400 Fire Tube Boiler

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Product Information

Specifications

• Model Numbers: 400, 500, 600, 725, 850
• Material: Stainless steel heat exchanger
• Gas Type: Natural Gas

Product Usage Instructions

Installation

1. This product must only be installed by a qualified heating
installer or service technician.

2. Read all instructions in the manual and the FTXL Service
Manual before beginning the installation process.

3. Follow the steps provided in the manual in the given order to
ensure proper installation.

Operation

1. Have the boiler serviced and inspected by a qualified service
technician at least annually.

2. Consider piping and installation when determining the
location for the boiler.

3. Do not install the unit in locations where gasoline or
flammable vapors are present.

Maintenance

1. Regularly inspect and maintain the boiler to ensure efficient
operation.

2. Follow the maintenance guidelines provided in the manual to
prolong the lifespan of the product.

FAQ

Q: What should I do if I smell gas?

A: If you smell gas, follow these steps
immediately:

• Evacuate the area and ensure everyone is at a safe
  distance.

• Avoid using any electrical devices or creating sparks.

• Contact your gas supplier or emergency services to report the
  gas smell.

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FTXL-I-O_100059358_2000005000_Rev AC
Installation & Operation Manual Models: 400, 500, 600, 725, & 850

WARNING

This manual must only be used by a qualified heating installer / service

technician. Read all instructions,

including this manual and the FTXL

Service Manual, before installing.

Perform steps in the order given.

Failure to comply could result in

severe personal injury, death, or

substantial property damage.

Save this manual for future reference.

Contents

HAZARD DEFINITIONS ………………………………………….. 2 PLEASE READ BEFORE PROCEEDING ………………… 3 THE FTXL — HOW IT WORKS ……………………………… 4-5 RATINGS ……………………………………………………………….. 6 1. DETERMINE BOILER LOCATION Provide Air Openings to Room …………………………………… 9 Flooring and Foundation …………………………………………… 9 Residential Garage Installation …………………………………… 9 Vent and Air Piping …………………………………………………… 9 Prevent Combustion Air Contamination ……………………….. 9 Corrosive Contaminants and Sources ……………………….. 10 Using an Existing Vent System to Install a New Boiler … 10 Removing a Boiler from Existing Common Vent………….. 11 2. PREPARE BOILER Remove Boiler from Wood Pallet ………………………………. 14 Gas Conversions………………………………………………… 14-15
Model 400 – 500…………………………………………………. 14 Models 600 – 850……………………………………………….. 15 3. GENERAL VENTING Direct Venting Options …………………………………………….. 16 Install Vent and Combustion Air Piping ……………………… 17 Requirements for Installation in Canada…………………….. 18 Sizing ……………………………………………………………………. 18 Min./Max. Combustion Air & Vent Piping Lengths ………… 18 Materials…………………………………………………………………. 18 Optional Room Air …………………………………………………… 19 PVC/CPVC ………………………………………………………… 20-21 Polypropylene…………………………………………………………. 22 Stainless Steel Vent ………………………………………………… 23 4. SIDEWALL DIRECT VENTING Vent/Air Termination – Sidewall…………………………….. 24-27 Determine Location………………………………………… 24-26 Prepare Wall Penetrations………………………………. 26-27 Multiple Vent/Air Terminations ………………………………….. 27 Sidewall Termination – Optional Concentric Vent ……. 28-30 5. VERTICAL DIRECT VENTING Vent/Air Termination – Vertical ……………………………… 31-32 Determine Location…………………………………………….. 31 Prepare Roof Penetrations ………………………………….. 32 Multiple Vent/Air Terminations ………………………………….. 32 Vertical Termination – Optional Concentric Vent……… 33-34 Alternate Vertical Concentric Venting ……………………. 35-36

6. HYDRONIC PIPING System Water Piping Methods………………………………….. 37 Low Water Cutoff Device …………………………………………. 37 Chilled Water System………………………………………………. 37 Freeze Protection Fluids ………………………………………….. 37 General Piping Information ………………………………………. 37 Relief Valve Installation …………………………………………… 38 Near Boiler Piping Components………………………………… 39 Circulator Sizing ……………………………………………………… 39 Near Boiler Piping Connections ………………………………… 40
Piping Diagrams ……………………………………………..42-47 7. GAS CONNECTIONS Connecting Gas Supply Piping …………………………………. 48 Natural Gas ……………………………………………………………. 49
Pipe Sizing for Natural Gas …………………………………. 49 Natural Gas Supply Pressure Requirements …………. 49 Propane Gas ………………………………………………………….. 49 Pipe Sizing for Propane Gas ……………………………….. 49 Propane Supply Pressure Requirements ………………. 49 Check Inlet Gas Supply …………………………………………… 50 Gas Pressure …………………………………………………………. 51 Gas Valve Replacement ………………………………………….. 51 8. FIELD WIRING Line Voltage Connections ………………………………………… 52 Low Voltage Connections ………………………………………… 52 Wiring of the Cascade……………………………………………… 54 9. CONDENSATE DISPOSAL Condensate Drain …………………………………………………… 56 10. STARTUP ……………………………………………………. 57-63 11. OPERATING INFORMATION General………………………………………………………………….. 64 Cascade ………………………………………………………………… 68 Sequence of Operation ……………………………………….. 69-70 FTXL Control Module ………………………………………………. 71 Status Display Screens ……………………………………….. 72-74 12. MAINTENANCE Maintenance and Annual Startup………………………….. 75-79 13. DIAGRAMS Wiring Diagram ………………………………………………….. 80 Ladder Diagram ………………………………………………… 81 Revision Notes ………………………………………….. Back Cover

Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

DANGER

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

WARNING

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

CAUTION

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

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

2

Installation & Operation Manual

Please read before proceeding

WARNING

Installer ­ Read all instructions, including this manual and the FTXL Service Manual, before installing. Perform steps in the order given.

User ­ This manual is for use only by a qualified heating installer/service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

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

NOTICE

When calling or writing about the boiler ­ Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

WARNING

Failure to adhere to the guidelines on this page can result in severe personal injury,

death, or substantial property damage.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.

When servicing boiler ­

· To avoid electric shock, disconnect electrical supply before performing maintenance.
· To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation ­
· Do not block flow of combustion or ventilation air to the boiler.
· Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
· Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water ­

· Thoroughly flush the system to remove debris. Use an approved pre- commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

Freeze protection fluids ­
· NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

WHAT TO DO IF YOU SMELL GAS

· Do not try to light any appliance.
· Do not touch any electric switch; do not use any phone in your building.
· Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.
· If you cannot reach your gas supplier, call the fire department.
· Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
3

Installation & Operation Manual

The FTXL – How it works…
1. Stainless steel heat exchanger Allows system water to flow around specially designed tubes for maximum heat transfer, while providing protection against flue gas corrosion.
2. Heat exchanger top plate Removal of the top plate allows access to the combustion chamber and tube sheet.
3. Blower The blower pulls in air and gas through the venturi (item 5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.
4. Gas valve The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.
5. Venturi The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if the flue gas temperature gets too hot. This protects the flue pipe from overheating.
7. Boiler outlet temperature sensor (limit rated)
This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct. 8. Boiler inlet temperature sensor This sensor monitors return water temperature (system return). If `selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.
9. Temperature and pressure gauge (field installed, not shown) Monitors the outlet temperature of the boiler as well as the system water pressure.
10. Electronic LCD display The display features a high resolution liquid crystal screen, four (4) buttons, and a navigation dial. A serial and USB port support additional communication with the control.
11. Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler.
12. Burner (not shown) Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet (system supply) A 2″ or 2-1/2″ NPT (depending on the model) water connection that supplies hot water to the system.
14. Water inlet (system return) A 2″ or 2-1/2″ NPT (depending on the model) water connection that returns water from the system to the heat exchanger.
15. Gas connection pipe Threaded pipe connection of 1″. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.
16. SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals to regulate the blower, gas valve, and pump functions to meet heating demand. An optional remote connectivity allows boiler settings to be monitored and modified when connected to the internet.
17. Manual air vent A manual air vent is used to remove trapped air from the heat exchanger shell.
18. Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler.
19. High voltage junction box The junction box contains the connection points for the line voltage power and all pumps.
20. Boiler drain connection A 1″ NPT drain connection is provided for easy access in the event the boiler needs to be drained .

21. Low voltage connection board The connection board provides easy access for connecting external low voltage devices.
22. Low voltage wiring connections (knockouts) Conduit connection points for the low voltage connection board.
23. Condensate trap The condensate trap is sized for a 1/2″ PVC outlet connection pipe.
24. Bezel (hinged) Provides access to the gas train, heat exchanger, and display.
25. Ignition electrode Provides direct spark for igniting the burner.
26. Flame inspection window The quartz glass window provides a view of the burner surface and flame.
27. Gas shutoff valve (Models 500 – 850 only) A manual valve is provided to isolate the gas valve from the boiler.
28. Relief valve (field installed, not shown) Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 PSI.
29. Flame sensor Used by the control module to detect the presence of burner flame.
30. Line voltage wiring connections (knockouts) Conduit connection points for the high voltage junction box.
31. Front panel Removable panel to gain access to the internal components.
32. Power switch Turns 120 VAC ON/OFF to the boiler.
33. Pump relay board The pump relay board is used to connect the boiler, system and DHW pumps.
34. Transformer The transformer provides 24V power to the integrated control.
35. High limit sensor (housed with the outlet temperature sensor) Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the boiler down.
36. Low water cutoff probe (LWCO) Protects the heat exchanger from overheating, by ensuring adequate water is supplied to the boiler. In the event of inadequate water levels, the boiler will shut down.
37. Stainless steel flue collector Flue gas and condensate enter the stainless steel flue collector through the firetubes. A 1″ drain connection allows condensate to flow through the collector into a condensate trap for disposal.
38. Reset switch Reset switch for the low water cutoff. Hold the switch for 10 seconds to reset.
39. Test switch The test switch permits manual triggering of the LWCO safety circuit to test the contacts and evaluate the integrity of the circuit. Hold the switch for 10 seconds to test.
40. Combustion measurement port A port near the flue vent which provides access for a combustion analyzer probe.
41. Burner plate (not shown) The burner plate attaches the blower to the burner and the heat exchanger. Removal allows easy access to the burner for inspection or replacement.

