Brute FT Series Manual Download

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Page 80

SECTION 10 Parts

10.1 100 MBH

Casing Assembly

Summary of Contents for FT Series

Page 1: ...e serious injury property damage or death Improper installation and or operation will void the warranty AVERTISSEMENT Assurez vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d incendie ou d explosion ou pour éviter tout dommage matériel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables...

Page 2: ...s 42 4 14 1 External Plumbing and Water Connection Guidelines 42 4 14 2 Applicable Backflow Preventer 42 4 14 3 Diaphragm type Expansion tank 42 4 14 4 Zoning with zone valve 43 4 14 5 Zoning with circulation pumps 44 4 14 6 Indirect Water Heating 45 4 14 7 Multiple units using zones pumps and an indirect for DHW 46 4 15 Pressure Relief Valve 47 4 16 Disposal of Condensate 48 4 17 Electrical Wirin...

Page 3: ...ained herein All electrical wiring is to be done in accordance with the local codes or in the absence of local codes with 1 The National Electrical Code ANSI NFPA No 70 latest Edition or 2 CSA STD C22 1 Canadian Electrical Code Part 1 This appliance must be electrically grounded in accordance with these codes Allapplicationandinstallation procedures must be read and reviewed completely before proc...

Page 4: ...iler FTHW all sizes 1 Installation Instructions and User s Manual 1 Condensate Hose 1 Wall Mount Bracket 1 2 types of Wall Anchors 4 Pressure Relief Valve CH LINE 3 4 30psi Model CASH ACME F 82 1 Mesh Screens 3 2 1 2 Included in the Box 4 FT1894 ...

Page 5: ...N with Pump 1 M SECTION 2 Product Characteristics 2 1 Model Nomenclature model number The Model Nomenclature is shown on your Rating Plate and consists of a series of letters and numbers Nomenclature that further identifies the characteristics of your FT Series Boiler Items Descriptions Qty Propane Conversion Orifice 1 O Ring and Gasket Kit 1 Outdoor Temperature Sensor with anchors and screws MODE...

Page 6: ...t Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Metal Ceramic Infrared Gas Valve System Combination modulating Current proportional Dimensions W17 H29 0 D14 Shipping Weight 98 lbs 44 kg Main Controller Control Display NGTB 900CP P 950EH Water Pressure CH Min 15 Max 30 PSI Connection Sizes CH Supply Return 1 NPT Gas Inlet 3 4 NPT Materials Casing ...

Page 7: ...ower Consumption 160W Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Metal Ceramic Infrared Gas Valve System Combination modulating Current proportional Dimensions W17 H29 0 D14 Shipping Weight 102 lbs 46 kg Main Controller Control Display NGTB 900CP P 950EH Water Pressure CH Min 15 Max 30 PSI Connection Sizes CH Supply Retu...

Page 8: ...on 160W Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Metal Ceramic Infrared Gas Valve System Combination modulating Current proportional Dimensions W19 H32 0 D16 Shipping Weight 118 lbs 54 kg Main Controller Control Display NGTB 900CP P 950EH Water Pressure Min 15 Max 30 PSI Connection Sizes CH Supply Return 1 NPT Gas Inle...

Page 9: ...1 17 A B C D E F 2 0 2 10 3 8 1 2 3 4 3 4 3 4 7 8 3 8 3 4 3 8 1 2 TOP VIEW BOTTOM VIEW FRONT VIEW Description Diameter A Air Intake Collar 3 B Vent Pipe Collar 3 C CH Supply 1 D CH Return 1 E Gas Inlet 3 4 F Condensate Line 1 2 FTHW 100 140 Heating only boiler 2 3 Dimensions ...

Page 10: ...ent Pipe Collar 3 C CH Supply 1 D CH Return 1 E Gas Inlet 3 4 F Condensate Line 1 2 9page 199 16 5 32 0 3 7 13 19 A B 4 11 C D E F 2 0 2 11 7 8 5 8 3 4 1 2 5 8 3 4 7 8 1 4 3 4 1 4 TOP VIEW BOTTOM VIEW FRONT VIEW FTHW 199 Heating only boiler 2 3 Dimensions ...

Page 11: ... Internal Pump 15 Gas Inlet Adapter 16 CH Supply Adapter NO Name of Component 17 CH Pressure Gauge 18 CH Return Adapter 19 Condensate Adapter 20 Condensate Trap 21 CH Return Temperature Sensor 22 Condensate Air Pressure Switch 23 Terminal Block 24 Heat Exchanger 25 Ignition Transformer 26 Sight Glass 27 Burner Overheat Switch 28 Igniter 29 BLDC Fan blower 30 Exhaust Temperature Sensor 31 Air Press...

