labelled. 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 `44′ 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.

Page 12

Before Operation
Note: FTHW301/399 is factory built for Natural Gas. For use with LP(Propane), refer to Section 4.15 Natural Gas to Propane Conversion.
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.

WARNING
Do not use the appliance for any other purpose than for space heating and DHW heating using an indirect water heater tank. 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. Check the Power (120V 60Hz). Check that the appliance is connected properly.

3. Check the Cold Water Feed 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) Minimum System Pressure: 15 psig(105 kPa)

4. Check the manual gas shut-off valve on top or below of the FT boiler gas connection. Make sure this manual gas shut-off valve is opened for operation.

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 manual gas shut-off valve. 3. Open windows for ventilation. 4. Do not create any sparks! Leave the property
immediately and call your local utility or qualified service technician for immediate repair.

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

The FT Series 301 / 399 Heating Only Boiler
SECTION 4

Installation

NOTE: For Cascading Installations, please refer to document `Cascading the FTHW301/399 Series Boiler’, available online.
4.1 Location and Clearances (wall)
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 in 7 cm

9 in 23 cm

3 in 7 cm

6024cmin

Page 13
WARNING
Installations must comply with · All the local, state, provincial, and national codes, laws, regulations and ordinances. · National Fuel Gas Code, ANSIz223.1 – The latest version. · National Electrical Code. · A National Standard of Canada CAN/CSA-B149.1
Check before placing the Boiler · Always check the connected components which are near to the heater. The components are below.
Waterpiping position / Venting adapter / Gas supply piping / Electrical power / Condensate drain hose. · Inspect area around Boiler. Remove any combustible materials, gasoline and other flammable liquids. Failure to keep 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 Boiler which has gas control system components must be protected from any possible danger during operation and service. · If new 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 boiler 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.
This boiler must be installed upright in the vertical position as described in this manual.

12 in 30 cm

Minimum clearances to combustibles.

For Installation from Non-Combustibles and Combustibles

TOP of appliance (alcove installation)

9 in (23 cm)

BACK of appliance 1 in (2.5 cm)

TOP (Closet Install) 22 in (56 cm)

FRONT of appliance 1 in (2.5 cm)

SIDE of appliance 1 in (2.5 cm)

BOTTOM of appliance 12 in (30 cm)

Suggested Service Clearance
24 in (61 cm)
1 in (2.5 cm) 22 in (56 cm) 18 in (46 cm) 6 in (15 cm) 24 in (61 cm)

Table 1. Table 1. Minimum Clearances to combustibles, when mounted on wall.

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.

Page 14

4.1.1 Wall Mount Bracket

4.1.2 Mounting Location Preparation
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!

Hangers on the back of the boiler with the knife edge of 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 knife edge of the Wall Mount Bracket.
· Fasten the bottom of the boiler to the wall using 2 suitable wall anchors (field supplied).

Mounting on framed structure (Field supply fasteners)
· Start by familiarizing yourself with how the included Wall Mount Bracket hooks underneath the protruding engaging edge on the back of the boiler.

Make sure that all mounting bolts are engaged at least 3″ to 4″ into the wall studs. If the position of the wall studs can not be found, use 2 pieces of 6 ft 2×6 lumber
centered on the 16″ spaced wall studs and secure both pieces of lumber with 2 4″ long 3/8″ wood screws into each stud. The boiler wall bracket is then mounted on the top 2×6 piece.

Position the Wall Mount Bracket at the location that it will go, make 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.

Mounting on concrete wall If mounting to a concrete wall, use concrete anchors. If the included anchors do not suit your installation, you must use field supplied anchors that are appropriate for the wall’s construction.
4.1.3 Hang the Boiler · Remove the front door of the boiler. · Lift the boiler up with at least 2 people, align the

The FT Series 301 / 399 Heating Only Boiler

Page 15

4.2 Location and Clearances for Boiler with Optional Floor Stand (Part #: 4AC1000)
The boiler must be installed on a level surface of sufficient strength and follow the clearances listed in Table 1. Leveling feet are provided with the floor stand kit to ensure a plumb installation.
Refer to the Floor Stand Kit instructions to attach the optional Floor Stand to the bottom of the boiler.

*Note: Floor stand is 18″ tall and bolts directly to the bottom of the boiler.

Appliance Surface

Clearance from Combustibles and Noncombustible Surfaces

Back Left Side Right Side
Front Top (Alcove Install) Top (Closet Install)*

1 in (2.5 cm) 1 in (2.5 cm) 1 in (2.5 cm) 1 in (2.5 cm) 9 in (22.86 cm) 22 in (56 cm)

Vent : Category IV

3 in (76 cm)

Suggested Serviceability Clearances

Front

18 in (46 cm)

Left Side

6 in (15 cm)

Right Side

6 in (15 cm)

Top

24 in (61 cm)

Table 2. Minimum Clearances to combustibles, using Optional Stand.

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 boiler · Always check the connected components which are
near to the boiler. The components are below.
Water piping position / Venting adapter / Gas supply piping / Electrical power / Condensate drain hose. · Inspect area around boiler. Remove any combustible materials, gasoline and other flammable liquids. Failure to keep 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 boiler which has gas control system components must be protected from any possible danger during operation and service. · If the new 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 boiler 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.
This boiler must be installed upright in the vertical position as described in this manual.
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.

Page 16
4.2.1 Flooring & Leveling : Installing the FTHW301/399 on the floor.
WARNING Make sure that the floor and structure of the installation location are sufficient to support the full installed weight of the boiler, including water content of the heat exchanger and related piping. Failure to ensure the floor and structure of the installation location are structurally sound before installation of the boiler can result in structural failure, substantial property damage, severe personal injury, or death.
This boiler is approved for installation on combustible flooring, but must never be installed on carpeting. Installing this boiler on carpeting could result in fire, property damage, severe personal injury, or death.
CAUTION In order for the condensate to properly flow out of the collection system, the area where you locate the boiler must be level. Location must also fully support the weight of the filled boiler.

CORRECT

INCORRECT

Boiler levelling feet are factory supplied with the optional floor stand. * If small adjustments are required, tilt the boiler either to the left or right side and adjust the proper
levelling feet.

ALWAYS use 2 people to adjust the levelling feet due to the weight of the boiler.

Note: When moving the boiler, grab the hand-holds provided on the left and right side of the boiler and gently move the boiler to its desired location. Do not slide boiler along the floor on its boiler feet, as this may damage the feet. Rather, “walk” the boiler to its designated location by carefully rocking the boiler from left to right.

The FT Series 301 / 399 Heating Only Boiler

Page 17

4.3 Combustion Air
FTHW 301/399 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 FTHW 301/399 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 CSA 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 at every 4 foot interval and at every elbow for proper support. The unit must not support the weight of the combustion air intake pipe. Maximum linear pipe length allowed is shown in Table 64. (See page 24). Subtract the required deduction in length for each installed elbow as per Table 4.
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.

COMBUSTION AIR INSTALLATION STANDARDS

MATERIAL

UNITED STATES

CANADA

ABS

ANSI/ASTM D1527

PVC, SCH 40 CPVC, SCH 40 Polypropylene

ANSI/ASTM D1785 or D2665 ANSI/ASTM F441 UL1738, ULC S636

Air pipe material must be chosen CPVC, sch 40, ANSI/ASTM, Polypropylene based upon the intended
application of the boiler.

Single wall galv. steel

26 gauge

Table 3. Required Combustion Air Pipe Material.

Page 18

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 4.5.1) or external (per section 4.5.2). · 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 4.5 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. · Visually inspect air intake piping for interior debris or shavings. It may be necessary to wash out the air intake piping.
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, using the furnished LP conversion kit.
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 Z223.1/NFPA 54, or In Canada, the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

The FT Series 301 / 399 Heating Only Boiler

Page 19

4.4 Venting (Exhaust)
NOTICE
DO NOT COMMON VENT FT UNITS WITH OTHER MAKES OF BOILERS. 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 Z223.1/NFPA 54, 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 material. 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 (PP) and PP Flex that complies with ULC-S636, ANSI/ASTM D1785 F441 (see Table 42) 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, (PP), PP Flex or other) shall NOT be insulated or covered. Insulating 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 be from a certified manufacturer.

VENTING INSTALLATION STANDARDS

MATERIAL

UNITED STATES

CANADA

Stainless Steel PVC, sch 40

UL 1738 ANSI/ASTM D1785

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.

CPVC, sch 40 Polypropylene (PP), PP Flex

ANSI/ASTM F441 UL1738 or ULC-S636

Class IIa, PVC material is not allowed as the exhaust flue gas can exceed the max. rating of 149°F(65°C).

Table 4. Required Exhaust Vent Material.

Page 20

4 . Venting system components can only be mixed with alternate manufacturers’ certified components when clearly listed in the Boiler manufacturers Installation Manual.
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.
4.5 General Location Guideline

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.).