4

The FTXL – How it works… (continued)
Models 400 – 850

Installation & Operation Manual

Front View Left Side (inside unit)

Rear View
21

19 27 18

17 26 36 20
Right Side (inside unit)

4
16 33 38 39 23
DIR #2000544916 00
5

Ratings

Installation & Operation Manual

Model Number
Note: Change “N” to “L” for L.P. gas models.
FTX400N FTX500N FTX600N FTX725N FTX850N

FTXL Boiler AHRI Rating

Input MBH

(Note 4)

Min

Max

39.9

399

50

500

85.7

600

103.6

725

121.4

850

Gross Output MBH (Note 1)
391
489
585
705
825

Net AHRI Ratings Water, MBH (Note 2)
340
425
509
613
717

Other Specifications

Boiler Water Content Gallons

Water

Gas

Air Vent

Connections Connections Size Size

(Note 3)

13.2

2″

1″

4″ 4″

11.9

2″

1″

4″ 4″

11.9

2″

1″

4″ 4″

17.2

2 1/2″

1″

4″ 6″

15.9

2 1/2″

1″

4″ 6″

NOTICE Maximum allowed working pressure is located on the rating plate.

Notes:
1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

6. Ratings have been confirmed by the Hydronics Section of AHRI.
7. FTXL boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the FTXL is listed to UL353.

3. FTXL boilers require special gas venting. Use only the vent materials and methods specified in the FTXL Installation and Operation Manual.

4. Standard FTXL boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.
5. High altitude FTXL boilers are equipped to operate from 3,000 to 12,000 feet only. The boiler will not de-rate up to 5,400 feet and will de-rate by 1.6% for each 1,000 feet above 5,400 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in Fig. A) is also affixed to the unit.

UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
IMG01068

De-rate values are based on proper combustion calibration and CO2’s adjusted to the recommended levels.
6

Figure A High Altitude Label Location

Installation & Operation Manual

1 Determine boiler location

Installation must comply with:

DO NOT install the boiler in a room likely to freeze.

· Local, state, provincial, and national codes, laws, regulations, and ordinances.
· National Fuel Gas Code, ANSI Z223.1 ­ latest edition. · Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required. · National Electrical Code. · For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.

WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.

NOTICE

The FTXL gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

specified in ANSI Z21.13 ­ latest edition.
Before locating the boiler, check: 1. Check for nearby connection to:
· System water piping · Venting connections · Gas supply piping · Electrical power
2. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.
3. Check area around the boiler. Remove any combustible

WARNING

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC/ stainless steel pipe section provided with the appliance. The field provided PVC vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Closet and alcove installations A closet is any room the boiler is installed in which is less than 171 cubic feet for FTX400 models, 193 cubic feet for FTX500 models, 223 cubic feet for FTX600 models, 247 cubic feet for FTX725 models and 278 cubic feet for FTX850 models.

materials, gasoline and other flammable liquids.

An alcove is any room which meets the criteria for a closet with

WARNING

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.

4. The FTXL must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for and correct system problems, such as:

the exception that it does not have a door.

Example: Room dimensions = 5 feet long, 4 feet wide,

and

8 foot ceiling = 5 x 4 x 8 = 160 cubic feet. This would

be considered a closet for a FTXL Boiler.

WARNING

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC or stainless steel vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this

· System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.
· Incorrectly-sized expansion tank. · Lack of freeze protection fluids in boiler water causing
system and boiler to freeze and leak. · Debris left from existing piping, if not flushed and
cleaned with an appropriate cleaner.

6. Check around the boiler for any potential air contaminants

that could risk corrosion to the boiler or the boiler

combustion air supply (see Table 1A on page 10).

Prevent combustion air contamination. Remove any of

these contaminants from the boiler area.

WARNING

DO NOT install units in rooms or environments that contain corrosive

contaminants (see Table 1A on page 10).

warning could result in fire, personal injury, or death.
Provide clearances:
Clearances from combustible materials 1. Hot water pipes–at least 1/4″ (6 mm) from combustible
materials. 2. Vent pipe ­ at least 1″ (25 mm) from combustible materials. 3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance
minimums.
Clearances for service access 1. See FIG.’s 1-1 and 1-2 on page 8 for recommended
service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

Failure to comply could result in severe

personal injury, death, or substantial

property damage.

7

Installation & Operation Manual

1 Determine boiler location (continued)

Figure 1-1 Closet Installation – Minimum Required Clearances

1/4″ (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1″ (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

CLOSET INSTALLATION

WARNING
18″ (457 MM) TOP

• VENTILATING
  AIR OPENING

For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

CLOSED DOOR

• VENTILATING
  AIR OPENING

0″ LEFT
6″

14″ (356 MM) REAR

0″ RIGHT

*AREA OF EACH OPENING:
1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES.

6″ (152 MM) FRONT

IMG00982

Figure 1-2 Alcove Installation – Minimum Required Clearances

1/4″ (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES 1″ (25 MM) MINIMUM CLEARANCE AROUND VENT PIPE

ALCOVE INSTALLATION WARNING
18″ (457 MM) TOP

For alcove installations, CPVC, polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

OPEN DOOR

0″ LEFT

14″ (356 MM)
REAR

6″ (152 MM) FRONT

0″ RIGHT
IMG00983

8

Installation & Operation Manual

1 Determine boiler location

Provide air openings to room:

Residential garage installation

FTXL alone in boiler room

Precautions

1. No air ventilation openings into the boiler room are needed when clearances around the FTXL are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Recommended service clearances

FRONT TOP REAR

– 30″ (762 mm) – 18″ (610 mm) – 24″ (610 mm)

FTXL in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

WARNING

The space must be provided with combustion/ventilation air openings

correctly sized for all other appliances

located in the same space as the FTXL.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the FTXL because it takes its combustion air from outside (direct vent installation).
Flooring and foundation

Flooring

The FTXL is approved for installation on combustible flooring, but must never be installed on carpeting.

WARNING

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
· Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.
· The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.
Vent and air piping
The FTXL requires a special vent system, designed for pressurized venting.
The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see the General Venting Section. Note prevention of combustion air contamination below when considering vent/air termination.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the FTXL using any other means.
Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the FTXL as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

WARNING

You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.
9

Installation & Operation Manual

1 Determine boiler location (continued)

Table 1A Corrosive Contaminants and Sources
Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine- type bleaches, detergents, and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry cleaning/laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops

When using an existing vent system to

install a new boiler:

WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Check the following venting components before installing:

· Material – For materials listed for use with this appliance, see Section 3 – General Venting. For polypropylene or stainless steel venting, an adapter of the same manufacturer must be used at the flue collar connection.

· Size – To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.

· Manufacturer – For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with flue producing condensate.

· Supports – Non-combustible supports must be in place allowing a minimum 1/4″ rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

· Terminations – Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3H for the manufacturer of the installed vent.

· Seal – With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.

With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on pages 20 and 21.

WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

10

Installation & Operation Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

DANGER

Do not install the FTXL into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.
c. Test vent system ­ Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
e. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from another source.
f. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

11

Installation & Operation Manual

1 Determine boiler location

Combustion and ventilation air requirements for appliances drawing air from the equipment room
Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
The equipment room MUST be provided with properly sized openings and/or be of sufficient volume to assure adequate combustion air and proper ventilation for all gas fired appliances in the equipment room to assure adequate combustion air and proper ventilation.
The requirements shown are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances.

IMG01075
Figure 1-4_Combustion Air Through Ducts
2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-4).

No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances and the building MUST NOT be of “Tight Construction”3.

A combination of indoor and outdoor combustion air may be utilized by applying a ratio of available volume to required volume times the required outdoor air opening(s) size(s). This must be done in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1.

IMG01076
Figure 1-5_Combustion Air from Interior Space
3. If air is taken from another interior space combined with the equipment room:
(a) Two spaces on same story: Each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-5).
(b) Two spaces on different stories: One or more openings should have a net free area of two square inches per 1000 Btu/hr (44 cm2 per kW).

IMG01074
Figure 1-3_Combustion Air Direct from Outside
1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room each with a net free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW) (see FIG. 1-3).

IMG01077

12

Figure 1-6_Combustion Air from Outside – Single Opening

Installation & Operation Manual

1 Determine boiler location (continued)

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12″ (30 cm) of the top of the enclosure (see FIG. 1-6).
Combustion air requirements are based on the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN/CSA B149.1. Check all local code requirements for combustion air.
All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.
Where two openings are provided, one must be within 12″ (30 cm) of the ceiling and one must be within 12″ (30 cm) of the floor of the equipment room. Each opening must have a net free area as specified in Table 1B. Single openings shall commence within 12″ (30 cm) of the ceiling. The minimum dimension of air openings shall not be less than 3″ (80 mm).

CAUTION

Under no circumstances should the equipment room ever be under negative

pressure. Particular care should be taken

where exhaust fans, attic fans, clothes dryers,

compressors, air handling units, etc., may

take away air from the unit.

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.