Page 12: ...1 Flame Detecting Sensor 12 Control Display 13 Manual ON OFF Power Switch 14 CH Internal Pump 15 Gas Inlet Adapter 16 CH Supply Adapter NO Name of Component 17 CH Pressure Gauge 18 CH Return Adapter 19 Condensate Adapter 20 Condensate Trap 21 CH Return Temperature Sensor 22 Condensate Air Pressure Switch 23 Terminal Block 24 Heat Exchanger 25 Ignition Transformer 26 Sight Glass 27 Burner Overheat ...

Page 13: ... Boiler Page 13 Water in the heating pipe is used for space heating 2 5 Product Flow Paths and Characteristics CH Supply Gas Supply CH Return CH Central Heat Vent Combustion Air CH Supply CH Return Gas Input Combustion Air Vent ...

Page 14: ...ns exactly a fire or explosion could result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will s...

Page 15: ... any part has been under water Immediately call a qualified technician for inspecting the Boiler and replacing any part of the control system and gas control which have been under water Do not power up the unit until the gas and water supply valves are fully opened Make sure that the fresh air intake port and exhaust gas port are opened and functional DO NOT attempt to install repair or service th...

Page 16: ...ler 2 Check the Power 120V 60Hz Check that the appliance is connected properly 3 Check the Cold Water Inlet valve Please keep the appliance water inlet valve open at all times The appliance will not ignite when insufficient water or no water is in the heating pipes valve always open position 4 Check the Gas Valve Check that the manual gas shut off valve that supplies the FT is opened 5 Check the a...

Page 17: ...h has gas control system components must be protected from any possible danger during operation and service If new Boiler replaces an existing appliance check and correct system problems for example Do not install if System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits Provide clearances If the boiler was installed in a narrow space or corner please ensure that t...

Page 18: ... wall through the Bracket If mounting to a concrete wall then use the concrete anchors If onto wood or 5 8 16 mm plywood then use the wood screws Do not hang the FT onto sheetrock unless it is possible to fasten directly into the structural studs If the included anchors do not suit your installation you must use Field Supplied anchors that are appropriate for the wall s construction Wall Mount Bra...

Page 19: ...all equipment in the enclosure When communicating to the outdoors through horizontal ducts each opening shall have a minimum free area of not less than 1square inch per 2000 Btu hr 1100 square mm kW of total input rating of all equipment in the enclosure Method 2 One permanent opening commencing within 12 300mm of the top of the enclosure shall be permitted The opening shall directly communicate w...

Page 20: ...for drainage of condensate NOTICE For long trouble free operation it is critical that the FT unit has always access to clean combustion air either drawn from an inside space per section 4 3 1 or external per section 4 3 2 Do NOT allow contaminated indoor air either by internal dust sheet rock PVC or CPVC pipe debris dust or similar contamination to be drawn in through the air intake connection If ...

Page 21: ...ay lead to property damage severe injury or death INSTALLATIONS IN CANADA require the use of venting material certified to ULCS636 All Gas vents connected to the FT plastic stainless steel or otherwise must be certified to this ULC standard Appropriate selection of vent material is very important for proper performance and safe operation of the FT The flue temperature of the FT changes dramaticall...

Page 22: ... the vent system must be from a certified manufacturer 4 Vent system components must not be mixed with alternate manufacturers certified components and or unlisted components 5 The venting must be installed according to the vent manufacturers installation instructions The unit s vent can terminate through the roof or through an outside wall Vent pipe must pitch upward toward the vent terminal not ...

Page 23: ...e 5 See Note 5 r e n r o c e d i s n i o t e c n a r a e l C G H Clearance to each side of centerline extended above meter regulator assy 3 ft 91 cm within a height of 15 ft 4 6 m m c 1 9 t f 3 t e l t u o t n e v r o t a l u g e r e c i v r e s o t e c n a r a e l C I J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for applia...

Page 24: ...izontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of the subdivision cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided h...

Page 25: ...e prises pour chaque appareil toujours raccordé au système d évacuation commun et qui fonctionne alors que d autres appareils toujours raccordés au système d évacuation ne fonctionnent pas 1 Sceller toutes les ouvertures non utilisées du système d évacuation 2 Inspecter de façon visuelle le système d évacuation pour déterminer la grosseur et l inclinaison horizontale qui conviennent et s assurer q...

