Lochinvar 400 Fire Tube Boiler Instruction Manual Product Information
- March 8, 2024
- Lochinvar
Table of Contents
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.
“`
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
- ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE
EQUIVALENT LENGTHS.
- 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