1. Vent system installation must be in accordance with Local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1 /NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
2. The Boiler is also designed to be installed as a Direct Vent (sealed combustion) type. The air for combustion must then 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
– Refer to Section 4.8, Table-3 for vent terminal clearances and US ANSI Z223.1/NFPA-54 / In Canada, CSA B149.1
– 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.

The FT Series 301 / 399 Heating Only Boiler

Page 21

4.6 Locations for Vent Pipe Terminator

Canadian Installations1

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

12 in (30 cm)

B = Clearance to window or door that may be opened

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)

C = Clearance to permanently closed window

See Note 4

D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61 cm) from the center line of the terminal
E = Clearance to unventilated soffit

See Note 4 See Note 4

F = Clearance to outside corner

See Note 4

G = Clearance to inside corner

See Note 4

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

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

I = Clearance to service regulator vent outlet 3 ft (91 cm)

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

6 in (15 cm) for appliances 10,000 Btuh (3 kW) 12 in (30cm) for appliances > 10,000 Btuh (3 kW) and
100,000 Btuh (30 kW) 36 in (91 cm) for appliances > 100,000 Btuh (30 kW)

K = Clearance to a mechanical air supply inlet
L = Clearance above paved sidewalk or paved driveway located on public property

6 ft (1.83 m) 7 ft (2.13 m)

M = Clearance under veranda, porch, deck, or 12 in (30 cm) balcony

U.S. Installations2
12 in (30 cm)
6 in (15 cm) for appliances 10,000 Btuh (3 kW) 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 6 in (15 cm) for appliances 10,000 Btuh (3 kW) 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 ft (91 cm) above if within 10 ft (3 m) horizontally 7 ft (2.13 m) for mechanical draft systems (Category I appliances). Vents for Category II and IV appliances cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard*
See Note 5

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. 4) For clearances not specified in CAN/CSA-B149, clearance is in accordance with local installation codes and the requirements of the gas supplier. 5) For clearances not specified in ANSI Z223.1/ NFPA 54, clearance is in accordance with local installation codes and the requirements of the gas supplier. 6) IMPORTANT: Terminal must be placed such that it remains a minimum of 12″ above maximum expected snow line. Local codes may have more specific
requirements, and must be consulted.

*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 5. Direct Vent Clearances

Page 22

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.

The FT Series 301 / 399 Heating Only Boiler
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

Page 23
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.

Page 24

4.8 Air Supply and Vent Connections

4.8.1 Vent / Air Pipe Lengths for dual pipe venting systems.

3″ Combustion Air or Vent Pipe

4″ Combustion Air or Vent Pipe

Min.

Min.

Combustion Air

Vent

Pipe

Pipe

Max.

Min.

Min.

Combustion

Combustion Air

Vent

Air or Vent Pipe

Pipe

Pipe

Max. Combustion Air or Vent Pipe

FTHW301/399 NG & LP

0 ft* (0 M)

3 ft (1 M)

65 ft (19.5 M)

0 ft* (0 M)

3 ft (1 M)

150 ft (45 M)

Deductions per 90° Elbow

5 ft (1.5 M)

5 ft (1.5 M)

Deductions per 45° Elbow

2.5 ft (.75 M)

2.5 ft (.75 M)

Max. # of Total Elbows on Air Intake/Exhaust Elbow

Intake: up to 6, Exhaust: up to 6

Intake: up to 8, Exhaust: up to 8

Table 6. Maximum Vent / Air Pipe Lengths for either 3″ or 4″ Intake Air or Exhaust Vent Pipes (PVC schedule 40, CPVC schedule 40, SS, PP)
*Appliance needs to vent outdoors using approved vent caps and following all guidelines as noted in the Installation Manual.

NOTES: · One must include all elbows on the air intake and exhaust piping in determining the maximum equivalent
length of the air intake and exhaust vent piping.

Example: 3″ venting system desired.

Air intake piping:

Two 90 elbows and 40 ft of straight pipe: 2 x 5 ft + 40 ft = 50 ft (okay)

Exhaust vent piping: Two 90 elbows and 45 ft of straight pipe: 2 x 5 ft + 45 ft = 55 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.

4.10.2 Direct Venting The FT boiler uses 3 or 4 diameter exhaust and 3 or 4 diameter intake air duct. To draw air directly from and send exhaust directly to the outside of the building, make sure to create an airtight seal from the boiler collar to the vent termination.
(For installations in Canada) field-supplied plastic vent piping must comply with 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). – Push the pipe into the collar (socket) until it touches
the bottom of the socket fitting. – For 4″ installations, install a field supplied 3″ to 4″
adaptor. Adaptor must be installed at the boiler’s exhaust connection.

3″ pipe 4″ pipe connected, using a (3″ to 4″) adapter

The FT Series 301 / 399 Heating Only Boiler

Page 25

4.9 Indoor Combustion Air
Read and follow section 4.5.1 Guidelines first. 1. Insert the termination end cap into the intake air duct.

Short pipe shown is not required. Included 3″ PVC Screen fits coupler hub size 3.5″ ID.

2. Provide two openings to allow for circulation of combustion air as specified by ANSI Z223.1/NFPA 54. In Canada refer to 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 sq. inch. per 1,000 BTU/H Table 7. Max BTU/H

FTHW301 301,000
301 in2 17.5 (W) x 17.5 (H)

FTHW399 399,000 399 in2 20″ (W) x 20″ (H)

4.10 Vent / Air Pipe Terminations
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 or 4″ vent screens are available for purchase.
3″ Vent Screen P/N – FT1730 4″ Vent Screen P/N – 10-391 (1 bird screen per part number)

4.10.1 Vertical Vent Termination
· Direct Vent – Vertical Terminations with Sloped Roof

Vent Screens are required

Page 26

Vent / Air Pipe Terminations (continued)

4.10.2 Horizontal Vent Termination (Direct Vent – Sidewall Termination)

Note: For cases
A thru C below, the location of
the exhaust
terminal MUST be downstream (or down-wind) of the location of
the combustion
air intake pipe to avoid flue gas recirculation.

Exhaust
12″ MIN Apart
NOTE: The Exhaust must be equal to or above the Combustion Intake while at a Minimum of 12″ apart.

Exterior Wall
Vent Screens are required

Exhaust
Exhaust Screen

1″ MIN 12″ MIN

90o Elbow

NOTE: Must be 12″ Minimum distance
above highest anticipated snow level or grade, whichever is
greater (TYP).

Air Intake Screen
Combustion Intake

A

FRONT VIEW

SIDE VIEW

Exhaust

Exhaust
Exhaust Screen

Exterior Wall

12″ MIN
12″ MIN

Vent Screens are required

12″ MIN 90o Elbow

1″ MIN Sill

Combustion Intake

NOTE: Must be 12″ Minimum distance
above highest anticipated snow level or grade, whichever is
greater (TYP).

Air Intake Screen
Combustion Intake

B

FRONT VIEW

SIDE VIEW

Exhaust
12″ MIN 12″ MIN
Combustion Intake

Exhaust

Exhaust Screen

12″ MIN
Combustion Intake
NOTE: Must be 12″ Minimum distance
above highest anticipated snow level or grade, whichever is
greater (TYP).

Exterior Wall
Vent Screens are
required
1″ MIN Sill

C

FRONT VIEW

SIDE VIEW

The FT Series 301 / 399 Heating Only Boiler
4.10.3 Low Profile Two-Pipe Sidewall Venting
NOTICE
Follow the manufacturer’s installation guidelines included with the Low Profile Vent Termination Kit for installation requirements and guidelines.
Failure to provide properly separated combustion air and exhaust air will result in flue gas cross-contamination which will cause shut-downs and ignition failures. Installations in alcoves or behind bushes, air conditioners,
and other obstructions, will introduce cross-contamination (exhaust air going back into the combustion air inlet) and this will result
in poor performance and reliability issues.
1. Low profile terminations must be installed in the proper orientation. See Figure 1 for possible mounting orientations.
2. Multiple Low profile terminations must be installed with a minimum horizontal separation between the edge of the air inlet and the edge of the vent of the adjacent termination of at least 36 inches (90 cm). See Figure 3.

Page 27
Exhaust (from appliance) Combustion Air (from outdoors)
*12″ Min above
grade/snow line. Figure 2. Exterior view of dual pipe termination

36″ Min between edge of air inlet and adjacent vent outlet

Figure 1. Possible orientations of low profile 2-pipe termination

*12″ Min above
grade/snow line.
Figure 3. Multiple 2 pipe low profiles termination minimum spacings

• Clearance above highest anticipated snow level or grade, or as required by local codes, whichever is greater.

Page 28
4.10.4 Flexible Vent Systems
Using flexible polypropylene in an existing vertical chimney.