Page 26: ... 25 equivalent feet 7 5 M of combus Use this table for Doc 1487 Min Combustion Air Pipe Min Vent Pipe Max Combustion Air Vent Pipe Min Combustion Air Pipe Min Vent Pipe Max Combustion Air Vent Pipe MFTCW 140 199 NG LP 0 FT 0 M 3 FT 1 M 50 FT 15 M 0 FT 0 M 3 FT 1 M 100 FT 30 M Deductions per 90 Elbow Deductions per 45 Elbow Max of Total Elbows on Air Intake Exhaust Vent When using 2 Combustion Air ...

Page 27: ... in2 per 1 000 BTU H 100 in2 13 1 4 W x 13 1 4 H 140 in2 13 1 4 W x 13 1 4 H 199 in2 13 1 4 W x 13 1 4 H Table 6 Adequate Free Area 4 7 3 Indoor Combustion Air Read and Follow Sections 4 3 Guidelines First 1 Insert the termination end cap into the intake air duct Vertical Vent Termination Direct Vent Vertical Terminations with Sloped Roof All Terminations After connecting terminals install vent sc...

Page 28: ...12 MIN Apart Exhaust 90o Elbow Exhaust Screen Exhaust Exhaust 12 MIN 1 MIN Sill Combustion Intake Combustion Intake SIDE VIEW FRONT VIEW Exterior Wall NOTE Must be 12 Minimum distance above highest anticipated snow level or grade whichever is greater TYP 12 MIN 12 MIN Exhaust Screen Exhaust 12 MIN 12 MIN 1 MIN Sill Combustion Intake Combustion Intake SIDE VIEW FRONT VIEW Air Intake Screen 90o Elbo...

Page 29: ... snow level Vent 12 Minimum clearance above highest anticipated snow level or grade whichever is greater 12 Minimum clearance above highest anticipated snow level or grade whichever is greater Side Wall Kit 2 or 3 Exterior Wall E Combustion Air Direct Vent Optional Side wall Terminations c Vent Termination t Optional Horizontal and Vertical Concentric Vent Strap 5mm to 100mm Combustion Air Vent 12...

Page 30: ...s fitted for the proper type of gas by checking the rating plate FT will function properly at elevations up to 10 000 feet 3050 m Refer to Section 4 12 for High Altitude Settings 2 For minimum and maximum gas supply pressures See Section 2 2 on page 6 3 Refer to Table 7 Table 8 and Table 9 to size piping 4 Run gas supply line in accordance with all applicable codes 5 Locate and install manual shut...

Page 31: ...112 97 87 80 69 62 48 44 1 383 269 218 188 168 153 132 118 91 82 1 1 4 639 456 374 325 292 267 232 208 171 148 1 1 2 1260 888 723 625 559 509 440 393 320 277 2 2930 2080 1700 1470 1320 1200 1040 933 762 661 Pipe size Length ft 10 20 30 40 50 60 80 100 150 200 1 2 172 118 95 81 72 65 56 50 40 34 3 4 360 247 199 170 151 137 117 104 83 71 1 678 466 374 320 284 257 220 195 157 134 1 1 4 1390 957 768 6...

Page 32: ... 208 186 143 129 1 1 4 971 661 528 449 397 359 307 270 217 183 1 1 2 1990 1400 1140 988 884 805 696 621 506 438 2 4640 3290 2680 2330 2080 1900 1650 1480 1210 1050 Pipe size Length ft 10 20 30 40 50 60 80 100 150 200 1 2 291 200 160 137 122 110 101 94 84 67 3 4 608 418 336 287 255 231 212 197 175 140 1 1150 787 632 541 480 434 400 372 330 265 1 1 4 2350 1620 1300 1110 985 892 821 763 677 543 1 1 2...

Page 33: ...he gas supply line should be installed close to the unit CLOSED POSITION UNION FITTING MANUAL SHUT OFF VALVE GAS PIPE To facilitate any future maintenance it is also recommended that an approved gas union fitting be installed in the supply line between the shut off valve and the 3 4 male NPT connection on the Boiler 1 Install an approved gas line pipe to gas line connection under the Boiler Includ...

Page 34: ...Layout NOTE Total gas supply capacity must not be less than the total demand capacity of the connected appliances NOTE Total gas supply capacity must not be less than the total demand capacity of the connected appliances Sediment Trap Gas Meter Sediment Trap Other Appliances Other Appliances Gas Regulator Supply Press 12 Gas Regulator Supply Press 12 Suggested Propane Gas LP Layout Gas Meter ...