Model Number
FTX400 FTX500 FTX600 FTX725 FTX850

TABLE – 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

FIG. 1-3

FIG. 1-4

FIG. 1-5

Inside Air from

*Outside Air from 2 Openings Directly from

*Outside Air from

2 Ducts Delivered from Interior

2 Ducts Delivered from

Space2

Outdoors1

Outdoors1

Same Story

Top Opening, in2
(cm2)
100 (646) 125 (807) 150 (968)
182 (1,174)
213 (1,374)

Bottom Opening, in2
(cm2)
100 (646) 125 (807) 150 (968)
182 (1,174)
213 (1,374)

Top Opening, in2
(cm2)
200 (1,291)
250 (1,613)
300 (1,936)
363 (2,342)
425 (2,742)

Bottom Opening, in2
(cm2)
200 (1,291)
250 (1,613)
300 (1,936)
363 (2,342)
425 (2,742)

Top Opening, in2
(cm2)
400 (2,581)
500 (3,226)
600 (3,871)
725 (4,677)
850 (5,484)

Bottom Opening, in2 (cm2)
400 (2,581)
500 (3,226)
600 (3,871)
725 (4,677)
850 (5,484)

FIG. 1-6
*Outside Air from 1 Opening Directly from
Outdoors, in2 (cm2)1
134 (865) 167 (1,078) 200 (1,291) 242 (1,561) 284 (1,832)

The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances. No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of ”Tight Construction”3.
1Outside air openings shall directly communicate with the outdoors.
2Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of ”Tight Construction”.
3″Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight Construction”, provide air openings into the building from outside.

13

Installation & Operation Manual

2 Prepare boiler

Remove boiler from wood pallet

Models 400 and 500 Only (Venturi w/LP

1. After removing the outer shipping carton from the boiler, Orifices)

remove the parts box.

1. Remove the top bezel from the unit (no tools required for

2. To remove the boiler from the pallet (after removing the

removal).

front door):

2. Disconnect the air inlet piping from the venturi by loosening

a. Remove the three (3) lag bolts from inside the front the band clamp around the rubber boot coupling. Slide the

of the boiler (FIG. 2-1).

rubber boot off of the venturi.

b. Remove the two (2) L-brackets and the two (2) lag 3. Disconnect gas piping from the venturi by loosening the

bolts inside the L-brackets on the rear of the boiler.

threaded nut on the venturi (replace gasket if damaged).

Once the lag bolts have been removed, re-install the

screws on the rear of the boiler.

4. Remove the bolts connecting the venturi to the fan and then

c. Disconnect the ribbon cable and remove the bezel

proceed to remove the Natural venturi from the unit (FIG.’s

(no tools required for removal) before removing the

2-2A and 2-2B).

boiler from the pallet or moving the boiler.

5. Install the LP venturi onto the fan taking note of the

following:

NOTICE

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

a. The UP arrow on the plastic housing is indeed pointing up.

b. The threaded connection for the gas piping is facing

Figure 2-1 Boiler Mounted on Shipping Pallet

towards the front of the unit. Reinstall the

bolts connecting the venturi to the fan.

FRONT

REAR

6. Reassemble the gas pipe to the threaded connection on the venturi. Install the new gasket provided in the kit and ensure it is seated properly before tightening the nut.

7. Reconnect the rubber boot on the air inlet to the venturi inlet and tighten the band clamp at this connection.

REMOVE THE LAG BOLTS (QTY. 3) FROM INSIDE THE FRONT OF THE BOILER

REMOVE THE L-BRACKETS (QTY. 2) AND LAG BOLTS (QTY. 2)

8. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag)

to the rear of the boiler underneath the gas supply piping.

Gas conversions

9. Replace the top bezel removed in Step 1 and resume

WARNING

For a boiler already installed, you must turn off gas supply, turn off power and

operation.

allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual. Failure to comply could result in severe personal injury, death, or

WARNING

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

substantial property damage.
For the 400 and 500 Models you must install a propane venturi to operate the FTXL on propane gas.

DANGER

Models 400 and 500: Inspect the O-ring when the blower is disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas

Models 600 – 850 do not require a venturi change for propane operation, but they will require a valve adjustment.

leak, resulting in severe personal injury or death.

Table 2A LP Conversion Kit

Model Description

400 – 500

LP Kit

Kit Number 100189174

14

2 Prepare boiler (continued)
Figure 2-2A 400 Model_Venturi with LP Orifice
BLOWER O-RING VENTURI SCREWS QTY. 3

GAS VALVE

IMG01069

Figure 2-2B 500 Model_Venturi with LP Orifice
BLOWER
O-RING VENTURI
SCREWS QTY. 5

Installation & Operation Manual

Models 600 – 850
1. Lift the top bezel (prop the bezel up for service).
2. Remove the cover on top of the gas valve (FIG. 2-3).
3. Use a combustion analyzer to verify CO2 is within the range of 9.0 ­ 11.0%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-3).
4. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the boiler rating plate. Attach the LP caution label (in the conversion kit bag) to the rear of the boiler underneath the gas supply piping.
5. Replace the gas valve cover and lower the bezel.

WARNING

Failure to check and verify combustion could result in severe personal injury,

death, or substantial property damage.

Figure 2-3 Gas Valve Adjustment – Models 600 – 850
COVER

ALLEN WRENCH

ADJUSTMENT SCREW

GAS COCK GAS VALVE

IMG01070

15

3 General venting
Direct venting options – Sidewall Vent

Installation & Operation Manual

IMG01060

IMG01061

Two Pipe Sidewall See page 24 for more details
Direct venting options – Vertical Vent

PVC/CPVC Concentric Sidewall Models 400 – 600 Only
See page 28 for more details

IMG01062

IMG01063

IMG01064

Two Pipe Vertical See page 31 for more details

PVC/CPVC Concentric Vertical Models 400 – 600 Only See page 33 for more details

16

Vertical Vent, Sidewall Air

Installation & Operation Manual

3 General venting (continued)
Install vent and combustion air piping

DANGER

The FTXL boiler must be vented and supplied with combustion and ventilation

air as described in this section. Ensure the

vent and air piping and the combustion

air supply comply with these instructions

regarding vent system, air system, and

combustion air quality. See also Section 1

of this manual.

Inspect finished vent and air piping

thoroughly to ensure all are airtight and

comply with the instructions provided and

with all requirements of applicable codes.

Failure to provide a properly installed vent

and air system will cause severe personal

injury or death.

WARNING

This appliance requires a special venting system. Use only approved stainless steel, PVC, CPVC or polypropylene pipe and fittings listed in Tables 3E, 3F, and 3H for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the
living space. Mixing of venting materials
will void the warranty and certification of
the appliance.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

WARNING

For closet and alcove installations, CPVC, polypropylene or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

The FTXL boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.
You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the FTXL boiler using any other means.
You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 19 of this manual. The resultant installation is direct vent (sealed combustion).
The FTXL is certified as a Category II/IV boiler. All venting systems used with this boiler must be suitable for Category IV operation except for factory approved common vent systems operating as allowed in the Common Venting Section on page 20.
Air intake/vent connections 1. Combustion Air Intake Connector (FIG. 3-1) – Used to
provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate. 2. Vent Connector (FIG.’s 3-2 thru 3-7) – Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
Figure 3-1 Near Boiler Air Piping
AIR

CAUTION NOTICE

Improper installation of venting systems may result in injury or death.
Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.

WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

IMG00986
17

Installation & Operation Manual

3 General venting

Requirements for installation in
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Canada

1. Installations must be made with a vent pipe system Model certified to ULC-S636.

Kit Number

Equivalent Vent Length

2. The first three (3) feet of plastic vent pipe from the

400

100140484

5′ (1.5 m)

appliance flue outlet must be readily accessible for visual 500 – 600

100140484

30′ (9 m)

inspection. The components of the certified vent system must not be

Air inlet pipe materials:

interchanged with other vent systems or unlisted The air inlet pipe(s) must be sealed. Choose acceptable

pipe/fittings. For concentric vent installations, the inner combustion air inlet pipe materials from the following list:

vent tube must be replaced with field supplied certified vent material to comply with this requirement.
4. The 4″ Concentric Vent Kit available from Lochinvar (see Section 4 ­ Sidewall Termination ­ Optional Concentric Vent) and the 4″ Concentric Vent Kit available from IPEX are both approved for use on the FTXL (400 – 600 models only) boiler. Both kits are listed to the ULC-S636 standard for use in Canada.

PVC, CPVC, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to

Sizing

specification of its manufacturer.

The FTXL uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

Table 3A Air Intake/Vent Piping Sizes

Pipe Diameter Model
Air Intake Vent

De-rate per 25 feet of Vent Direct Vent Room Air

WARNING

Using air intake materials other than those specified can result in personal

injury, death or property damage.

400 4″ (102 mm) 4″ (102 mm) 500 4″ (102 mm) 4″ (102 mm) 600 4″ (102 mm) 4″ (102 mm) 725 4″ (102 mm) 6″ (152 mm)

0.00% 0.40% 1.20% 1.20%

0.00% 0.40% 1.20% 1.20%

NOTICE

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

850 4″ (102 mm) 6″ (152 mm) 1.40%

1.40%

NOTICE

Increasing or decreasing combustion air or vent piping sizes is not authorized.

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:
Combustion Air = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum
Vent = 12 equivalent feet (3.7 m) minimum / 100 equivalent feet (30.5 m) maximum
When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System: a. Seal all joints and seams of the air inlet pipe using
either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric. b. Do not install seams of vent pipe on the bottom of horizontal runs. c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe. d. Ensure that the air inlet pipes are properly supported.

EXAMPLE: 20 feet (6 m) of PVC pipe + (3) 90° elbows +

(3) 45° elbows + (1) concentric vent kit (100140484) = 49

equivalent feet (15 m) of piping.