NOTE : Only VERTICAL installations are allowed. Horizontal terminations are prohibited. The use of proper adapters and supports are required to fully complete the installation. The following table lists the flexible vent models that are approved for use with this appliance in addition to the maximum allowable vent lengths for the desired vent system.

Model Type.

Vent Dia.

Flexible PP

FTHW301/399

3 in

65ft

All flexible vent pipe must be installed VERTICALLY through the roof. No horizontal terminations are permitted. All installation using the flexible vent materials must be in room air for combustion only. Refer to the manufacturer’s literature for detailed information and guidelines.

NOTE : Equivalent length of horizontal piping and elbow(s) must be deducted from the maximum allowed 65 ft of 3″ flexible PP venting.

The FT Series 301 / 399 Heating Only Boiler
4.10.5 Concentric Vent Termination · Direct Vent – Optional Horizontal and Vertical Concentric Vent using 3″ or 4″ intake air and exhaust vent pipes.
NOTE: The intake and exhaust pipe lengths of a concentric termination must be included in the maximum allowed venting length calculation.
NOTE: Concentric Vent Terminations cannot be less than 36″ apart in multi-unit installations. Consult local codes and the manufacturer’s guidelines for acceptable separation distances.

Exterior Wall
Side Wall Kit (2″ or 3″)
12″ (30cm) Minimum clearance above highest anticipated snow level or grade, whichever is greater.

Page 29 Exhaust

1″ (25mm) to 4″ (100mm)
12″ (30cm) Minimum clearance above highest anticipated snow level or grade, whichever is greater.

Strap

Combustion Air

Vent

12″ (30cm) Minimum clearance above highest anticipate snow level.

Vent Combustion Air

Page 30

4.11 Gas Supply and Piping
Gas piping should be supported by suitable hangers or floor stands, near the appliance.
Review the following instructions before proceeding with the installation.
1. Verify that the Natural Gas rating plate on the appliance matches with the available gas supply. FT will function properly at elevations up to 10,000 feet (3050 m). Refer to Section 4.14 for High Altitude Settings.
2. For minimum and maximum supply pressures, see Table 11 on page 33.
3. Refer to Tables 5, 6 and 7 for proper gas pipe sizing.
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 in case the gas connection is made on the bottom of the boiler. When using the top gas connection, the boiler is equipped with an internal sediment trap.
7. All threaded joints should be coated with piping compound resistant to action of liquefied petroleum gas.
8. The unit must be isolated from the gas supply 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 PSIG (3.45kPa).
9. The appliance and its gas connection must be leak tested before placing it in operation.
10. Purge all air from gas lines.

Schedule 40 Metal Pipe Capacity for 1.6 Specific Gravity Undiluted Propane

Nominal Pipe Size @ 11″ W.C. Inlet and 0.5″ W.C. Pressure Drop

Size

1″

1-1/4″

1-1/2″

2″

Length

Maximum Capacity in Thousands of BTU per Hour

20′

787

1616

2422

4664

40′

541

1111

1664

3205

60′

434

892

1337

2574

80′

372

763

1144

2203

100′

330

677

1014

1952

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 8. Nominal Pipe Size, Propane

Schedule 40 Metal Pipe Capacity for 0.60 Specific Gravity Natural Gas

Nominal Pipe Size @ 0.30″ W.C. Pressure Drop

Size

1″

1-1/4″

1-1/2″

2″

Length

20′

350

730

1100

2100

40′

245

500

760

1450

60′

195

400

610

1150

80′

170

350

530

990

100′

150

305

460

870

Table 9. Nominal Pipe Size, Natural Gas

WARNING: Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life.
NOTE: The FT boiler and all other gas appliances sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. The gas supply pressure MUST be measured at the gas pressure test port location at the top and bottom gas connection on the boiler.. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line.

Equivalent Lengths of Straight Pipe for Schedule 40 Fittings

Nominal Pipe Size

Fitting

1″

1-1/4″

1-1/2″

2″

Linear Feet

90° Elbow 5.2

6.6

7.4

8.5

Tee

6.6

8.7

9.9

12

Table 10. Equivalent Pipe Lengths

The FT Series 301 / 399 Heating Only Boiler Gas Supply and Piping (continued)

Page 31

The gas connection fitting is, 1″ male NPT. The FT boiler is standard equipped with top and bottom gas connections. Factory standard, the top connection is capped. If the contractor wants to connect the gas supply to the top connection,
simply remove its cap and install this cap on the
bottom gas connection. The bottom connection now services as the sediment trap. If the lower gas connection is used, an external sediment trap must be installed. The supply line must be sized for the maximum output of the boiler model being installed. If there are additional gas appliances from the main
supply line, you must measure connected on
the same main gas 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 boiler. Use the tables in this manual or refer to the gas line manufacturers
sizing information to determine the correct supply pipe size.

The manual gas shut-off valve in the gas supply line should be installed close to the unit as shown below. 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 1 male NPT connection on the boiler. 1) Install an approved gas line pipe to gas line
connection gas boiler . Include manual shut off valve and gas union on top of the connection, as
shown or below the boiler, incase gas piping is brought in from the bottom.. 2) Test gas pressure to make sure it meets the minimum standards and does not exceed the
maximum standards for the 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 boiler until all connections have
been completed, checked for leaks, and ensure that the heat exchanger is filled with water.

GAS PIPE
MANUAL SHUT OFF VALVE
UNION FITTING

OPEN POSITION CLOSED POSITION
Figure 4. Gas Line Shut Off Valve

Page 32
Suggested Natural Gas (NG) 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

Suggested Propane Gas (LP) Layout
NOTE: Total gas supply capacity must not be less than the total demand capacity of the connected appliances.

Other Appliances

Gas Regulator (Supply Press 12

Gas Meter

Other Appliances
The boiler must be installed downstream of the gas meter for adequate gas supply. The gas piping must not be less than 1″ female NPT on FTHW301/399 models.

The FT Series 301 / 399 Heating Only Boiler 4.12 Gas Supply Pressure

Page 33

Supply Gas INLET port
Manifold/Offset
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 4.13 on page 34 for step by step details.
Gas OUT / Manifold Pressure Port
The Maximum and Minimum gas line pressures must be at Max Fire operation.

Photo 1. Gas Valve

LP Gas

Natural Gas

Maximum Pressure 13.0″ WC Maximum Pressure 10.5″ WC

Minimum Pressure 8.0″ WC Minimum Pressure 3.5″ WC

Table 11. Gas Supply Pressures

NOTE: The gas supply pressure must be measured at the gas pressure test port located at the top or bottom gas connection external to the boiler. This eliminates removal of the front door.
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).
Shut off the gas supply valve prior to loosening the pressure port screws before you check the gas inlet pressure.
Make sure to install the front door and engage both the top and bottom latches of the front door during combustion testing. Tighten gas pressure port screw(s) when completed with the combustion set-up.

Page 34

4.13 Adjusting Combustion

1. Remove the front cover by opening the four clips on the boiler front cover – (2 top, 2 bottom) pick up the cover and lift the cover off.
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 FTHW floor is installed at an altitude of 2,000 ft,or greater the correct altitude setting should be set according to Section 4.14 before you continue tuning this unit.
5. Check gas inlet pressure at inlet pressure test port. (See previous page).
6. Establish a call for heat. You may need to disconnect the outdoor reset if you are making this gas pressure reading during warm weather.
7. 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 13.

Note: When in Low Fire the burner should remain on. If the flame dies out after a few seconds while in Low Fire the gas input to the burner is too lean and will need to be increased slightly by using the offset adjustment. Turn the offset adjustment 1/8″ clockwise and allow burner to cycle. Only adjust clockwise until the burner is able to remain lit. Once stable on Low Fire continue onto Step 12.
12. WAIT for your combustion analyser to stabilize. Then check the CO2 measurement for MIN fire. Refer to Table 9 for acceptable MIN fire combustion readings.
13. Open the Gas Valve Adjustment Port by removing the cap screw with a # T15 wrench.
14. Then use the # T15 wrench to make a minor adjustment (1/8 turn) to either increase or decrease CO2. See Photo 1 on page 33.
15. 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.

8. Setup your combustion analyser and place the sensor into the combustion test port located on the exhaust adaptor on top of the boiler.
9. Per Section 4.15 (page 37) for Max Fire, change dip switch 6 to ON. The unit will cycle up to MAX fire.
10. WAIT for your combustion analyser to stabilize. This may take up to 3 minutes depending on your combustion analyser. Then check the CO2 measurement for MAX Fire. Refer to Table 12 for acceptable MAX fire combustion readings Do NOT attempt to adjust CO2 at MAX Fire. ONLY adjust CO2 in MIN Fire operation.
11. For MIN Fire, change dip switch 6 to OFF and 7 to ON. The unit will cycle down to MIN Fire.