Page 35: ... individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1 2 psi 3 5 kPa Loosen the pressure port screws before you check the gas inlet pressure Inlet Gas Pressure Port Manifold Pressure Port Inlet Gas Pressure Port Manifold Pressure Port The minimum and maximum inlet gas line pressures must be Natural Gas LP Gas Maxim...

Page 36: ...E Conversion label 14 Setup your combustion analyzer and place the sensor into the combustion test port 15 Per Table B for Max Fire change dip switch 6 to ON and 7 to OFF The unit will cycle up to MAX fire 16 WAIT for your combustion analyzer to stabilize This may take up to 3 minutes depending on your combustion analyzer Then measure the CO2 for MAX fire Refer to Table D for acceptable MAX fire c...

Page 37: ...Set the high altitude value by turning the dial Refer to table 5 Press the dial again E to save the setting 6 Press the Modes button for one second to Save the number and to go back to initial status 4 12 High Altitude Installations 2 000 to 10 000 The FT is shipped with a default factory setting for installation at an altitude of 0 to 2000 approx For maximum efficiencies at higher altitudes 2 000...

Page 38: ...ice agency in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction If the information in these instructions is not followed exactly a fire an explosion or production of carbon monoxide may result causing property damage personal injury or loss of life The qualified service agency is responsible for the proper and complete in...

Page 39: ...illips screwdriver remove the 4 screws on the front cover See Figure A 4 Locate the Gas Inlet Pipe at the top of the unit as is shown in Figure A and loosen the Brass Fittings at both ends of the Gas Inlet Pipe 5 Completely un thread the Brass Fittings at the blower end of the Gas Inlet Pipe and then carefully swing the Gas Inlet Pipe to the left just enough so that it is out of the way See Figure...

Page 40: ...Port Table C Manifold pressure Propane Gas LP Natural Gas NG MFTHW 100 0 075 WC 0 070 WC 0 003 WC 0 000 WC MFTHW 140 0 130 WC 0 100 WC 0 004 WC 0 002 WC MFTHW 175 0 169 WC 0 129 WC 0 015 WC 0 015 WC MFTHW 199 0 169 WC 0 129 WC 0 015 WC 0 015 WC CO2 value Propane Gas LP Natural Gas NG 2 VENT 3 VENT 2 VENT 3 VENT MFTHW 80 100 120 140 175 199 9 5 11 8 5 10 5 9 10 5 8 10 Refer to the below table Manif...

Page 41: ...HI Fire and LOW Fire several times and making adjustments only at LOW Fire before CO2 at both are within acceptable levels Be sure to put the adjustment port cap screw back onto the valve when done 22 Once the CO2 and manifold pressure measurements for both MIN and MAX Fire are acceptable set DIP switches 6 and 7 to the OFF position for Nominal Fire normal operation 23 Write in the correct convers...

Page 42: ...ets local codes and industry standards The pipe end must be clean and free of debris Do not apply torch heat within 12 of the bottom connections of the unit The CH supply and return connections are 1 1 4 The system piping must be a minimum of 1 1 4 See Sections 4 14 4 4 14 5 Isolation valves Shutoff valve will be used All piping should be insulated 4 14 2 Backflow Preventer and Boiler Feed Valve A...

Page 43: ...ld mixing valve at domestic hot water outlet boiler location to reduce potential for scalding Contact Manufacturer for recommended models Check with local codes 6 It is strongly recommended to use a 10 kOhm sensor for DWH sensing especially in high temp DHW applications PRIMARY LOOP CH SUPPLY CH RETURN 1 Min Piping SPACE HEATING ZONE 1 ZONE 2 ZONE 3 SECONDARY LOOP SPACE HEATING Do not exceed 12 Se...

Page 44: ...nsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be 12 or 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 Install a minimum of 12 diameters of straight pipe upstream of all circulators 5 Manufacturer strongly recommends the use of an anti ...

Page 45: ...ncept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be 12 or 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 Install a minimum of 12 diameters of straight pipe upstream of all circulators 5 Manufacturer strongly r...

Page 46: ...water outlet boiler location to reduce potential for scalding Contact Manufacturer for recommended models Check with local codes 7 Auto Fill Valve and Backflow Preventer Valves are NOT included Field Supplied 8 DHW Sensor Aquastat must connect to LEAD boiler It is strongly recommended to use a DHW sensor in case of high DHW set points CH RETURN ZONE 1 ZONE 2 ZONE 3 1 1 4 1 1 2 Min OR piping depend...

Page 47: ... on installing the pressure relief valves and discharge piping can result in personal injury death or substantial property damage Direct the discharge piping of the pressure relief valve so that hot water will not splash on anyone or any nearby equipment Attach the discharge line to the pressure relief valve and run the end of the line within 6 12 150 300mm of the floor Test the operation of the v...