NOTICE

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent

18

length.

Installation & Operation Manual

3 General venting (continued)

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

Follow the polypropylene manufacturer’s instructions when using polypropylene material as an inlet pipe.

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

DANGER

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

Optional room air

NOTICE

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

Commercial applications utilizing the FTXL boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

· The unit MUST be installed with the appropriate bird screen (Table 3C).
· The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.
· Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.
· Vent system and terminations must comply with the standard venting instructions set forth in this manual.

NOTICE

There will be a noticeable increase in the noise level during normal operation from the inlet air opening.

WARNING

When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

Table 3C Optional Room Air Kit

Model Description

Kit Number

400 – 850 Room Air Kit

100157616

Air contamination
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

WARNING

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

WARNING

To prevent the potential of severe personal injury or death, check for areas and products

listed in Table 1A, page 10 before installing

the boiler or air inlet piping.

If contaminants are found, you MUST: · Remove contaminants permanently. –OR– · Relocate air inlet and vent terminations to other areas.

19

Installation & Operation Manual

3 General venting

Common venting
FTXL boilers may be common vented; however, the following criteria MUST BE followed:
1. Only FTXL boilers may be connected to the common vent. DO NOT mix other manufacturer’s appliances or other Lochinvar models.

Table 3D Flue Damper Kits

Flue Damper Kits

Model Damper Size

Kit Number

2. FTXL boilers connected to the common vent must all be of the same size.

3. Each FTXL boiler must have a Lochinvar supplied flue damper installed (see Table 3D).

4. A condensate drain must be installed above the flue damper.

5. Only vertical direct vent, positive pressure, Category IV or vertical/chimney vent, negative pressure, Category II may be used when common venting FTXL boilers. Sidewall common venting is not allowed.

6. FTXL boilers in a common vent must be connected and controlled with the integral FTXL SMART SYSTEM Cascade.
a. The Leader may be controlled through the FTXL SMART SYSTEM control through BMS (external 0 – 10V signal), ModBus, BACnet, or its own internally calculated set point.
b. The Cascade (Members) must be controlled by the FTXL Leader boiler using the Lead/Lag Cascade option.
For approved common vent sizing, contact the factory.

WARNING

When FTXL boilers are common vented, the criteria above MUST BE followed. Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.

NOTICE

When FTXL boilers are common vented, hot water generators must be piped to the primary heating loop and tank thermostats must not be connected to the FTXL.

NOTICE

A field supplied inline condensate collection section MUST BE installed directly above the backflow preventer.

400

4″

100056141

500

4″

100056141

600

4″

100056141

725

6″

850

6″

100056142 100056142

PVC/CPVC
This product has been approved for use with the PVC/CPVC vent materials listed in Table 3E on page 21.
Installing vent and air piping

WARNING

The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3E to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

NOTICE

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

NOTICE WARNING

All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).
Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

20

Installation & Operation Manual

3 General venting (continued)

Table 3E PVC/CPVC Vent Pipe and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

Item

Material

Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe PVC – DWV

ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

PVC Schedule 40 ANSI/ASTM D2466

PVC Schedule 80 ANSI/ASTM D2467 Vent fittings CPVC Schedule 80 ANSI/ASTM F439

PVC – DWV

ANSI/ASTM D2665

Pipe Cement / PVC

Primer

CPVC

ANSI/ASTM D2564 ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/ primer must be ULC-S636 certified. 1. Work from the boiler to vent or air termination. Do not
exceed the lengths given in this manual for the air or vent piping.
2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2″ beyond the socket depth.
c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.
g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Figure 3-2 Near Boiler PVC/CPVC Venting – Models 400 – 600 Figure 3-3 Near Boiler PVC/CPVC Venting – Models 725 – 850

VENT

VENT

4″ COUPLING ( FIELD SUPPLIED )

4″ CPVC STARTER PIECE ( FACTORY SUPPLIED )
4″ CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION
NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

IMG00987

6″ COUPLING ( FIELD SUPPLIED )
6″ CPVC STARTER PIECE ( FACTORY SUPPLIED )
6″ CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION
NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS

IMG00988

21

Installation & Operation Manual

3 General venting

Polypropylene This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3F.
All terminations must comply with listed options in this manual and be a single-wall vent offering.
For support and special connections required, see the manufacturer’s instructions. All vent is to conform to standard diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length for polypropylene single-wall piping:
· 1 foot of Duravent 4 inch single-wall pipe is equivalent to 1.6 feet of piping
Flexible polypropylene For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations (FIG. 3-4).
Figure 3-4 Near Boiler Flexible Polypropylene Venting

CAP CHIMNEY

Duravent 3″

Duravent 4″

“A” DIM

“B” DIM

“A” DIM

“B” DIM

3″ RIGID 3″ FLEX 4″ FLEX 4″ RIGID 4″ FLEX 5″ FLEX

10 FT 60 FT 90 FT

10 FT 30 FT 90 FT

20 FT 53 FT 80 FT

20 FT 27 FT 80 FT

30 FT 47 FT 70 FT

B

40 FT 40 FT 60 FT

30 FT 23 FT 70 FT 40 FT 20 FT 60 FT

50 FT 33 FT 50 FT

50 FT 17 FT 50 FT

60 FT 27 FT 40 FT

60 FT 13 FT 40 FT

70 FT 20 FT 30 FT

70 FT 10 FT 30 FT

80 FT 13 FT 20 FT

80 FT 7 FT 20 FT

90 FT 7 FT 10 FT

90 FT 3 FT 10 FT

NOTICE

The installer must use a specific vent starter adapter at the flue collar connection. The adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. Discard CPVC starter piece.

NOTICE WARNING

All vent connections MUST be secured by the vent manufacturer’s joint connector (FIG. 3-5). Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

WARNING NOTICE

Use only the adapters and vent system listed in Tables 3F and 3G. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage. Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

NOTICE

Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.

Figure 3-5 Near Boiler Polypropylene Venting

A

Centrotherm 3″

Centrotherm 4″

“A” DIM

“B” DIM

“A” DIM “B” DIM

3″ RIGID 3″ FLEX 4″ FLEX 4″ RIGID 4″ FLEX

10 FT 45 FT 90 FT

10 FT 33 FT

20 FT 40 FT 80 FT

20 FT 29 FT

30 FT 35 FT 70 FT

30 FT 26 FT

40 FT 30 FT 60 FT

40 FT 22 FT

50 FT 25 FT 50 FT

50 FT 18 FT

60 FT 20 FT 40 FT

60 FT 15 FT

70 FT 15 FT 30 FT

70 FT 11 FT

80 FT 10 FT 20 FT

80 FT 7 FT

90 FT 5 FT 10 FT

90 FT 4 FT

*NOTES: 1) FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION

2. ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE

EQUIVALENT LENGTHS.

3. SECTION A IS EQUIVALENT FEET OF RIGID PIPE, WHICH MAY

INCLUDE 45 AND 90° ELBOWS. PLEASE SEE SIZING SECTION

FOR DETERMINING EQUIVALENT FEET.

IMG00840

Table 3F Polypropylene Vent Pipe and Fittings

4″ POLYPROPYLENE ADAPTER
4″ POLYPROPYLENE JOINT CONNECTOR REQUIRED AT ALL THE COMPONENTS OF THE VENT SYSTEM
4″ POLYPROPYLENE ADAPTER
MODELS 400 – 600

IMG00990

Approved Polypropylene Vent Manufacturers

Make

Model

6″ POLYPROPYLENE PIPE

Centrotherm Eco Systems

InnoFlue SW/Flex

Duravent (M & G Group) PolyPro Single-Wall / PolyPro Flex

6″ POLYPROPYLENE ADAPTER

Table 3G Approved Polypropylene Terminations

Model Manufacturer Vent Model Vent Type Adapter Number Joint Connector

Centrotherm Eco Systems 400-600 DuraVent
(M & G)

Innoflue PolyPro

Single-Wall Flex
Single-Wall Flex

ISAAL0404 4PPS-AD

IANS04 4PPS-LB

Centrotherm Eco Systems 725-850
DuraVent (M & G)

Innoflue PolyPro

Single-Wall Flex
Single-Wall Flex

ISAAL0606
6PPS-06PVCM6PPF

—

• These parts are only needed if the sidewall termination assembly is used (see FIG. 4-5B on page 27).

22

MODELS 725 – 1000

IMG00989

Sidewall Kit* ISLPT0404

Retaining Bracket /
Adapter*
IATP0404/ ISTAGL0404

4PPS-HLK

—

—

IATP0606 / ISTAGL0606

6PPS-HLK

—

Installation & Operation Manual

3 General venting (continued)
Stainless steel vent This product has been approved for use with stainless steel using the manufacturers listed in Table 3H.

WARNING

Use only the materials, vent systems, and terminations listed in Tables 3G and 3I. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3I for approved vent adapters. Discard CPVC starter piece.

NOTICE

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

NOTICE

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

Figure 3-6 Near Boiler Stainless Steel Venting Models 400 – 600
4″ STAINLESS STEEL PIPE
4″ STAINLESS STEEL ADAPTER
IMG00991
Figure 3-7 Near Boiler Stainless Steel Venting Models 725 – 850

Table 3H Stainless Steel Vent Pipe and Fittings

Approved Stainless Steel Vent Manufacturers

Manufacturer

Model

Dura Vent (M & G)

FasNSeal Vent / FasNSeal Flex*

Z-Flex

Z-Vent

Heat Fab

Saf-T Vent

Metal Fab

Corr/Guard

Security Chimney

Secure Seal

ICC

VIC

Jeremias

—

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.

