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30

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 5-6  

Existing Vent as a Chase

*For concept illustration only.  Individual installations

may vary due to job site specific equipment.

     

Installation & Operation Manual

FLUE EXHAUST

SEAL

AIR INLET

SEAL

FLUE OUTLET

SEALED CAP

EXISTING

2000603605   00

Summary of Contents for FTXL 1000

Page 1: ...cian 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 substa...

Page 2: ...ct Venting Options 15 Install Vent and Combustion Air Piping 16 Requirements for Installation in Canada 17 Sizing 17 Min Max Combustion Air Vent Piping Lengths 17 Materials 17 Optional Room Air 18 PVC...

Page 3: ...ficiency 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 NE...

Page 4: ...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...

Page 5: ...Front View Left Side inside unit DIR 2000544916 00 19 27 18 4 16 33 38 39 23 21 17 26 36 20 Right Side inside unit The FTXL How it works continued Rear View 5 Installation Operation Manual...

Page 6: ...al remains the same as the standard boilers A high altitude label as shown in Fig A is also affixed to the unit De rate values are based on proper combustion calibration and CO2 s adjusted to the reco...

Page 7: ...r combustion air supply see Table 1A on page 10 Prevent combustion air contamination Remove any of these contaminants from the boiler area WARNING Provide clearances Clearances from combustible materi...

Page 8: ...closet structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death Installation Operation Manual 14 356 MM REAR 18 457 MM TOP 0 LEFT 0 RIGHT 6...

Page 9: ...3 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...

Page 10: ...sure 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 list...

Page 11: ...nected 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...

Page 12: ...tion 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 i...

Page 13: ...ardous condition that must be corrected immediately 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...

Page 14: ...lts inside the L brackets on the rear of the boiler Once the lag bolts have been removed re install the screws on the rear of the boiler c Disconnect the ribbon cable and remove the bezel no tools req...

Page 15: ...tails Direct venting options Sidewall Vent 3 General venting Two Pipe Vertical See page 37 for more details Vertical Vent Sidewall Air Direct venting options Vertical Vent Installation Operation Manua...

Page 16: ...te 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...

Page 17: ...eter De rate per 25 feet of Vent Air Intake Vent Direct Vent Room Air 1000 6 152 mm 6 152 mm 0 72 0 48 The FTXL uses model specific combustion air intake and vent piping sizes as detailed in Table 3A...

Page 18: ...g option the following conditions and considerations must be followed The unit MUST be installed with the appropriate bird screen Table 3B The equipment room MUST be provided with properly sized openi...

Page 19: ...DO NOT mix other manufacturer s appliances or other Lochinvar models 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 dam...

Page 20: ...Fittings Approved PVC CPVC Vent Pipe and Fittings Item Material Standard Vent pipe PVC Schedule 40 80 ANSI ASTM D1785 PVC DWV ANSI ASTM D2665 CPVC Schedule 40 80 ANSI ASTM F441 Vent fittings PVC Sched...

Page 21: ...l Centrotherm Eco Systems InnoFlue SW Flex Duravent M G Group PolyPro Single Wall PolyPro Flex Table 3E Polypropylene Vent Pipe and Fittings WARNING Insulation should not be used on polypropylene vent...

Page 22: ...s 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 a...

Page 23: ...e same pressure zone TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION VENT AIR TERMINATION GRADE OR SNOW LINE 12 MIN 12 MIN TO OVER HANG POSSIBLE ORIENTATIONS Figure 4 1B PVC CPVC Poly...

Page 24: ...way 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 ter...

Page 25: ...nto the vent plate openings Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3D on page 21 to seal the vent pipe 3 Use a sidewall termination plate as a template for...

Page 26: ...ws 5 Seal all gaps between the pipes and wall Seal around the plate to the wall assuring no air gaps 6 Assemble the vent cap to the vent plate see FIG s 4 5B and 4 5C Insert the stainless steel screws...

Page 27: ...let 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...