Page 48: ...few months for depletion Apply only corrosion resistant materials for the condensate drain lines such as 1 2 PVC CPVC Polypropylene pipe or included plastic hose NOTICE Category II IV boilers must be installed with a means provided for the drainage of condensate AVIS les chaudières de catégories II et IV doivent être installées avec un moyen de drainage du condensat CAUTION Condensate is mildly ac...

Page 49: ...on 66 UL 94V 2 Terminal Copper Alloy Terminal block External power connector DFT 20A 10P 20 amps at 300VAC DHW and CH pump terminals for external pump are live 120V limited to 2 0 A They operate respective to an external call e g T T for heat WARNING Install wiring and electrically ground boiler in accordance with authority having jurisdiction or in the absence of such requirements follow the Nati...

Page 50: ...manifold gas pressure Refer to Table C ON OFF MIN Fire Normal Operation MAX Fire Normal Operation NG Natural LP Propane 3 Vent Size 2 Vent Size Figure D Gas Valve for 100 140 MBH Gas Valve for 199 MBH The gas valve on the smaller models is mounted vertically Manifold Pressure Port Manifold Pressure Port Manifold pressure Propane Gas LP Natural Gas NG CO2 value Propane Gas LP Natural Gas NG 2 VENT ...

Page 51: ...e Sensor 2 9 BL W 5 12 BR BK 1 8 BK R M DC FAN MOTOR R BL Y W BK 3 6 2 5 4 DHW Temperature Sensor CN5 4 12 R W Display Control 10 2 R G Water Level Sensor T T 3 P 11 P Flame sensor AC 120V Netural AC 120V Live Ignitor 10 4 R R 12 6 V V W BK 8 2 11 5 BL CH Pump Over Heat Temperature Sensor 7 W 14 BL Gas Valve 4 11 BL BL Return Temperature Sensor Ground G 1 CN1 RS 485 limit LWC System Temperature Se...

Page 52: ...Page 52 4 20 Ladder Diagram ...

Page 53: ...D 1 RS 485 RS485 SELV 5V 2 RS485 SELV 5V 3 4 RS485 SELV 5V 5 RS485 SELV 5V CN4 LWD1140 06D 1 FAN Unuse 2 GND SELV 30V 3 VDD SELV 14V 4 Fan power start coil SELV 30V 5 Fan power end coil SELV 30V 6 Fan speed feedback signal SELV 14V CN8 SMW250 04D 1 MCU ISP GND SELV 5V 2 ISP Reset port SELV 5V 3 ISP TOOL0 Data port SELV 5V 4 VCC SELV 5V CN11 LWD 1140 16 1 HWL AC 24V Input Heat Demand SELV 12V 9 2 L...

Page 54: ...temperature sensor SELV 5V 9 3 DH S Exhaust temperature sensor SELV 5V 10 4 I S CH Return temperature sensor SELV 5V 11 5 BG S DHW temperature sensor or Mechanical aquastat connection SELV 5V 12 6 ST S System temperature sensor SELV 5V 13 7 SP S CH over heat temperature sensor SELV 5V 14 CN3 SMW250 06D 1 APS VCC SELV 5V 2 GND SELV 5V 3 Voltage input SELV 5V 4 6 FLUX1 Unuse ...

Page 55: ...180 F D Time Date Set No Change To SET Year Month Week Day Time Min E Scroll Select Menu select or value up down or setting dial The Control Display has a Control Dial E 4 buttons A B C D and a Liquid Crystal Display with 72 back lit segments This section of this manual gives instruction on how to navigate into the many functions of the FT and to change temperature set points set system variables ...

Page 56: ...ication state indication Time setting mode Time Dispaly Install mode indication Fan operating mode Fan operating mode indication Flame signal Flame Signal indication CH pump mode CH pump mode indication Storage pump mode Storage pump mode indication Internal boiler pump Internal Boiler pump mode indication Celsius mode Indicated as Celsius temperature Fahrenheit mode Indicated as Fahrenheit temper...

Page 57: ...that have specific LCD output and dedicated controls Set point change mode Lock mode Error mode Status display mode Outside Temperature mode Installer mode Control Display will not allow changing of button in case of lock mode activated Indicate Indicator Current Operating Temperature Set point If the Fan is operating If a flame is detected Celsius or Fahrenheit or Date and Time indicator If Outsi...