STAINLESS STEEL PIPE
STAINLESS STEEL ADAPTER

IMG00992

Table 3I Approved Stainless Steel Adapters and Terminations

Model

Manufacturer

Adapter Flue

DuraVent (M & G) (Fas-N-Seal)

FSA-4PVCM-4FNSF

Heat Fab (Saf-T-Vent)

9401PVC

Intake F303759
9401PVC

400-600

Z-Flex (Z-Vent)
Metal Fab (Corr/Guard)
Security Chimney (Secure Seal) Jeremias
DuraVent (M & G) (Fas-N-Seal)
Heat Fab (Saf-T-Vent)

2SVSLA04
4CGPVCA
SS4PVCU
SWKL4-PVC FSA-6PVCM-6FNSF
300538 9601PVC

2SVSLA04 4CGPVCA SS4PVCU SWKL4-PVC F303759 9601PVC

725-850

Metal Fab (Corr/Guard) Security Chimney (Secure Seal) ICC
Jeremias

6FCGPVCA SS6PVCU HE-6DSA-F SWKL6-PVC

6FCGPVCA SS6PVCU
-SWKL4-PVC

Termination

Flue

Intake

FSBS4 FSRC4 (R.C.)

FSAIH04 303888

0492 5400CI

9414TERM

2SVSTP04 2SVSRCX04

2SVSTEX0490

4CGSWHT 4CGSWC

4CGSW90LT

SS4STU SS4RCBU

SS4ST90AU

SWKL4-WRC FSBS6

SWKL4-90ET FSAIH04 303888

9601PVC

9601PVC

6FCGSWMC 6FCGSWC
SS6STU SS6RCBU
HE-6MC-F HE-6RC-F

6CGSW90L SS6ST90AU
—

SWKL6-WRC

SWKL4-90ET

23

Installation & Operation Manual

4 Sidewall direct venting
Vent/air termination ­ sidewall

WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

WARNING

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe except as noted in Section 3 on page 20. Failure to comply could result in severe personal injury, death, or substantial property damage.

f. Do not terminate above any door or window. Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage to exterior finishes.
Figure 4-1A PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings

CAUTION

Sidewall venting commercial products will result in large exhaust plumes in cold

climates. Consideration should be taken

when locating in proximity to windows,

doors, walkways, etc.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location Locate the vent/air terminations using the following guidelines:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1A. This arrangement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1A.

WARNING

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 18 of this manual.
2. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

WARNING
24

Sidewall vent and air inlet terminations must terminate in the same pressure zone.

Figure 4-1B PVC/CPVC/Polypropylene Sidewall
Termination of Air and Vent
TO BOILER INTAKE AIR CONNECTION

FROM BOILER VENT PIPE
CONNECTION POSSIBLE ORIENTATIONS
VENT / AIR TERMINATION

12″ MIN TO OVERHANG

12″ MIN
GRADE OR SNOW LINE

Table 4A Sidewall Vent Kits

Model 400 – 600 725 – 850

Kit Number 100157611 100157613

Air

Vent

Centerline Width

4″

4″

(102 mm) (102 mm)

4″

6″

(102 mm) (152 mm)

5 5/8″ (143 mm)
7 3/4″ (197 mm)

Installation & Operation Manual

4 Sidewall direct venting (continued)

Vent/air termination ­ sidewall

Figure 4-2A PVC/CPVC/ Polypropylene Sidewall Termination Models 400 – 850 w/Field Supplied Fittings

TO BOILER INTAKE AIR CONNECTION

BIRD SCREEN

FROM BOILER VENT PIPE
CONNECTION

12″ (305 MM) MIN 15″ (381 MM) MAX
BIRD SCREEN

c. Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet (1.2 m) horizontally.
6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
Figure 4-3A Clearance to Gravity Air Inlets w/Field Supplied Fittings

12″ (305 MM) MIN

GRADE OR SNOW LINE
Figure 4-2B Stainless Steel Sidewall Termination Models 725 – 850 w/Field Supplied Fittings

12″ (305 MM) MIN

BIRD SCREEN (TYPICAL)

TO BOILER INTAKE AIR CONNECTION

12″ (305 MM) MIN 15″ (381 MM) MAX

12″ (305 MM) MIN

FROM BOILER VENT PIPE CONNECTION

12″ (305 MM) MIN

12″ (305 MM) MIN
Figure 4-3B Clearance to Gravity Air Inlets

GRADE OR SNOW LINE
NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4B, pages 24 thru 26. Also maintain the following: a. Vent must terminate: · At least 6 feet (1.8 m) from adjacent walls. · No closer than 12 inches (305 mm) below roof overhang. · At least 7 feet (2.1 m) above any public walkway. · At least 3 feet (.9 m) above any forced air intake within 10 feet (3 m). · No closer than 12 inches (305 mm) below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches (305 mm) above grade or snow line; at least 12 inches (305 mm) below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches (610 mm) vertically outside the building.

12″ MIN.

12″ MIN.

12″ MIN.

VENT / AIR TERMINATION

25

4 Sidewall direct venting
Vent/air termination ­ sidewall
Figure 4-4A Clearance to Forced Air Inlets w/Field Supplied Fittings
IF LESS THAN 10′ (3 M)
36″ (914 MM) MIN

7′ (2.1 M) MIN ABOVE ANY PUBLIC WALKWAY

FORCED AIR INLET
BIRD SCREEN (TYPICAL)

Installation & Operation Manual

3. Use a sidewall termination plate as a template for correct location of hole centers.
4. Follow all local codes for isolation of vent pipe when passing through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-5A A Typical Sidewall Termination Assembly – Models 400 – 850 PVC/CPVC/ Polypropylene or Stainless Steel

SIDEWALL TERMINATION PLATE
VENT PIPING

GALVANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES)
ELBOW
AIR PIPING

Figure 4-4B Clearance to Forced Air Inlets
IF LESS THAN 10′

VENT / AIR TERMINATION

36″ MIN.

FORCED AIR INLET

7′ MIN. ABOVE ANY PUBLIC WALKWAY

Prepare wall penetrations 1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-5A.

BIRD SCREEN
ELBOW BIRD SCREEN
Prepare wall penetrations (Factory Supplied Option)
1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.
Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe
Drill 3/16″ diameter holes for inserting the plastic anchors into the wall.
2. For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3G on page 22 into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate (FIG. 4-4A).
3. For PVC/CPVC Only: Install the vent and air intake piping through the wall into the vent plate openings. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3E on page 21 to seal the vent pipe.

26

Installation & Operation Manual

4 Sidewall direct venting (continued)

4. Mount and secure the vent plate to the wall using stainless Multiple vent/air terminations

steel screws.

5. Seal all gaps between the pipes and wall. Seal around the 1. When terminating multiple FTXL’s terminate

plate to the wall assuring no air gaps.

each vent/air connection as described in this manual

6. Assemble the vent cap to the vent plate (see FIG.’s 4-5B (FIG. 4-6A).

and 4-5C). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap

WARNING

All vent pipes and air inlets must terminate at the same height to avoid possibility of

to the vent plate.

severe personal injury, death, or substantial

7. Seal all wall cavities.

property damage.

8. PVC/CPVC terminations are designed to accommodate any 2. Place wall penetrations to obtain minimum clearance of

wall thickness of standard constructions per the directions

12 inches (305 mm) between vent pipe and adjacent air

found in this manual.

inlet elbow, as shown in FIG. 4-6B for U.S. installations.

9. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.

For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

Figure 4-5B PVC/CPVC Sidewall Termination Assembly

3. The air inlet of a FTXL is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 4-6A Multiple Vent Terminations w/

VENT AIR

Field Supplied Fittings (must also comply with

Figure 4-1A)

AIR PIPING

CENTERLINE WIDTH

VENT

VENT PIPING
WALL PLATE
GALVANIZED THIMBLE

VENT PLATE VENT CAP

12″ (305 MM) MIN 15″ (381 MM) MAX

Table 4B Sidewall Vent Centerline Dimensions

Model Air Vent Centerline Width

400 – 600 4″ (102 mm) 4″(102 mm) 5 5/8″ (143 mm) 725 – 850 4″ (102 mm) 6″ (152 mm) 7 3/4″ (197 mm)

Figure 4-5C Polypropylene Sidewall Termination Assembly

SIDEWALL

ADAPTER

(AIR)

WALL

PLATE

SIDEWALL RETAINING PLATE

12″ (305 MM) MIN. BETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE
AIR

Figure 4-6B Multiple Vent Terminations (must also comply with Figure 4-1B)

VENT

12″ MIN. BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET

AIR

SIDEWALL ADAPTER (VENT)

VENT PLATE
VENT CAP

VENT / AIR TERMINATION

GALVANIZED THIMBLE

IMG00085

27

Installation & Operation Manual

4 Sidewall direct venting
Sidewall termination ­ optional concentric vent: Models 400 – 600 Only

Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit (#100140484 for 4″ (102 mm) diameter – Models 400 – 600). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-7.
The required combustion vent pipe materials are listed in Table 3E, on page 21 of this manual.
Figure 4-7 Concentric Sidewall Termination – Models 400 – 600
OVERHANG OR ROOF

3. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 installations into the structure to install the termination kit.
4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions. a. Cement the Y concentric fitting to the larger kit pipe (FIG. 4-8). b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-8).
Figure 4-8 Kit Contents_100140484 – Models 400 – 600

RAIN CAP

12″ (305 MM) MIN
12″ (305 MM) MIN
GRADE / SNOW LINE
Sidewall termination installation 1. Determine the best location for the termination kit
(see FIG. 4-7). 2. Reference the Determine Location Section on page 24 of
this manual for general termination considerations.