16 Once the CO2 and manifold pressure measurements for both MIN and MAX Fire are acceptable, set DIP switches 6 and 7 to the OFF position for Nominal Fire (normal operation).
17. Remove your combustion analyser from the Test Port and be sure to thread the Test Port plug back into position.
18. Re-connect outdoor reset if it was disconnected, put the boiler cover back on and secure the clips that hold the cover in place.
WARNING

Standard Factory Setting is for MAX Fire. 9.0% CO2 @ 0-2,000 ft altitude (Natural Gas).

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

CO2 value

Natural Gas (NG)

3 VENT

4 VENT

Propane Gas (LP)

3 VENT

4 VENT

FTHW301/399 (all altitudes)

MAX FIRE MIN FIRE

8.5 – 10.5% 8 – 10%

9.5 – 11% 9 – 10.5 %

Table 12. CO2 Values

The FT Series 301 / 399 Heating Only Boiler

Adjusting Combustion (continued)

Manifold Pressure

FTHW301 FTHW399

Max Fire Min Fire Max Fire Min Fire

Table 13. Manifold Pressures

Natural Gas

3″ VENT -0.28″ WC -0.015″ WC -0.48″ WC -0.015″ WC

4″ VENT -0.28″ WC -0.015″ WC -0.48″ WC -0.015″ WC

Liquid Propane

3″ VENT

4″ VENT

-0.28″ WC

-0.28″ WC

-0.015″ WC

-0.015″ WC

-0.48″ WC

-0.48″ WC

-0.015″ WC

-0.015″ WC

Page 35

Note: Values in the range of -0.01 to -.50 inches of WC are indicative of proper set-up. If your values are outside this range, call technical support.

4.14 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 Boiler has an adjustment in the Installer Parameters Mode.

Follow these instructions if your installation is at 2,000′ – 10,000′.
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 `33:HA’ appears.

3. Press the dial (E).

4. Select the proper high altitude value by turning the dial.

0 – 2 2 – 5 5 – 8 8 – 10

Altitude of Installation 0 – 2,000 ft (0 – 609 m) 2,000 – 5,000 ft (609 – 1,522 m) 5,000 – 8,000 ft (1,522 – 2,436 m) 8,000 – 10,000 ft (2,436 – 3,045 m)

Derate 0% 10% 20% 25%

Table 14. High Altitude Fan Speed Adjustments

P-953EH
E

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

6. Press the `Modes button’ off.

and the display will turn

7. Push the power button on the display to turn the boiler back on.

Page 36
4.15 Natural Gas to Propane Conversion
The FTHW301 and FTHW399, condensing boilers are configured for Natural Gas (NG) from the factory. A 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.
WARNING
This gas conversion kit 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. The information in these instructions must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury or death. The qualified 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 specified 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 CSA-B149.1. Failure to follow instructions could result in serious injury or property damage. The qualified agency performing this work assumes responsibility for gas conversion.
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. 4.14
CAUTION
This boiler has already been set to burn natural gas, but can be converted to burn LP gas. Before placing the boiler into operation, verify that the proper type of gas is supplied to your boiler.

Squeeze the release button to unlatch the clasp
Photo 2. Clasps (4X)
Figure 5. Open Front Panel

Model FTHW301 FTHW399

Natural Gas (NG)
Part # FT4143 6.55 mm (0.258″)
Part # FT4118 6.7 mm (0.264″)

Table 15. Gas Conversion Parts

Propane Gas (LP)
Part # FT4119 5.40 mm (0.216″)
Part # FT4119 5.40 mm (0.216″)

Orifices

The FT Series 301 / 399 Heating Only Boiler

Page 37

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 fire, an explosion

or production of carbon monoxide may result causing

property damage, personal injury or loss of life. The

qualified 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 assumes responsibility

qualified agency performing for gas conversion.

this

work

·

1. Turn OFF the FT, by using the service switch installed by the contractor.
2. Open the 4 toggle latch clamps fixed to the top (2) and bottom (2) front door of the boiler and tip the door top forward. Remove the front door from the product by lifting the front door up and away from the boiler cabinet.
3. Turn OFF the GAS and WATER supply to the FT (valves are located on the plumbing pipes.)
4. Locate the Gas Inlet Pipe from the gas valve to the venturi as shown in Figure 6, and loosen the fittings at both ends of the Gas Inlet Pipe.
5. Completely unthread the brass fitting 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.
6. Remove the existing natural gas nozzle or orifice. Install the new LP (Propane) orifice. Use the new gaskets supplied with the LP conversion kit.
7. Return the Gas Inlet Pipe to its original position and tighten both fittings.
8. Locate the DIP Switches on the PCB.
( continues on next page )

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 vérifiée comme spécifié 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 qualifié effectuant ce travail suppose la responsabilité de conversion au gaz.

·

·

·

·

Blower

Orifice

Venturi Gasket
Gas Valve

Figure 6. Location of Orifice

Figure 7. Location of the DIP Switches

Page 38

4.15 Natural Gas to Propane Conversion (continued)
Shown is a Model 301 Natural Gas with 4″ Venting.

ON MIN Fire MAX Fire NG Natural

OFF Normal Operation Normal Operation
LP Propane

N/A Smart DHW
N/A Model Size

FACTORY SET

MBH 399

301

Table 16. Dip Switch #5 for Gas Type

Photo 3. PCB Control Board

*Dip Switches #6 and #7 (See Photo 3) are Maximum and Minimum fire test Switches which are used only when setting up combustion (See Section 4.13) These Switches should only be in the ON position during either High or Low fire Testing. When finished testing, ensure both of these switches are in the OFF position.

Dip Switches #1, 2 and 3 are Set at the factory and should not need adjusting. Dip Switch defines the boiler model: #1: ON – 399, #1 OFF: 301 Dip Switch #3 is set to ON for “Smart” DHW Priority (factory default). OFF – Regular DHW Priority. Dip Switch #4 has no function for the FT301 and FT399

When Dip Switch #3 is set to “Smart” DHW Priority,

the boiler controlling DHW production can operate for

space heating and DHW at the same time until its

firing rate exceeds 80% firing rate. Then, the boiler

shuts down its boiler pump and runs only its DHW

pump. This feature reduces rapid cycling of the

burner, avoids the boiler running up to high limit

resulting in longer burner run times at lower firing

rates and reduced thermal stress on the heat

exchanger. Once the firing rate drops below 50%, the

control system turns on the boiler pump again,

provided the CH call is still present and the boiler

temperature does not exceed the desired CH temperature range.

9. Per Table 16, 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 4.13 on page 34

12. Upon completion of set up, write in the correct Conversion Date and the Technicians Name to
the included gas conversion sticker. See Figure 8. Then apply that sticker adjacent to the rating plate.

Photo 4. Gas Valve Adjustment Port

The FT Series 301 / 399 Heating Only Boiler

Page 39

NOTE: Installer is required to verify combustion settings as part of the installation process. CO should not exceed 200 ppm.

CO2 Value

FTHW301/399 (all altitudes)

Max Fire Min Fire

Natural Gas (NG)

3 Vent

4 Vent

8.5 – 10.5%

8 – 10%

Propane Gas (LP)

3 Vent

4 Vent

9.5 – 11%

9 – 10.5 %

Manifold Pressure

FTHW301 FTHW399

Max Fire Min Fire Max Fire Min Fire

Natural Gas

3″ VENT -0.28″ WC -0.015″ WC -0.48″ WC -0.015″ WC

4″ VENT -0.28″ WC -0.015″ WC -0.48″ WC -0.015″ WC

Table 17. Manifold Pressure at Hi Fire & Low Fire

Liquid Propane

3″ VENT

4″ VENT

-0.28″ WC

-0.28″ WC

-0.015″ WC

-0.015″ WC

-0.48″ WC

-0.48″ WC

-0.015″ WC

-0.015″ WC

NOTE: Values in the range of -.01 to -.50 Inches WC are indicative of proper set-up. If your values are outside this range, call technical support.

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 8. Conversion Sticker

Page 40
4.16 Plumbing and Wiring Guidelines
This Section will show the basic plumbing diagrams AND also the electrical connections for three (3) common installation configurations.

Plumbing and

Electrical Connections

Piping diagrams will have a legend. And the electrical connections will show the devices.

Photo 5. 120 VAC Input & Pump Power Terminal Block
*Note: Do NOT connect 24 V to the T/T, L-T/T , L-T/T Sensor or DHW Sensor terminals. Only connect a dry contact closure to these terminals.

The FT Series 301 / 399 Heating Only Boiler

Page 41

Photo 6. Low Voltage Photo 7. Low Voltage, Sensors

Page 42
4.16.1 Single wall-mounted boiler with DHW heating and high and low temperature zones w/ 24 V motorized mixing valve.
4.16.1.a Plumbing

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. The minimum size of the piping to the Indirect Tank Heat Exchanger is ¾” inside diameter.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. Manufacturer strongly recommends the use of an anti-scald mixing valve at the domestic hot water (DHW) outlet from the Indirect Tank to reduce potential for scalding. Check with local codes.