Page 58: ...E to the desired month number Then press the dial E to Save c Set the DATE 1 31 Day of the Month by turning the dial E Then press the dial E to Save d Set the HOUR 1 24 Hour of the Day by turning the dial E Then press the dial E to Save e Set the MIN 1 60 Minute of the Hour by turning the dial E Then press the dial E to Save f Set the Day Sun Sat by turning the dial E Then press the dial E to Save...

Page 59: ...d Time indicator If CH pump is operating If there currently a Demand for Central Heat CH Default CH set point is 180 F 82 C CH set point range is 130 F 180 F 54 C 82 0 C To change CH Set point press the C button The CH Icon and current CH Set point will flash Turn the E dial clockwise to increase and counterclockwise to decrease CH set point until desired temperature is reached Press E dial to sav...

Page 60: ...e for ignition Cycle 10 times the displayed unit 5 IH Cycle for ignition Cycle 10 000 times the displayed unit M CC SELF Percentage of self units running Percentage of self units running ALL Capacity for all operating cascade units Percentage of all cascade units running This screen shows the overal cascade power output The range of this value of boilers communicating with theMaster x 100 For exam...

Page 61: ...mperature 9 F Default 30 F 6 cH Maximum Supply temperature Sets the maximum design supply temperature based on the minimum outdoor design temperature Maximum supply temperature must be set at least 9 F above the minimum supply temperature Range Minimum Supply Temperature 9 F 180 F Default 180 F 5 7 Installer Mode 61page B C E A D WARNING For low temperature heating applications adjust P6 to desire...

Page 62: ...NO 16 Ft CH Anti Cycling time This function delays burner operation during CH mode Range 0 20 min Default 1 17 bo Set differential temperature to turn burner ON When set the appliance will operate to heat CH water when water temperature falls below a differential setting Example If set point is 180 F and differential is 27 F the appliance will turn on when CH water temperature falls below 153 F Ra...

Page 63: ...lows the user to set the year of next service reminder XX XX XXXX MONTH DAY YEAR SS br Allows the user to set the service reminder based on BURNER RUN HOURS Allows the user to set the service reminder based on BURNER RUN HOURS 0 OFF 1 9000Hours Default 0 36 UC FAH F Allows the user to change the unit Allows the user to change the unit Range F or C CEL C 37 CM OFF CH Step Modulation Allows the user...

Page 64: ... Hold Button B to get into the Installer Mode Rota te Dial E until you find 25 St Tap Dial E to enter Storage Mode Storage Mode indicates that the boiler is heating the water held in an indirect water heater When Storage Mode is active the display will appear as shown Turn the E dial clockwise to increase and counterclockwise to decrease setting Press E dial to save changes and to Exit NOTE If usi...

Page 65: ...lts the appliance will ignite As the signal continues to rise towards its maximum of 10 volts the appliance will increase in set point temperature Adjust 6 cH and 7 cL to set MIN and MAX boiler water temperatures respectively Connect a building management system or other auxiliary control signal to the terminals marked for this purpose on the appliance terminal block shown in Piping Diagrams this ...

Page 66: ...ntrol Display and the main controller is lost the will not be displayed The Control Display will show the following information when an Error is presented Indicate Indicator Error Er sign Segment Error Code Er 11 If Communication state is activated 5 11 Error Mode ...

Page 67: ...ch Max Fire setting is ON Switches 6 and 7 should be OFF for normal operation 2 Check if CH inlet pipe is blocked Ensure there is enough water flowing to the appliance 3 Check Operating Temperature sensor at CH heat exchanger outlet If resistance is zero replace the sensor 4 Verify operation of internal boiler pump by checking rotation of pump shaft Manually spin pump shaft by removing round cap a...

Page 68: ... placement Check and record SFN revision of printed circuit board during start up for future reference 5 If the problem persists contact technical support Hard Lock 42 LWCO Jumper Disconnected Press the Power button to clear the Error Code If Error happens again 1 Ensure the LWCO Jumper is properly connected 2 If the problem persists contact technical support Soft Lock 43 Burner Overheat Switch Op...

Page 69: ...ease refer to Manufacturer s Document 1349 for Cascading the FT 80 Low Water Level Sensor Low Water Level Detected Four 4 Consecutive times This Error Code will go away when the condition is remedied If Error happens again 1 Ensure all valves are open to the appliance and there are no leaks 2 Ensure all air has been purged from the system 3 Check wiring connections to low water level sensor Ensure...

Page 70: ...Page 70 6 2 Fault Tree Analysis 6 2 1 1 Flame detection ...