6″ (152 MM) TO 4″ (102 MM) REDUCER 6″ (152 MM) DIA.
6″ (152 MM) DIA.
4″ (102 MM) DIA. “Y” CONCENTRIC FITTING 6″ (152 MM) DIA. “FLEXIBLE” PIPE COUPLING

28

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination ­ optional concentric vent: Models 400 – 600 Only

Figure 4-9 Concentric Vent Dimensional Drawing – Models 400 – 600

“A”

“C” DIA.

“B” DIA.

3″

“D”

(76 MM)

“E”

“G”

“H” DIA.

“B” DIA. PVC

“F”

VENT / EXHAUST

A

B

C

D

E

F

G

H

60″

4″

6″ 21 1/8″ 10″ 7 5/8″ 3″ 6 5/8″

(1524 MM) (102 MM) (152 MM) (537 MM) (254 MM) (194 MM) (76 MM) (168 MM)

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-10).

WARNING

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 4-10 Rain Cap to Vent Pipe Alternate Assembly

5. Install the Y concentric fitting and pipe assembly through the structure’s hole from an inside wall.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly

when installing through the hole.

6. Install the rain cap and small diameter pipe assembly

into the Y concentric fitting and large pipe assembly

from an outside wall. Ensure small diameter pipe is

fastened tightly into the rubber adapter for #100140484

installations.

7. Secure the assembly to the structure as shown in

FIG. 4-11 using field-supplied metal strapping or

equivalent support material.

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-7.

NOTICE NOTICE

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied standard schedule 40 PVC for #100140484. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9).
If assembly depth needs to be reduced, dimension D can be as short as possible.

STAINLESS STEEL SCREW (FIELD SUPPLIED)
DRILL CLEARANCE HOLE IN RAIN CAP & PILOT HOLE IN VENT PIPE

Table 4C Alternate Centrotherm Concentric Vent Terminations

Roof Terminations

Size

Part No.

2″

ICRT2435

3″

ICRT3539

4″

ICRT4679

Wall Terminations

Size

Part No.

2″

ICWT242

3″

ICWT352

4″

ICWT462

29

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination ­ optional concentric vent: Models 400 – 600 Only

Figure 4-11 Concentric Vent Sidewall Attachment

ELBOW (FIELD SUPPLIED)

STRAP (FIELD SUPPLIED)

COMBUSTION AIR

COMBUSTION AIR

VENT

VENT

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-11 for proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing sidewall terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-12). When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-12. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

VENT

12″ MINIMUM

COMBUSTION AIR Figure 4-12 Concentric Vent and Combustion Air Termination
30

Installation & Operation Manual

5 Vertical direct venting
Vent/air termination ­ vertical

WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

Determine location
Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 18 of this manual.

2. Prepare the vent termination and the air termination elbow (FIG. 5-1A) by inserting bird screens. Bird screens should be obtained locally.

3. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

4. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

5. The vent piping must terminate in an up-turned coupling as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36″ (914 mm) above the air inlet. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 1 foot above the air intake.

6. Maintain the required dimensions of the finished termination piping as shown in FIG. 5-1A.

Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ (610 MM) OF VENT PIPE

BIRD SCREEN (TYPICAL)
COUPLING (FIELD SUPPLIED)
VENT OUTLET 12″ MINIMUM
ABOVE AIR INLET

VENT
COMBUSTION AIR

6″ (152 MM) MINIMUM ABOVE ROOF / SNOW LINE

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24″ (610 MM) OF VENT PIPE

BIRD SCREEN

VENT

(TYPICAL)

6″ (152 MM) MINIMUM ABOVE ROOF / SNOW LINE

VENT OUTLET 36″ (914 MM) MINIMUM
ABOVE AIR INLET

COM,BUSTION AIR

8. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent, Sidewall Air Section.

31

Installation & Operation Manual

5 Vertical direct venting
Vent/air termination ­ vertical
Prepare roof penetrations
1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: · 5½ inch hole (140 mm) hole? for 4 inch (102 mm) vent pipe · 7½ inch hole (191 mm) hole? for 6 inch (152 mm) vent pipe b. Insert a galvanized metal thimble in the vent pipe hole (when required by local codes).
3. Space the air and vent holes to provide the minimum spacing shown in FIG.’s 5-1A and 5-1B, page 31.
4. Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe and air pipe.

Multiple vent/air terminations

1. When terminating multiple FTXL boilers, terminate each vent/air connection as described in this manual (FIG. 5-2).

WARNING

Terminate all vent pipes at the same height and all air pipes at the same height

to avoid recirculation of flue products and

the possibility of severe personal injury,

death, or substantial property damage.

2. Place roof penetrations to obtain minimum clearance of 12 inches (305 mm) between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a FTXL boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 5-2 Vertical Terminations with Multiple Boilers

VENT AIR

VENT AIR

12″ (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET
12″ (305 MM) MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER

Figure 5-3 Alternate Vertical Terminations with Multiple Boilers

VENT

VENT

AIR AIR

12″ (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET

32

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination ­ optional concentric vent: Models 400 – 600 Only

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
The required combustion vent pipe fittings are listed in Table 3E, on page 21 of this manual.
Vertical termination installation
1. See Section 5, Vertical Direct Venting – Determine Location (where applicable).
Figure 5-4 Concentric Vertical Termination

2. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 installations) into the structure to install the termination kit.
3. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions. a. Cement the Y concentric fitting to the larger diameter kit pipe (see FIG. 4-8, page 28). b. Cement rain cap to the smaller diameter kit pipe (see FIG. 4-8, page 28).

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-10, page 29).

VENT
12″ (305 MM) (18″ (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24″ (610 MM) ABOVE ROOF.

COMBUSTION AIR

WARNING

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

Figure 5-5 Do Not Install U-Bend to Rain Cap

33

Installation & Operation Manual

5 Vertical direct venting

Vertical termination ­ optional concentric vent: Models 400 – 600 Only

WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

4. Install the Y concentric fitting pipe assembly up through the structure’s hole and field supplied roof boot/flashing.

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is fastened tightly into the rubber adapter for #100140484 installations.

7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.

Figure 5-6 Concentric Vent Roof Installation

COMBUSTION AIR
ROOF BOOT / FLASHING (FIELD SUPPLIED)

VENT

12″ (305 MM) (18″ (457 MM) FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24″ (610 MM) ABOVE ROOF.

8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.
Multiventing vertical terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

SUPPORT (FIELD SUPPLIED)
ELBOW (FIELD SUPPLIED)

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination
12″ MINIMUM

VENT

COMBUSTION AIR

NOTICE NOTICE

Ensure termination height is above the roof surface or anticipated snow level (12 inches (305 mm) in U.S.A. or 18 inches (457 mm) in Canada) as shown in FIG. 5-4, page 33.
If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied standard schedule 40 PVC for 100140484. Do not extend dimension D* more than 60 inches (1524 mm) (see FIG. 4-9, page 29).

34

12″ (18″ FOR CANADA) MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF
24″ ABOVE ROOF.

COMBUSTION AIR (TYPICAL)

Installation & Operation Manual

5 Vertical direct venting (continued)

Alternate vertical concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.

Figure 5-8 Concentric Vent Example 1
FLUE EXHAUST
SEAL

Concentric Venting Arrangement
The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.
The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A.
The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.
Approved venting materials must be used as specified in Table 3E on page 21.
Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.
The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.
If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A on page 10 for a list of corrosive contaminants and sources.

EXISTING
SEALED CAP

COMBUSTION AIR
AIR INLET W/ SCREEN
12″ MIN. SEAL

IMG01065

FLUE OUTLET

*For concept illustration only. Individual installations may vary due to job site specific equipment.

Figure 5-9 Concentric Vent Example 2

SEAL

FLUE EXHAUST

EXISTING
SEALED CAP
SEAL

COMBUSTION AIR INLET W/ SCREEN
SEAL

Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Model
400 – 600 725 – 850

Vent / Air Inlet Size
4″ 6″

Minimum Existing Vent / Chase Size
7″ 10″

FLUE OUTLET
IMG01066
*For concept illustration only. Individual installations may vary due to job site specific equipment.

35

5 Vertical direct venting

Existing vent as a chase
Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.

Figure 5-10 Existing Vent as a Chase

FLUE EXHAUST

AIR INLET

SEAL EXISTING
SEAL

CAP

FLUE OUTLET
IMG01067
*For concept illustration only. Individual installations may vary due to job site specific equipment.

Installation & Operation Manual

36

Installation & Operation Manual

6 Hydronic piping
System water piping methods
The FTXL is designed to function in a closed loop system pressurized to not less than 12 psi (83 kPa) (Non-metallic system piping must have an oxygen barrier to be considered a closed loop). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

It is important to note that the boiler has a minimal amount of pressure drop which must be accounted for when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation or basic service of circulator replacement, valves, and others.

Observe a minimum of 1/4 inch (6 mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non- combustible materials.

Low water cutoff device
This boiler comes equipped with a low water cutoff device. On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system
If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection fluids

Freeze protection fluids for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

WARNING

Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

General piping information

IMPORTANT

All boiler piping must contain an oxygen barrier. This will help prevent any excess oxygen from entering the system.

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-5 through 6-10), which will guide you through the installation of the FTXL (reference FIG.’s 6-3A and 6-3B).

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line, (15 psi (103 kPa) nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi (83 kPa).

6. Install a circulator as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi (103 kPa).

10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

NOTICE

The relief valve, tee and any other necessary fittings are shipped in the install kit with the boiler and are to be field installed (FIG.’s 6-1 and 6-2).

11. Install a field supplied strainer/filter to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre-existing system, a strainer/filter capable of removing debris left in the system is recommended.

12. Install a field supplied magnetic separator in the heating system return line as close as practical to the boiler per the manufacturer’s instructions.