5. The FTHW boiler has two heating zone inputs. Two independent heating curves may be programmed for each input. Parameters P6, P7 and P40, P41 are used to adjust the heating curves for T/T and L-T/T respectively. The FTHW boiler will provide the appropriate temperature based upon which zone is calling. If both zones are calling for heat, the FTHW boiler will default to the target temperature set for the T/T zone. The L-T/T zone is designed for a lower operating temperature. The FTHW can control a 24 V mixing valve motor and has a mixed temp sensor input/ Each of the two inputs (T/T and L-T/T) have corresponding pump relays. Ensure pumps are wired to the corresponding 120V output terminals. Turn P42 (MI) to ON to enable 24 V mixing valve operation.
6. The DHW zone will have priority over the CH and L-CH zones.

The FT Series 301 / 399 Heating Only Boiler

4.16.1.b

Wiring, Single wall-mounted boiler with DHW heating and high and low temperature zones w/ motorized mixing valve.

Page 43

Max: 1.6 Amp per pump output

From 120VAC Circuit Panel 24 VAC

120 VAC / 15 Amp Power

1. Do not bring 24 V to any terminals on the FTHW boiler. Calls for heat (either thermostat or end switch calls) must be dry contacts and should wire to the appropriate terminals.
2. Wire the Indirect tank sensor or aquastat to the DHW Temp Sensor terminals. Use parameter 39 in Section 5.7 on page 64 to define the input type (Aquastat or Resistance Sensor)
3. Connect the low and high temp heating pumps, DHW pump and mixing valve controls to the proper terminals.
4. Connect the outdoor sensor (OS) for outdoor reset operation to the O/S terminals. Strap on the mixed temp sensor for the low temp zone downstream of the mixing valve (10 pipe diameters away) and insulate the sensor and pipe.
5. Connect the ZC terminal from the relay panel back to the L/ZC terminal on the FTHW boiler. Make sure to remove the factory jumper from ZC to ZR on the relay panel. Set dip switch #3 to OFF for regular DHW priority.

6. The FTHW boiler has two heating zone inputs. Two independent heating curves may be programmed for
each input. Parameters P6, P7 and P40, P41 are used to adjust the heating curves for T/T and L-T/T respectively. The FTHW boiler will provide the appropriate temperature based upon which zone is calling. If both zones are calling for heat, the FTHW boiler will default to the target temperature set for the T/T zone. If the L-T/T zone is designed for a lower operating temperature, a 24 V mixing valve actuator is controlled by the boiler. See parameter P42 to activate this functionality. (See Section 5.7). Each of the two inputs (T/T and L-T/T) have corresponding pump relays. Ensure pumps are wired to the corresponding 120V output terminals.

Page 44 4.16.2 Floor stand application: Zoning with zone valves and indirect DHW tank pump. 4.16.2.a Plumbing
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. The heat exchanger in the Indirect Tank (by others) is piped as a separate zone. The indirect pump must be sized for the combined pressure drop the FTHW boiler and coil size pressure drop.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4. Manufacturer strongly recommends the use of an anti-scald mixing valve at the hot water outlet of the
Indirect Tank to reduce the potential for scalding. Check with local codes. 5. The tank aquastat or DHW sensor connects back to the DHW sensor terminals. Use parameter
39 in Section 5.7 on page 64 to define aquastat (default) or DHW sensor setting to the boiler. 6. Connect the Outdoor Sensor (OS) for outdoor reset operation to the O/S terminals. 7. In case “Smart” Priority is enabled by setting dip switch #3 to ON, the boiler pump P1 can operate during a
DHW call. As the firing rate exceeds 80%, the control shuts down P1 while P4 continues to operate. This feature reduces rapid burner cycling and allows more gradual heat-up of the boiler. P1 turns ON again once the firing rate drops below 50%. Important note: The DHW Pump P4 must be sized for the DHW Indirect require flow rate and Total Head Loss through the DHW Indirect coil, piping and boiler head loss.

The FT Series 301 / 399 Heating Only Boiler

4.16.2.b

Wiring with zone valves and indirect DHW tank
THERMOSTAT THERMOSTAT THERMOSTAT

24 VAC INPUT

MODE

NORMAL

POWER IN

RESET

T T ZONE 1

T T ZONE 2

T T ZONE 3

ZONE 4 PRIORITY
OFF ON
T T ZONE 4

FUSE (3 AMP MAX)

ZVC 404
FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY

END SW.

N/O C N/C

ZONE 1 1 2 3 4

ZONE 2 1 2 3 4

ZONE 3 1 2 3 4

ZONE 4 1 2 3 4

POWER

DRY CONTACTS

JUMPER 3 & 4

2 WIRE ZONE VALVE (NO END SWITCH)

1 2 3
3 WIRE ZONE VALVE

MOTOR END SW.
4 WIRE ZONE VALVE (POWER OPEN SELF CLOSING)

DHW Temperature Sensor or Aquastat
(18 Gauge Wire)

Page 45

MAIN POWER BOILER PUMP SYSTEM PUMP L-T/T PUMP

DHW PUMP

LNGLNG LNGLNGLNG

R 0~10V W AC24V (+) INPUT (-) OUTPUT

LWC

CASCADE SYSTEM SENSOR

DHW TEMP. SENSOR

N CW CCW MIXING VALVE

L-T/T

L-T/T TEMPERATURE
SENSOR

T/T

O/S

120 VAC/ 15 Amp Power

(P1)
Boiler Pump
(14 Gauge Wire)

(P2)
System Pump
(14 Gauge Wire)

(P4)
DHW Pump
(14 Gauge Wire)

Non-Power Switch Dry-contact to L-T/T and T/T Only

1. The traditional Taco SR-504 zone switching relay panel was used for illustrative purposes; other, similar zone relay panels may be used. The relay panel does not require hot water priority because it is provided by the FTHW boiler control. Modern zone switching relay panels with 2 end switches can be wired directly to the T-T and DHW terminals without a ZC connection. End switches must be dry contacts only. Refer to item 7 below for proper setup of parameter P39.
2. Connect the end switch from the high temperature zone relay panel back to the T/T terminals on the FTHW boiler.
3. Do not bring 24 V back to the T/T, L-T/T and DHW terminals. Only a dry contact switch is permitted.
4. Connect all heating zone circulators to the relay panel as indicated.
5. Connect the outdoor sensor (OS) to the OS terminals on the lead boiler.
6. The tank aquastSection 5.7 on page 64 sensor connects back to the DHW sensor terminals of 1 or 2 follower boilers. Use parameter 39 in Section 5.7 to define aquastat or DHW sensor setting to the boiler.
7. A call for DHW has priority over the T/T and L-T/T calls and the Follower boilers will ramp up to high temperature for DHW production. The lead and other Follower boilers (except for DHW boilers) will continue to operate for space heating. If Smart Priority is selected for boiler 2 and/or 3, those boilers will continue to operate their individual boiler pump (P1) during a DHW call until boiler firing rate exceeds 80%. Boiler pump(s) come on again once the firing rate drops below 50%.
8. This system allows simultaneous space heating using outdoor reset via the lead boiler and priority DHW heating via 1 or 2 follower boilers

Page 46 4.16.3 Cascade system with separate control of space heating and DHW heating. 4.16.3.a Plumbing The DHW Pumps B2-P4 & B3-P4 must be sized for the DHW Indirect require flow rate and Total Head Loss through the DHW Indirect coil, piping, and respective Boiler B2 & B3 head loss.
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. The minimum size piping to the Indirect Tank heat exchanger is 1″ to 1-1/2″ inside diameter. 3. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4. The low loss header must be sized based on the total CH load and desired delta T on the system. 5. The lead boiler must be placed on the right; the cascade sensor must be placed on the system size of the low loss header. 6. The heat exchanger in the Indirect Tank shall be piped as a separate zone to one or both follower boilers. A DHW load is a
boiler direct demand. Power the pump for the indirect tank from the DHW tank terminals. The (dry contact) aquastat or DHW sensor connects back to the DHW sensor terminals of the boiler. (See parameter 39, Section 5.7 on page 64 for proper programming of DHW sensor or aquastat). 7. Manufacturer strongly recommends the use of an anti-scald mixing valve at the hot water outlet of the Indirect Tank to reduce the potential for scalding. Check with local codes. 8. In case “Smart” Priority is enabled by setting dip switch #3 to ON (Default) on boilers B2 and B3, their respective boiler pump P1 can operate during a DHW call. As each boiler’ firing rate exceeds 80%, the control shuts down P1 while P4 continues to operate. This feature reduces rapid burner cycling and more gradual heat-up of the boiler. This feature works individually for each boiler connected to a DHW load and allows the boiler plant to provide different water temperatures at the same time. P1 turns ON again once the firing rate drops below 50%.