Page 71: ...s Heating Only Boiler Page 71 6 2 2 2 Gas Detection Storage DHW OP CH overheat Exhaust heat Error code contents E28 DHW NTC open or short E33 OP NTC open or short E35 Exhaust NTC open or short 6 2 3 Sensor detects ...

Page 72: ...mperature fluctuates at the opened tap Make sure that the filter in the cold water supply line is clean Make sure that the gas supply type is correct Check the supply gas pressure is sufficient The blower is still operating after the combustion stops This is normal because the blower keeps operating for 1 minute to vent exhaust the flue gas from the chamber once the combustion has stopped Temperat...

Page 73: ...power boiler Is there 120 Volts at the service switch Troubleshoot and correct the power supply to the manual switch Is the ON OFF POWER SWITCH inside boiler case turned on Turn ON the manual power switch inside the boiler case Check for 120 volts at the line voltage terminal block located inside the boiler case Correct wiring inside the boiler case using the wiring diagram in this manual Inspect ...

Page 74: ...f Reset using manual reset screen on Control Display Power button Check wire harness for loose connections and pin engagement at blower Connections Boiler in standby mode and blower not running If BLOWER SPEED is not 0 RPM then replace blower If blower does not rotate during ignition sequence check for 120V power at blower connection If 120Vac power at blower motor and it doesn t start replace blo...

Page 75: ... joints are properly sealed Call your qualified service technician if you notice any problems Check the relief valve Inspect the Boiler relief valve and the relief valve discharge pipe for any signs of weeping or leakage If the relief valve often weeps immediately contact your qualified service technician for inspecting the Boiler and system Check the condensate outlet While the Boiler is running ...

Page 76: ...ician for inspecting the valve and system Check the burner state You can clean the exterior of burner However if you need to clean the inside of the burner stage you should call an expert WARNING Leaks must be fixed by a qualified service technician immediately Failure to comply with this instruction could result in severe personal injury death or substantial property damage This discharge line mu...

Page 77: ...erent glycol products may provide varying degrees of protection Glycol products must be maintained properly in a heating system or they may become ineffective Consult the glycol specifications or the glycol manufacturer for information about specific products maintenance of solutions and set up according to your particular conditions 8 Ensure service valves V3 V4 are closed and shut off valves V1 ...

Page 78: ...items to consider are Consider the effects of reduced heat transfer and an increase in head pressure against the system circulator For example A 30 mixture of glycol will result in a BTU output loss of 15 with a 5 increase in head against the system circulator Glycol mixtures should not exceed 50 A 50 mixture of glycol will result in a BTU output loss of 30 with a 50 increase in head against the s...

Page 79: ...Vent S636 PVC CPVC for Category IV appliances in accordance with this manual and or your local code Is the vent termination at least 12 above the exterior grade Is the total vent length within the maximum vent length restriction Have you checked the air vent piping for leaks Have you properly supported the vent termination Are all vent runs properly supported Is the vent sloped upward toward the v...

Page 80: ...Page 80 SECTION 10 Parts 10 1 100 MBH Casing Assembly ...

Page 81: ...09 9 Air vent FT1321 10 Air vent adaptor FT1548 11 Air vent rubber pad FT1939 12 Air pressure sensor 80 FT1804 13 Control bracket FT1049 14 Ignition transformer ST1006 15 Display panel bracket FT2004 16 Display panel FT2050 17 Bracket FT2006 18 Condensate blockage air pressure switch FT1022 19 PCB Control NGTB 900CP FT1052 20 Power switch FT1020 21 Terminal block 6P FT1827 22 Terminal block 12P FT...

Page 82: ...Page 82 Heat Exchanger Assembly 100 MBH ...

Page 83: ... 5c Ignitor ceramic paper FT2017 32 6 Burner downside case FT2049 32 7 Refractory FT1665 33 Temperature sensor FT1324 34 Low level sensor FT1325 35 Flame detector sensor assembly FT2096 35 1 Flame detector sensor bracket FT1669 35 2 Flame detector sensor FT1327 35 3 Flame detector sensor cover FT1069 36 CH Outlet Pipe 100K assembly FT2138 36 1 CH Outlet Pipe 100K FT1853 P 5 3 4 Packing FT1646 P 6 ...

Page 84: ...Page 84 Blower Assembly 100 MBH ...