NOTICE

A magnetic separator is recommended when a unit is installed in a retrofit system, or a

system containing steel and/or cast iron pipe.

See the piping illustrations included in this section, FIG.’s 6-5

and 6-10 for suggested guidelines in piping the FTXL.

NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
37

Installation & Operation Manual

6 Hydronic piping

Relief valve and temperature pressure gauge installation

and Figure 6-1 Flow Switch, Relief Valve and Temperature and Pressure Gauge Installation_Models 400 – 600

Basic steps are listed below to guide you through the

installation of the relief valve, and temperature and pressure

gauge provided with the unit.

1. Install the tee directly to the outlet connection of the heat exchanger with the 3/4 inch fitting positioned vertically and on the top (see FIG. 6-2).
2. For Models 725 – 850 install the 3/4 inch close nipple in the tee. Install the relief valve on the 3/4 inch close nipple (FIG. 6-2). For Models 400 – 600 install the relief valve directly into the 3/4 inch fitting on the tee (FIG. 6-1).
3. Install the close nipple on the downstream side of the relief valve tee (FIG. 6-1).
4. Install the tee with the 1 inch fitting positioned vertically and on the top (FIG. 6-1).
5. Install a field provided close nipple on the downstream side of the flow switch (if used), see FIG.’s 6-1 and 6-2.

FLOW SWITCH (OPTIONAL)
PADDLE (OPTIONAL)
TEMPERATURE AND PRESSURE GAUGE
TEE WITH FITTING ON TOP
(FIELD PROVIDED)
CLOSED NIPPLE (FIELD PROVIDED) TEE WITH 1″ FITTING
ON TOP (FIELD PROVIDED)

RELIEF VALVE
TEE WITH 3/4″ FITTING ON TOP CLOSE NIPPLE (FIELD PROVIDED)
IMG00993

6. Install a field provided tee with the gauge fitting

positioned vertically and on the top (FIG.’s 6-1 and

6-2)

Figure 6-2 Flow Switch, Relief Valve and Temperature and

7. Install the temperature and pressure gauge provided Pressure Gauge Installation_Models 725 – 850

with the unit into the top fitting of the tee (a bushing

may be necessary) installed in Step 6 (FIG.’s 6-1 and

6-2).

NOTICE

If using a flow switch, be sure to install the flow switch so that the arrow on the flow switch is pointing in the direction of the flow.

FLOW SWITCH (OPTIONAL)
PADDLE (OPTIONAL)

RELIEF VALVE

TEMPERATURE AND PRESSURE GAUGE

TEE WITH FITTING ON TOP
(FIELD PROVIDED)
CLOSED NIPPLE (FIELD PROVIDED)
TEE WITH 1″ FITTING ON TOP (FIELD PROVIDED)

TEE WITH 3/4″ FITTING ON TOP
CLOSE NIPPLE (FIELD PROVIDED)
IMG00994

38

Installation & Operation Manual

6 Hydronic piping (continued)
Near boiler piping components
1. Boiler system piping: Boiler system piping MUST be sized per the pipe requirements listed in Table 6B. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on a full flow application.
2. Boiler system circulating pump: Field supplied. The boiler circulating pump should be based on system requirements.
3. Domestic hot water circulating pump: Field supplied. The pump MUST be sized to meet the specified minimum flow requirements listed in FIG. 6-4. Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.
4. Variable speed boiler circulator: FTXL boilers are capable of controlling a variable speed boiler circulator. Variable speed circulators MUST be sized to meet the specified minimum flow requirements listed in FIG. 6-4 on page 41 at full speed. To be used in primary/secondary systems only.
5. Boiler isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
6. Check valves: Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-5 through 6-10. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.
7. Domestic indirect hot water isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
8. Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F (46°C).
9. Unions: Field supplied. Recommended for unit serviceability.
10. Temperature and pressure gauge: Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.
11. Pressure relief valve: Factory supplied. The pressure relief valve is sized to ASME specifications.

12. Boiler purge valve: Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.
13. System temperature sensor: Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. The sensor should be located far enough downstream to sense system diluted water temperature.
14. Water Meter: Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.
15. Strainer/Filter: Field supplied. Install a Y-strainer or equivalent multipurpose strainer/filter just before the boiler pump at the inlet of the heat exchanger. This item is used to remove system debris from older hydronic systems and to protect newer systems.
16. Motorized isolation valve (optional): Field supplied. A motorized isolation valve can be used to isolate the boiler from the system piping.
17. Magnetic Separator: Field supplied. Install a magnetic separator in the heating system return line as close as practical to the boiler per the manufacturer’s instructions.
Circulator sizing The FTXL heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graphs in FIG. 6-4 for pressure drop through the FTXL heat exchanger.
39

Installation & Operation Manual

6 Hydronic piping
Near boiler piping connections
Figure 6-3A Near Boiler Piping w/Y-Strainer

Variable speed pump option
Variable speed pump setup Before operation, ensure the following:
– Pump is set for an input signal of 0 – 10VDC by the dip switches on the pump control

– Pump is set for external signal control (if applicable)

– Pump is set for linear output (if applicable)

FROM SYSTEM

P

TP

BOILER

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DRAIN PORT
EXPANSION TANK
FLOW SWITCH OPTIONAL MAGNETIC SEPARATOR

PRESSURE RLEEDGUECNIDNG VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
SYSTEM SUPPLY SENSOR

STRAINER / FILTER T P TEMPERATURE &
PRESSURE GAUGE WATER METER
PIPING
DIR #2000546697 01

Figure 6-3B Near Boiler Piping w/Low Loss Header

TO SYSTEM
MAKE UP WATER

– If pump does not come equipped with a 0 – 10 VDC input option, an optional module will be required from the vendor
SMART SYSTEM / Multi-temperature loop control option

The FTXL boiler is capable of producing up to three (3) set point temperatures to meet different space heating demands. When using more than one temperature demand it is necessary to protect the lower temperature loop(s) from overheating. To help aid with this protection, Lochinvar offers the MultiTemperature Loop Control Board Kit (100167843).

CAUTION

The maximum allowable water flow rate through a single FTXL boiler is 105 GPM

(Models 400 – 600) and 150 GPM (Models

725 – 850). Exceeding this flow rate will

result in damage to the heat exchanger and/

or piping.

NOTICE

Reference Table 6A1 for the minimum recommended flow rate through a single

FTXL boiler at full fire to maintain a 80°F

temperature rise. Reference Table 6A2 for

the absolute minimum flow rate through a

single FTXL boiler.

Table 6A1 Minimum Flow Rate with the Boiler at Full Fire

TO SYSTEM
FROM SYSTEM MAKE UP WATER
40

LOW LOSS HEADER
TP P

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DRAIN PORT
EXPANSION TANK
FLOW SWITCH OPTIONAL MAGNETIC SEPARATOR

PRESSURE RLEEDGUECNIDNG VALVE
PRESSURE RELIEF VALVE
P PRESSURE GAUGE
SYSTEM SUPPLY SENSOR

STRAINER / FILTER T P TEMPERATURE &
PRESSURE GAUGE WATER METER
PIPING
DIR #2000546698 01

TEMPERATURE RISE APPLICATIONS

MODEL

FLOW RATE (GPM)

FTX(N,L)400

10

FTX(N,L)500

12

BOILER

FTX(N,L)600

15

FTX(N,L)725

18

FTX(N,L)850

21

[Based on 80°F Temperature Rise]

Table 6A2 Absolute Minimum Flow Rate @ Low Fire

ABSOLUTE MINIMUM FLOW RATE

MODEL

FLOW RATE (GPM)

FTX(N,L)400

4

FTX(N,L)500

4

FTX(N,L)600

4

FTX(N,L)725

4

FTX(N,L)850

4

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-4 Pressure Drop vs. Flow

HEX Pressure Drop (Full Flow Application)

FTX725-850

FTX400-600

Pressure Drop (Feet of Head)

15 ft

15 ft

14 ft

FTX725-850 14 ft

13 ft

13 ft

12 ft

FTX400-600

12 ft

11 ft

11 ft

10 ft

10 ft

9 ft

9 ft

8 ft

8 ft

7 ft

7 ft

6 ft

6 ft

5 ft

5 ft

4 ft

4 ft

3 ft

3 ft

2 ft

2 ft

1 ft

1 ft

0 ft

0 ft

Flow Rate

Table 6B Sizing Information for Temperature Rise Applications_20°F, 30°F, 40°F, 60°F and 80°F

TEMPERATURE RISE APPLICATIONS

MINIMUM

20°F

Model PIPE SIZE

GPM FT/HD

30°F GPM FT/HD

40°F GPM FT/HD

60°F GPM FT/HD

80°F GPM FT/HD

400

2″

39

3.5

26

2.8

20

2.5

13

2.4

10

2.3

500

2″

49

4.8

33

3.4

24

2.9

16

2.5

12

2.4

600

2″

59

4.4

39

3.2

29

2.8

20

2.5

15

2.3

725 2 1/2″

71

4.9

47

3.5

35

3.0

24

2.7

18

2.6

850 2 1/2″

83

5.7

55

3.9

41

3.3

28

2.8

21

2.6

41

Installation & Operation Manual

6 Hydronic piping
Figure 6-5 Multiple Boilers – Alternate – Fixed or Variable Flow Primary System Piping

Number of Units

Model 2

3

4

5

6

7

8

Manifold Pipe Sizes in Inches (mm)

400 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 500 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 600 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 725 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254) 850 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

FROM SYSTEM

TO SYSTEM
P
MAKE UP WATER

TP

BOILER 1

TP

BOILER 2

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING

DIR #2000546062 01

CAUTION NOTICE

Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.