The FT Series 301 / 399 Heating Only Boiler

Page 47

4.16.3.b Wiring of cascade system with separate control of space heating and DHW heating.

Boiler Cascade Harness FT1861 wiring missing in diagram.

FT1868

1. The traditional Taco SR-504 zone switching relay panel was used for illustrative purposes; other, similar zone relay panels may be used. The relay panel does not require hot water priority because it is provided by the FTHW boiler control. Modern zone switching relay panels with 2 end switches can be wired directly to the T-T and DHW terminals without a ZC connection. End switches must be dry contacts only. Refer to item 7 below for proper set-up of parameter P39.
2. Connect the end switch from the high temperature zone relay panel back to the T/T terminals on the FTHW boiler.
3. Do not bring 24 V back to the T/T, L-T/T and DHW terminals. Only a dry contact switch is permitted.
4. Connect all heating zone circulators to the relay panel as indicated.
5. Connect the outdoor sensor (OS) to the OS terminals on the lead boiler.
6. The tank aquastat or DHW sensor connects back to the DHW sensor terminals of 1 or 2 follower boilers. Use parameter 39 in Section 5.7 on page 64 to define aquastat or DHW sensor setting to the boiler.
7. A call for DHW has priority over the T/T and L-T/T calls and the Follower boilers will ramp up to high temperature for DHW production. The lead and other Follower boilers (except for DHW boilers) will continue to operate for space heating. If Smart Priority is selected for boiler 2 and/or 3, those boilers will continue to operate their individual boiler pump (P1) during a DHW call until boiler firing rate exceeds 80%. Boiler pump(s) come on again once the firing rate drops below 50%.
8. This system allows simultaneous space heating using outdoor reset via the lead boiler and priority DHW heating via 1 or 2 follower boilers

Page 48

– 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 top connections of the unit.
– The Boiler supply and return connections are 1-1/2″ NPT. System piping should be sized based on your design load and flow requirements. Refer to sections 4.16.4 through 4.16.8 for details.
– Isolation valves (shutoff valve) should be used.
– All piping should be insulated.
4.17 Applicable Backflow Preventer

CAUTION
The FTHW301/399 boiler is equipped with top and bottom water connections. Return connections are located on the right side; supply connections are located on the left side of the boiler. One must use 1 return and 1 supply connection, or one can use more than 1 depending on your application. Refer to the 4.16 for typical piping and wiring scenarios.
CH pipe size : Two 1-1/2″ female NPT caps are provided to close off unused water connections. One cap has a 3/4″ threaded opening for a plug (furnished) or boiler drain (not furnished). In case top connections are used, a boiler drain can be installed in this cap at the bottom right water connection or use the 3/4″ plug.

– Apply a backflow preventer valve in the DHW supply inlet (water Inlet) to the system as required by local codes.
4.18 Hydronic Accessories and Water side Pressure Drop.

CAUTION
For guidelines in the use of Glycol Products. Please refer to Section 9.3 on page 82

– 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.
– Install the supplied brass adaptor, automatic air vent and relief valve on the top front left piping connection.
– One can use the 1-1/2″ threaded outlet connection of the brass adaptor for a supply connection or cap this connection with the 1-1/2″ cap provided.
– If an external LWCO or externally manual reset high limit is required/ desired, the horizontal body of the brass adaptor fitting has a 3/4″ connection for a remote LWCO or manual reset high limit aquastat.

CAUTION
Scalding Risk: Manufacturer strongly recommends the installation of an anti- scald mixing valve at domestic hot water outlet (indirect tank location) to reduce potential for scalding.
Check with local codes

The FT Series 301 / 399 Heating Only Boiler

Page 49

Water side Pressure Drop
12.0

10.0

Pressure Drop (ft of head)

8.0

6.0

4.0

2.0

0.0
0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

Water Flow (GPM)

Figure 9. Water side pressure drop versus water flowrate for FT301 and FT399 Models

NOTE: Pipe size is 2″ for boiler pump selection and 30 ft of pipe.

4.19 Boiler pump (P1) selection for primary/secondary piping

Model 301 399

Delta T = 20F TACO 0012
N/A

Table 18. Taco Circulators

Delta T = 25F N/A
TACO 0012

Delta T = 30F TACO 0010 TACO 0012

Delta T = 40F TACO 007 TACO 0010

Model 301 399

Grundfos Circulators

Delta T = 20F N/A

Delta T = 30F UPS15-58

N/A

UPS43-44

Delta T = 40F UPS15-58 UPS15-58

Table 19. Grundfos Circulators NOTE: Pipe size is based on 1″ for indirects with 10 ft of pipe.

Indirect pump (CPo4m) smeelerccitaiol ntybpaesIenddiorencCtsommercial type Indirects.

Model

TACO Pump

Grundfos pump

65 gallon

TACO 0012

UPS43-44

80 Gallon

TACO 0012

UPS43-44

120 gallon

TACO 0012

UPS43-44

Table 20. Commercial Type Indirects

Page 50
4.20 Pressure Relief Valve
External pressure relief valve 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 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″ 30 psi Relief Valve and Auto Air-Vent (Eliminator)

A special brass adaptor, air eliminator and relief valve are supplied in the accessory box. Install this fitting on the top left 1-1/2″ NPT connection as shown here. This safety relief valve (30 psi) is shipped loose for field installation. Install the air eliminator and relief valve as shown. For safety, the relief valve must be installed into its designated 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 to a nearby floor drain so that hot water will not splash on anyone or any nearby equipment. Attach the hard piped copper discharge line to the pressure relief valve and run the end of the full port line within 6-12 (150 – 300mm) of the floor. A separate external LWCO can be installed by removing the 3/4″ plug on the brass adaptor to install the LWCO.
WARNING
DO NOT install a CH pipe line relief valve with a pressure higher than 50 psi. This is the maximum allowable relief valve setting for the 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 replacement pressure relief valve is equal to or greater than the maximum input rating of the boiler.

Boiler Outlet brass adapter
CAUTION The included Pressure Relief Valve (PRV) must be installed immediately at the brass adaptor, which itself must be installed at the top of the boiler outlet, without any valves in between.
ATTENTION PVR (inclus) doit etre installe sur l’adapture de brass immediate a la sortie de la chaudière. On doit pas install un vane entre le PVR et la chaudière.

The FT Series 301 / 399 Heating Only Boiler

Page 51

4.21 Disposal of Condensate
· High efficiency gas condensing boilers create condensation when operating. Condensation is acidic with a pH ranging from 4 to 5.
· Install the furnished condensate trap through the opening in the bottom of the boiler cabinet and secure with the screws provided.
· Attach the supplied condensate drain hose to the installed condensate trap. Make sure to attach the 1/8″ air vent tube and secure this 6″ long hose to a bracket so it will not spill condensate. Follow your local code with regards to the disposal of condensation.
One of 3 disposal methods must be followed 1. to a floor drain 2. Combination neutralizer and condensate pump
kit (optional kit Part # FT3007 available from manufacturer) 3. to a 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 3/4″ PVC, CPVC, Polypropylene pipe or included plastic hose.
· When placing the FT3007 kit or other suitable condensate pump/ neutralizer combination below or near the cabinet, it may be necessary with a small clip (not provided) to secure the condensate hose coming from the trap to this cover. One can also use the soft plastic insert, shorten the condensate drain hose and carefully “thread” the hose into this insert and place it into its designation location of the FT3007 kit.
· A small piece of velcro is provided to secure the condensate hose or small air tube to jacket side/rear panel.

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.
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.

Condensate Trap

Page 52
4.22 Electrical Wiring Connections FTHW 301/399 Boiler Electrical Circuit Requirement: 120VAC, 15 Amps, Single-Phase. 120 V field wiring connects to the bottom terminals on the 120 V strip. Pump connections: Max 120 V, 1.6 Amps. Note: For pumps over 1.6 Amps, use 120V isolation relay/starter and separate pump power circuit. Low voltage field wiring connects to the upper terminals on the low voltage terminals.
See Section 4.16 on page 40 for typical Field Connections.

High Voltage Terminals

Low Voltage Terminals

0-10 VDC Signal Input, 24 VAC Output, External

LWCO, Cascade Sensor, DHW Sensor

24 VAC Mixing Valve, L-T/T, L-T/T Sensor, T/T, OS

WARNING
Install 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 that the FT boiler is hard wired directly into a separate breaker with proper grounding. A service switch must be installed near the boiler as per local code.
Do not attach the ground wire to either the gas or the water piping as plastic pipe or dielectric unions may isolate the 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)

The FT Series 301 / 399 Heating Only Boiler 4.23 DIP Switches

Page 53
The DIP Switches are located at the bottom of the Printed Circuit Board (PCB). The PCB faces forward at the inside of the boiler. Remove the cover to locate the PCB.