Page 85: ...7 Nozzle NG Ø4 6 FT2056 Nozzle LP Ø3 6 FT2057 54 Gas pipe upper 100K assembly FT2140 54 1 Gas pipe upper 100K FT2058 P 7 1 2 Spiral packing FT1710 55 Gas valve assembly FT1413 55 1 Gas valve outlet adaptor FT1919 55 2 Gas valve O Ring FT1727 55 3 Gas valve FT1416 55 4 Gas valve inlet adaptor FT1538 55 5 Gas valve bracket FT1539 P 7 1 2 Spiral packing FT1710 56 Gas pipe down assembly FT2104 56 1 Ga...

Page 86: ...Page 86 Casing Assembly 10 2 140 MBH ...

Page 87: ...T1609 9 Air vent FT1321 10 Air vent adaptor FT1548 11 Air vent rubber pad FT1939 12 Air pressure sensor 80 FT1804 13 Control bracket FT1049 14 Ignition transformer ST1006 15 Display panel bracket FT2004 16 Display panel FT2050 17 Bracket FT2006 18 Condensate blockage air pressure switch FT1022 19 PCB Control NGTB 900CP FT1052 20 Power switch FT1020 21 Terminal block 6P FT1827 22 Terminal block 12P...

Page 88: ...Page 88 Heat Exchanger Assembly 140 MBH ...

Page 89: ...ramic paper FT2017 32 6 Burner downside case FT2049 32 7 Refractory FT1665 33 Temperature sensor FT1324 34 Low level sensor FT1325 35 Flame detector sensor assembly FT2096 35 1 Flame detector sensor bracket FT1669 35 2 Flame detector sensor FT1327 35 3 Flame detector sensor cover FT1069 36 CH Outlet Pipe 140K assembly FT2097 36 1 CH Outlet Pipe 140K FT1070 P 5 3 4 Packing FT1646 P 6 1 Packing FT16...

Page 90: ...Page 90 Blower Assembly 140 MBH ...

Page 91: ...7 Nozzle NG Ø6 2 FT2027 Nozzle LP Ø4 7 FT2028 54 Gas pipe upper 140K assembly FT2103 54 1 Gas pipe upper 140K FT2063 P 7 1 2 Spiral packing FT1710 55 Gas valve assembly FT1413 55 1 Gas valve outlet adaptor FT1919 55 2 Gas valve O Ring FT1727 55 3 Gas valve FT1416 55 4 Gas valve inlet adaptor FT1538 55 5 Gas valve bracket FT1539 P 7 1 2 Spiral packing FT1710 56 Gas pipe down assembly FT2104 56 1 Ga...

Page 92: ...Page 92 Casing Assembly 10 3 199 MBH ...

Page 93: ...T1321 10 Air vent adaptor FT1548 11 Air vent rubber pad FT1939 12 Air pressure sensor 80 FT1804 13 Control bracket FT1751 14 Ignition transformer FT2031 14 1 Ignition transformer bracket FT2032 15 Control sub bracket FT2033 16 Display Control FT2005 17 Bracket FT1753 18 Condensate blockage air pressure switch FT1022 19 PCB Control NGTB 900CP FT1052 20 Power switch FT1020 21 Terminal block 6P FT182...

Page 94: ...Page 94 Heat Exchanger Assembly 199 MBH ...

Page 95: ... 5 Overheat sensor FT1310 32 6 Burner downside case FT2041 32 7 Refractory FT2042 33 Temperature sensor FT1324 34 Low level sensor FT1325 35 Flame detector sensor assembly FT2129 35 1 Flame detector sensor bracket FT1669 35 2 Flame detector sensor FT1327 35 3 Flame detector sensor cover FT1069 36 CH Outlet Supply Pipe 199K assembly FT2130 36 1 CH Outlet Supply Pipe 199K FT1765 P 5 3 4 Packing FT16...

Page 96: ...Page 96 Blower Assembly 199 MBH ...

Page 97: ...Gas valve assembly FT1950 53 1 Gas valve outlet adaptor FT1919 53 2 Gas valve O ring FT1415 53 3 Gas valve FT1416 53 4 Gas valve inlet adaptor FT1538 53 5 Gas valve bracket FT1779 P 7 1 2 Spiral packing FT1710 Nozzle natural FT1780 Nozzle propane FT1802 55 Gas pipe upper assembly FT2136 55 1 Gas pipe upper FT1781 P 7 1 2 Spiral packing FT1710 56 Gas pipe down assembly FT2137 56 1 Gas pipe down FT1...

Page 98: ...Page 98 Notes ...

Page 99: ...The FT Series Heating Only Boiler Page 99 Notes ...

Page 100: ... 20 Industrial Way Rochester NH USA 03867 Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement H2412200 Notes For Product and Service VIDEOS 20 10 Document 1483 The FT Series Heating Only Boiler ...

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