42

6 Hydronic piping (continued)
Figure 6-6 Single Boiler – Multiple Temperatures

Installation & Operation Manual

WIRES TO LOOP SENSORS
120VAC TO PUMPS

SHIELDED CABLE TO BOILER

MULTI TEMP. LOOP CNTL (OPTIONAL)
24VAC SIGNAL TO MIXING VALVES

SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3

TEMP LOOP 1

TEMP LOOP 2

TEMP LOOP 3

SENSOR 1

SENSOR 2

SENSOR 3

PUMP 1 VALVE 1

PUMP 2 VALVE 2

PUMP 3 VALVE 3

TO SYSTEM

P
MAKE UP WATER

FROM SYSTEM

TP

BOILER

INDIRECT DHW TANK

DHW HOT WATER OUT
COLD WATER IN

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING
DIR #2000546092 01

CAUTION NOTICE

Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.

43

6 Hydronic piping
Figure 6-7 Single Boiler – Primary/Secondary Piping

Installation & Operation Manual

TO SYSTEM
MAKE UP WATER

MAY SUBTITUTE LOW LOSS HEADER
P

FROM SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX OF 12″ APART

DHW HOT WATER OUT
COLD WATER IN

INDIRECT DHW TANK

TP

BOILER

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING
DIR #2000559501 01

CAUTION

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

NOTICE
NOTICE
44

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Installation & Operation Manual

6 Hydronic piping (continued)

Figure 6-8 Multiple Boilers – Multiple Temperatures

Number of Units

Model 2

3

4

5

6

7

8

Manifold Pipe Sizes in Inches (mm)

400 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 500 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 600 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 725 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254) 850 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

WIRES TO LOOP SENSORS
120VAC TO PUMPS

SHIELDED CABLE TO BOILER

MULTI TEMP. LOOP CNTL (OPTIONAL)
24VAC SIGNAL TO MIXING VALVES

SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3

TEMP LOOP 1

TEMP LOOP 2

TEMP LOOP 3

SENSOR 1

SENSOR 2

SENSOR 3

PUMP 1 VALVE 1

PUMP 2 VALVE 2

PUMP 3 VALVE 3

TO SYSTEM

P
MAKE UP WATER

FROM SYSTEM

DHW HOT WATER OUT
COLD WATER IN

INDIRECT DHW TANK

TP

BOILER 1

TP

BOILER 2

CAUTION CAUTION NOTICE

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING
DIR #2000546165 01

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.

45

Installation & Operation Manual

6 Hydronic piping

Figure 6-9 Multiple Boilers – Primary/Secondary Piping

Number of Units

Model 2

3

4

5

6

7

8

Manifold Pipe Sizes in Inches (mm)

400 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 500 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 600 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 725 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254) 850 4 (102) 5 (127) 6 (152) 8 (203) 8 (203) 8 (203) 10 (254)

TO SYSTEM
MAKE UP WATER

MAY SUBTITUTE LOW LOSS HEADER
P NOT TO EXCEED 4 PIPE DIA OR MAX OF 12″ APART

FROM SYSTEM

DHW HOT WATER OUT
COLD WATER IN

INDIRECT DHW TANK

TP

BOILER 1 (LEADER)

TP

BOILER 2

TP

BOILER 3

TP

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING

DIR #2000559502 01

BOILER 4

CAUTION NOTICE
NOTICE
46

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in operation to prevent short cycling and high limit issues.

Installation & Operation Manual
6 Hydronic piping (continued)
Figure 6-10 Single Boiler – Multiple Temperatures with DHW Piped as a Zone

WIRES TO LOOP SENSORS
120VAC TO PUMPS

SHIELDED CABLE TO BOILER

MULTI TEMP. LOOP CNTL (OPTIONAL)
24VAC SIGNAL TO MIXING VALVES

SENSOR 1 SENSOR 2 SENSOR 3
PUMP 1 PUMP 2 PUMP 3
VALVE 1 VALVE 2 VALVE 3

TEMP LOOP 1

TEMP LOOP 2

TEMP LOOP 3

SENSOR 1

SENSOR 2

SENSOR 3

PUMP 1 VALVE 1

PUMP 2 VALVE 2

PUMP 3 VALVE 3

TO SYSTEM

P
MAKE UP WATER

FROM SYSTEM

TP

BOILER

INDIRECT DHW TANK

AIR SEPARATOR
BACKFLOW PREVENTER
BALL VALVE
CIRCULATION PUMP

DIFFERENTIAL PRESSURE BYPASS VALVE DRAIN PORT
EXPANSION TANK
FLOW CHECK VALVE

FLOW SWITCH OPTIONAL
MAGNETIC SEPARATOR LEGEND
MIXING VALVE ANTI SCALD
PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE
P PRESSURE GAUGE

T P TEMPERATURE & PRESSURE GAUGE
WATER METER

SYSTEM SUPPLY SENSOR

2 WAY MOTORIZED VALVE (OPTIONAL)

STRAINER / FILTER

PIPING WIRING

DIR #2000546252 01

DHW HOT WATER OUT
COLD WATER IN

CAUTION

Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler output does not exceed indirect water heater transfer capabilities.

CAUTION Mixing valves are required for the protection of low temperature loops.

NOTICE NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Connection locations shown are for reference only and will vary with boiler type.
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

47

Installation & Operation Manual

7 Gas connections

Connecting gas supply piping
1. Remove the top access panel and refer to FIG.’s 7-1 and 7-2 to pipe gas to the boiler. a. Install ground joint union for servicing, when required. b. Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements. c. In Canada ­ When using manual main shutoff valves, it must be identified by the installer.
2. Install sediment trap / drip leg.
Figure 7-1 Gas Supply Piping – Model 400 – 600
MANUA L SHUTOFF VALVE (FACTORY SUPPLIED)
GAS SUPPLY

SEDIMENT TRAP/ DRIP LEG
UNION (FIELD SUPPLIED)

IMG01004

Figure 7-2 Gas Supply Piping – Models 725 – 850
MANUAL SHUTOFF VALVE (FACTORY SUPPLIED)

3. Support piping with hangers, not by the boiler or its accessories.

WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

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

c. The appliance and its gas connection must be leak tested before placing it in operation.

WARNING

Do not check for gas leaks with an open flame ­ use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

GAS SUPPLY

SEDIMENT TRAP/ DRIP LEG
UNION (FIELD SUPPLIED)
48

IMG01002

Installation & Operation Manual

7 Gas connections (continued)

WARNING

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

WARNING

Use two wrenches when tightening gas piping at boiler (FIG. 7-3), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Figure 7-3 Inlet Pipe with Backup Wrench
USE BACKUP WRENCH TO PREVENT PIPE FROM ROTATING

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:
· Maximum 14 inches w.c. (3.5 kPa) with no flow (lockup) or with boiler on.
· Models 400 & 600 – 850: Minimum 4 inches w.c. (.99 kPa) with gas flowing (verify during boiler startup).
Model 500 Only: Minimum 5 inches w.c. (1.25 kPa) with gas flowing (verify during boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. (3.5 kPa) at any time. Adjust lockup regulator for 14 inches w.c. (3.5 kPa) maximum.

Propane Gas:

WARNING

FTXL boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing a LP venturi or by making a gas valve adjustment (see pages 14 and 15). In order to operate on LP gas, a LP venturi MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

NOTICE

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

Natural gas:
Pipe sizing for natural gas
1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).
a. Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas piping of 0.3 inches w.c.
b. For additional gas pipe sizing information, refer to ANSI Z223.1 (or B149.1 for Canadian installations).

Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. (3.2 kPa) maximum pressure.

2. Pressure required at gas valve inlet pressure port:

· Maximum 14 inches w.c. (3.2 kPa) with no flow (lockup) or with boiler on.

· Minimum 8 inches w.c. (1.9 kPa) with gas flowing (verify during boiler startup).

WARNING

Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the

appliance.

49

Installation & Operation Manual

7 Gas connections
Table 7A Natural Gas Pipe Size Chart

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30″ w.c. pressure drop)

Pipe Size (Inches)
1/2
3/4 1 1 1/4 1 1/2
2 2 1/2
3 4

10 20 30

131 90 273 188 514 353 1,060 726 1,580 1,090 3,050 2,090 4,860 3,340 8,580 5,900 17,500 12,000

72 151 284 583 873 1,680 2,680 4,740 9,660

Length of Pipe in Straight Feet

40 50 60 70 80 90 100

62 129 243 499 747 1,440 2,290 4,050 8,270

55 114 215 442 662 1,280 2,030 3,590 7,330

N/A 104 195 400 600 1,160 1,840 3,260 6,640

N/A 95 179 368 552 1,060 1,690 3,000 6,110

N/A 89 167 343 514 989 1,580 2,790 5,680

N/A 83 157 322 482 928 1,480 2,610 5,330

N/A 79 148 304 455 877 1,400 2,470 5,040

125
N/A 70 131 269 403 777 1,240 2,190 4,460

150
N/A 63 119 244 366 704 1,120 1,980 4,050

175
N/A 58 109 224 336 648 1,030 1,820 3,720

200
N/A N/A 102 209 313 602 960 1,700 3,460

Check inlet gas supply

NOTICE

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.

WARNING

DO NOT adjust gas valve outlet pressure. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.
3. On Models 400 – 500 loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. On Models 600 – 850 remove the 1/8″ (3 mm) pipe plug on the inlet flange to the valve and install a suitable 1/8″ (3 mm) fitting (field supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the set screw is loosened or the 1/8″ (3 mm) fitting is installed (depending on model) as shown in FIG.’s 7-5 and 7-6 on page 51.

4. Slowly turn on the gas supply at the field installed manual gas valve.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat.
7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.
8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this s

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