ON MIN Fire MAX Fire NG Natural

OFF Normal Operation Normal Operation
LP Propane

N/A Smart DHW
N/A Model Size

FACTORY SET

MBH 399

301

Table 21. Dip Switch Settings Shown is a Model 301 Natural Gas with 4″ Venting.

*Dip Switches #6 and #7 are Maximum and Minimum fire test Switches which are used only when setting up combustion (See Section 4.13 on page 34). These switches should only be in the ON position during either High or Low fire testing. When finished testing, ensure both of these switches are in the OFF position.

Dip Switches #1 and 2 are Set at the factory and should not need adjusting. Dip Switch #1 defines the boiler model: #1: ON – 399, #1 OFF: 301

Dip Switch #3 set to ON for “Smart” DHW Priority. OFF – Regular DHW Priority.

System Control Setting Maximum flame detecting voltage Pre-purge time (Tp) Safety Time (igniting time) (Ts) Igniting interval time Post-purge time (Tip) Over-heating 1,2,3 protection detection time Pump1 post circulating time (T1pv) Pump2 post circulating time (T1pv) High & Low Water Level detection time High & Low Water Level Recover time

2.4V Maximum 10s, minimum 1s 2s 10s 120S (1st : 60s + 2nd 60s) <3s 60s 60s <6s <6s

Page 54 4.24 Control Board, Electrical Diagram
Control Board, NGTB-1000C (399 MBH)

NGTB-1000C (399K BTU)

L T/T OP Water Sensor
DHW Sensor Return Sensor Exhaust Sensor
L T/T Sensor System Sensor

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

W W
Y
Y Y
BK
BL BL
BL BL
BK W
BK R

M

1 PWM W

4 DC24V R

2 GND

BL

5 GND

BK

6 RPM

Y

HIGH Limit APS

LWCO

LOW Water Level Sensor

GND GND
LW COM

RS-485 RS-485 (cascade) (BACnet)
54321 3 2 1
BA BA A B

G BK W

W

W G BK G

16 8 15 7 R RO O
MIX
3 21
NC GND NO
W R BK

14 6 WW
12 4
W R

10 2
T/T
11 3 VV G
BK

Flame Rod COM
1
G/Y AC 24V TRANS
12 R BK

Display Control

0-10V O/S

BK 24VAC_N

3

W

CCW

2

Y

CW

1

MIXING V/V

CO2
WPS

1 VCC

R

2 GND

BK

3 PWM

G

4 HD

W

5 RX

Y

6 TX

BL

1 VCC

BK

2 GND

W

3 SIGNAL R

CN4 LWD1140-06(WHT) H:CHD1140-06(WHT) T:CTD1140
CN19 SMW250-06(WHT) H:SMH250-06(WHT) T:YST025
CN3 SMW250-06(RED) H:SMH250-06(RED) T:YST025

CN7 LWD1140-14(WHT) H:CHD1140-14(WHT)
T:CTD1140

CN18 SMW250-05D(WHT) H:SMH250-05(WHT) T:YST025

CN1

CN23

SMW250-03D(WHT) SMW250-03D(RED)

H:SMH250-03(WHT) H:SMH250-03(RED)

T:YST025

T:YST025

IC3 IC14

CN11
LWD1140-16(WHT) H:CHD1140-16(WHT) T:CTD1140

CN21 LWD1140-02(WHT) H:CHD1140-02(WHT) T:CTD1140

CN22 LW6A4-03(YEL)
H:SMH600-03B1(YEL) T:SMT603B-L

CN10 LW6A4-03(WHT) H:SMH600-03B1(WHT) T:SMT603B-L
CN20 LWD1140-04(WHT) H:CHD1140-04(WHT) T:CTD1140

Color Designations (15-3.11 of ANSI Y14.15)

Black (BK)

Brown (BR)

Red (R)

Orange (O)

Yellow (Y)

Green (G)

Blue (BL)

Vio

(V)

Gray (GY)

White (W)

CN8

MCU ISP

CN15 SUB MCU ISP

NAME:NGTB-1000C REVISION:A01 DATE:2023.05.12;NANOKEM MADE IN KOREA

CN16 YDW236-01(WHT) H:YDH236-01(WHT)
T:YDT236-SSB

CN2 OUTSIDE GAS SENSOR

CN9 65001WS-12(WHT) H:65001HS-12(WHT) T:65001TS

R 3 Ground

BL 2 BK 1

M ebm papst

Y

2

BK

4

W

3

BL

1

V

12

V6

BL 11

BK 5

R

10

R4

BK

9

W3

W

8

BK 2

G

1

Low temp pump DHW pump
Gas Valve High temp pump Ignitor Boiler Pump AC 120V Netural AC 120V Live CASE_EARTH

R

Flame Rod

The FT Series 301 / 399 Heating Only Boiler 4.25 Ladder Diagram

Page 55

F/ B
level & Flame rod

Page 56

4.26 Electrical Connections, (table) Connector

, Location, Type

CN1 SMW250-03D
CN3 SMW250-06D
CN4 LWD1140-06
CN4 LWD1140-14
CN8 SMW250-04D
CN9 65001WS-12

PIN

Label

1

2

RS485

(BACnet)

3

1

2

WPS

3

4

–

5

–

6

–

1

2

3

FAN

4

MOTOR

5

6

1

2

3

4

5

6

7

Temperature

8

Sensor

9

10

11

12

13

14

1

2

Flash

3

Write

4

1

2

3

4

5

6

AC Output

7

Power

8

9

10

11

12

Description
data (-) data (+) GND
VCC(5V)
GND
WPS –
PWM GND DC 24V GND RPM L T/T OP Water Temperature Sensor DHW Temperature Sensor Return Temperature Sensor Exhaust Temperature Sensor L T/T Temperature Sensor System Sensor(or Over-Heat) GND GND GND GND GND GND GND GND Nreset Flash Write VCC(5V) Case Earth Phase Boiler Pump Ignitor High Temp Pump Gas Valve Earth Neutral AC Boiler Pump Com AC Ibnitor Com AC High Temp Pump Com AC Gas Valve Com

HT SELV

The FT Series 301 / 399 Heating Only Boiler

Connector

, Location, Type PIN

1

CN10 LW6A4-03

2

3

1

2

3

4

5

6

7

CN11

8

LWD1140-16

9

10

11

12

13

14

15

16

CN16 YDW236-01P

1

1

2

CN18 SMW250-05D

3

4

5

1

2

CN18

3

SMW250-06D

4

5

6

1

CN20

2

KWD1140-04

3

4

CN21

1

LWD1140-02

2

1

CN22 LW6A4-03

2

3

1

CN23 SMW250-03D

2

3

Description Label

EBM PAPST
Safety Function
Flame Rod Cascade
CO2 Sensor
PUMP AC 24V Trans Mixing
Valve MIX

L N Earth LW Com Sensor LW Com Sensor T/T Thermostat(+) VCC(5V) VCC(12V) High Limit VCC(12V) High Water Level Low Water Level GND Thermostat(-) GND LWCO APS High Limit
Flame Roc
Data(+) Data(-) GND Data(+) Data(-) VCC(5V) GND PWM HD RX TX DHW Pump Low Temp Pump N N 24VAC_L 24VAC_N CW CCW 24VAC_N GND MIX_NO MIX_NC

Page 57
HT SELV

Page 58

Control Display and Operation

5.1 Control Dial and Buttons

(Status Light) (Constant green
when operating normally)

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 Boiler and to change temperature set points, set system variables and controller parameters.

Buttons

PRESS (Tap)

Functionality PRESS and HOLD (5 seconds)

A

Display Power

Turns control Display ON/OFF

B

Modes Tap to return to menu

(If Display Power was on) Status Display Mode Installer Mode

C

Heating Water

CH set point change mode (Maximum 82°C (180°F))

(Only functional when no outdoor sensor is connected)

D

Time/Date Set

No Change

To SET:Year/Month/Week/Day/Time/Min

E

Scroll/ Select

Menu select or value up(+) /down(-) or setting dial

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.

WARNING
Do not use this appliance if any part has been
technician to inspect the appliance and to replace any part of the control system and any gas control that may have been under water.

The FT Series 301 / 399 Heating Only Boiler 5.2 LCD Overview

Page 59

Symbol

Name Service Reminder Mode

Description Service Reminder Mode Indication

Outside Temperature Mode

Outside Temp Setting Indication

Anti-freeze Mode

Anti-Freeze Mode Indication

Storage Mode

Storage Mode Indication

Informations Mode

Information Mode Indication

Communication State
Time /FGR reading/ FGR accumulator counter
Fan Operating Mode

Communication State Indication
Display cycles through actual time, Flue Gas Recirc (FGR) reading and FGR accumulator counter when burner is operating
Fan Operating Mode Indication

Flame Signal

Flame Signal Indication

System Pump Mode

System Pump Indication

DHW Pump Mode

DHW Pump Indication

Boiler Pump Mode

Boiler Pump Mode Indication

L-TT Pump Mode

L-TT Pump Mode Indication

Celsius Mode

Indicated as Celsius Temperature

Fahrenheit Mode

Indicated as Fahrenheit Temperature

Heat Demand Mode

Heat Demand Mode Indication

Day Mode

Current Day Mode Indication

Cascade System Connecting Mode

Cascade System Connecting Mode Indication

Cascade System Operating Mode

Cascade System Operating Mode Indication

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

Page 60
5.3 Operating Mode
Operating Mode After the Power is turned on, and/or the Control Display is turned on , the Control Display will go through a Start Up’ checklist and briefly show a sequence of diagnostic codes before entering into the Operating Mode’. It will then display the following information.
oPLX-9T5R3gEdH

Indicator Current Operating Temperature Set point If the Fan is operating If a flame is detected Celsius or Fahrenheit Time /CO2 reading/ CO2 accumulator counter If Outdoor Temperature Sensor is Operating If there is a demand for Central Heat (CH) If boiler pump is operating If communication state is activated

Indicator
or

The Control Display can operate through user and service modes that have specific LCD outputs and dedicated controls:

· Set-Point change mode · Error mode
· Outside Temperature mode

· Lock mode · Status Display mode
· Installer mode

• Control Display will not allow changing of button in case of lock mode activation.

The FT Series 301 / 399 Heating Only Boiler 5.4 Setting the Clock

Page 61

P-953EH
E

The P-953EH Control Display does NOT have a daily timer or programmable thermostat.

Setting the Clock.

a. Press and hold the
the dial E to Save.

E Clock button’ for about 5 seconds. Set theYear’ by turning the dial . And then, press

E E b. Set the `MON’ (Month) by turning the dial to the desired month number. Then press the dial to Save.

E E c. Set DATE (1-31, Day of the Month) by turning the dial . Then press the dial to Save.

E E d. Set HOUR (1-24, Hour of the Day) by turning the dial . Then press the dial to Save.

E E e. Set MIN (1-60, Minute of the Hour) by turning the dial . Then press the dial to Save.

E E f. Set HOUR (1-24, Hour of the Day) by turning the dial . Then press the dial to Save.

To Exit at any time, tap the

button.

Page 62
5.5 CH Set Point Change Mode
CH set point Change Mode (This mode is only functional when the outdoor sensor (O/S) is not connected.)
In accordance with the United States Energy Policy and Conservation Act, this boiler is equipped with outdoor reset capability, a feature that saves energy by reducing boiler water temperature as heating load decreases Refer to Section 5.9 regarding the O/S details.

P-953EH

B

C

E

A

D

To change the high temperature CH Setpoint:
· Press the C button once: The CH icon, 1:Ht and its current setpoint value will appear. · Turn dial E clockwise to increase, and counterclockwise to decrease it value to reach desired set point. · Press dial E to save the value and exit.
To change the low temperature CH Setpoint (if applicable):
· Press the C button twice: The CH icon, 2:Lt and its current setpoint value will appear. · Turn dial E clockwise to increase, and counterclockwise to decrease its value to reach desired set point. · Press dial E to save the value and exit.

Indicate Table 22. Current CH Temperature Set point

Indicator

Table 23. Celsius or Fahrenheit

or

Table 24. If Communication state is activated

Table 25. If flame is detected

Time /CO2 reading/ CO2 accumulator counter

Table 26. If CH pump is operating
Table 27. If there currently a Demand for Central Heat (CH)
Default value for CH 1:Ht is 140°F (60°C). Factory set range is 130°F to 180°F ( 54°C – 82°C). This range can be adjusted per Installer Modes P6 and P7. See Section 5.7 on page 64. If applicable, default value for CH 2:Lt is 140°F (60°C). Factory set range is 130°F to 180°F ( 54°C – 82°C). This range can be adjusted per Installer Modes P40 and P41. See Section 5.7 on page 64.

The FT Series 301 / 399 Heating Only Boiler

Page 63

5.6 Status Display Mode

To view any Status Parameter,

Press and Hold Button B Display Mode.

to get into the Status

Rotate Dial E until you find the Parameter that you wish to view. Tap Dial E to enter that Parameter as required. Press Dial E to save and to exit the Status Information Menu. To go to the Operation Screen, Press button B.

P-953EH

Digital Display

Status Display Parameter

Description

O: ot

Outdoor temperature

Current outdoor sensor temperature

A: In

0-10 V display

Current voltage of (0-10V input)

1: CH CH target temperature

Current CH target temperature

2: dH DHW target temperature b: tt
3: SY SYSTEM target temperature

Current DHW target temperature Current SYSTEM target temperature

4: Lt LT/T target temperature

Current LT/T target temperature

C: It

CH water return temperature

Current CH water return temperature

d: Fr

Fan Speed (rpm)

E: oP

CH supply temperature (Operating temperature)

F: Eh

Exhaust gas temperature

H: dH

Indirect DHW tank temperature * If a temperature sensor is not connected then it will display with 0°F (0°C).

1: PH

Time for supply power

Current Fan Speed (rpm) Current heating temperature Current exhaust gas temperature Current DHW tank temperature
Unit : 1000hour

2: rh

Time for burner operation

3: rH

Time for burner operation

L: rt

Burner Operation Time

4: It

Cycle for ignition

5: IH

Cycle for ignition

6: C2

Current accumulated count

SELF Percentage of self units running.

M: CC ALL Capacity for all operating cascade units

F1 – F14 Capacity for individual boilers

System Temperature (cascade mode)

N: st

• If system temperature sensor is not connected then it will

display with 0°F (0°C).

O: Lt

L-TT Temperature (L-TT mode)

Unit : 1hour

L: rt on display on sub menu

Unit : 1,000hour

Cycle : 10 times the displayed unit

Cycle : 10,000 times the displayed unit
Cycle : Increase by 1 at the time of operation above the ppm reference value (Display accumulative count / 10)

Percentage of self units running.

Percentage of all cascade units running. This screen shows the overall cascade power output. The range of this value of boilers communicating with the Master x 100. For example, if 4 boilers are connected and communicating, the maximum cascade power is 400% . Range: 0-100%

Percentage of each cascade units running. Ex. F1, F2, …

Current System Temperature (cascade mode)

Current LT/T target temperature (L-TT mode)

P: FM

Volt Flame Current Volt

Current Volt Flame Current Volt

r: AP

APS Volt Current air pressure sensor Volt

Current air pressure sensor Volt

S: C2

Flue Gas Recirc Current sensor ppm

Current flue gas recirc (FGR) sensor ppm Ex. Ppm = 6000 Marked as 600

Page 64
5.7 Installer Mode
These changes are to be made only by a qualified technician.

P-953EH

B

C

E

A

D

WARNING
For Low temperature heating applications, adjust P6 to desired value. For cascade applications, adjust P31 to desired water temperature. Call Technical services for assistance in changing settings.

To change any of the Installer Parameter,

Start by turning OFF the Power

(Button A) to the Display Control.

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

to get into the Installer Mode.

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 using Dial E and then press (tap) Dial E to save and to Exit.

Finish by pressing button B

and then turning the power back on to the control (Button A).

Index Numbers
1: EH

Default

2: cE

OFF

3: In

OFF

4: OH

68°F (20°C)

5: OL

30°F (-1°C)

6: cH

180°F (82°C)

Parameter

Description

Error history up to 10 Delete Error history
System initialize
Maximum Outdoor Temperature
Minimum Outdoor Temperature
Maximum Supply Temperature

Check last 10 error codes (E0 – E9)
Select “ON” to delete error code history Range: ON or OFF
Select “ON” to reset to factory setting
When used with an outdoor sensor, sets the maximum outdoor design temperature for the system design. Maximum outdoor temperature must be set at least 9°F above the minimum outdoor temperature. Range: (Minimum Outdoor Temperature + 9°F) to 110°F
Sets the minimim outdoor design temperature for the system. Minimum outdoor temperature must be set at least 9°F below the maximum outdoor temperature. Range: -4°F to (Maximum Outdoor Temperature – 9°F) – 180°F
Sets the maximum design supply temperature based on the minimum outdoor design temperature. Maximum supply temperature must be set at least 9°F above the minimum supply temperature. Range: (Minimum Supply Temperature + 9°F) – 180°F

The FT Series 301 / 399 Heating Only Boiler

Page 65

5.7 Installer Mode (continued)

Index Numbers

Default

7: cL

130°F (54°C)

8: OF 9: bt 10: bd 11: bl

100°F (38°C)
0
10°F (6°C)
20 Min

Parameter
Minimum Supply Tempe

References

• kgf.cm - kgf Resources and Information.
• Laars Boilers and Water Heaters for Residential and Commercial | Laars
• P65WARNINGS.CA.GOV

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