Page 28: ...tiple FTXL boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of flu...

Page 29: ...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 unuse...

Page 30: ...ths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 6 Existing Vent as a Chase For concept illustration only Individual installations may vary due to...

Page 31: ...ow 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...

Page 32: ...f 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...

Page 33: ...ixing 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 temperatu...

Page 34: ...ower temperature loop s from overheating To help aid with this protection Lochinvar offers the Multi Temperature Loop Control Board Kit 100167843 Installation Operation Manual Near boiler piping conne...

Page 35: ...D GPM FT HD GPM FT HD 1000 2 1 2 98 4 5 65 3 9 49 3 8 32 3 5 25 3 2 6 Hydronic piping continued Installation Operation Manual FTX725 850 FTX400 600 FTX1000 0 ft 1 ft 2 ft 3 ft 4 ft 5 ft 6 ft 7 ft 8 ft...

Page 36: ...NAL MIXING VALVE ANTI SCALD FLOW SWITCH OPTIONAL WIRING BOILER 2 T P Figure 6 5 Multiple Boilers Alternate Fixed or Variable Flow Primary System Piping Please note that these illustrations are meant t...

Page 37: ...TURE PRESSURE GAUGE T P SYSTEM SUPPLY SENSOR BACKFLOW PREVENTER MAGNETIC SEPARATOR WATER METER STRAINER FILTER PRESSURE REDUCING VALVE PRESSURE RELIEF VALVE BALL VALVE EXPANSION TANK PIPING DRAIN PORT...

Page 38: ...E OPTIONAL MIXING VALVE ANTI SCALD FLOW SWITCH OPTIONAL WIRING Figure 6 7 Single Boiler Primary Secondary Piping NOTICE System flow should always remain higher than the required flow for the boiler s...

Page 39: ...G DRAIN PORT DIFFERENTIAL PRESSURE BYPASS VALVE 2 WAY MOTORIZED VALVE OPTIONAL MIXING VALVE ANTI SCALD FLOW SWITCH OPTIONAL WIRING BOILER 2 T P COLD WATER IN DHW HOT WATER OUT Figure 6 8 Multiple Boil...

Page 40: ...WATER IN DHW HOT WATER OUT Figure 6 9 Multiple Boilers Primary Secondary Piping NOTICE System flow should always remain higher than the required flow for the boiler s when the boiler s is in operation...

Page 41: ...G DRAIN PORT DIFFERENTIAL PRESSURE BYPASS VALVE 2 WAY MOTORIZED VALVE OPTIONAL MIXING VALVE ANTI SCALD FLOW SWITCH OPTIONAL WIRING COLD WATER IN DHW HOT WATER OUT Figure 6 10 Single Boiler Multiple Te...

Page 42: ...on 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...

Page 43: ...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 durin...

Page 44: ...nstaller or service agency to determine the necessary steps to provide proper gas pressure to the control 11 Turn the power switch to the OFF position 12 Shut off the gas supply at the manual gas valv...

Page 45: ...ting dynamic mode If an in line regulator is used it must be a minimum of 10 feet 3 m from the FTXL boiler It is very important that the gas line is properly purged by the gas supplier or utility comp...

Page 46: ...SERVICE SWITCH L2 N G L1 BK G W BK G W BK G W Figure 8 1 Line Voltage Field Wiring Connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dange...

Page 47: ...s provided to detect low gas pressure remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts FIG 8 3 2 If both a high and low gas pressure swi...

Page 48: ...through 6 10 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor see FIG 8 3 The Leader control will use the water temperature a...

Page 49: ...MANAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO OUTDOOR SENSOR DHW RECICULATION SENSOR SHIELD SHIELD TO NEXT BOILER A B A B FROM PREVIOUS BOILER ROOM THERMOSTAT 1 ROOM THERMOSTAT 2 AB NOTE CONNECTION B...

Page 50: ...primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement Do not use copper or black iron pipe or fittings 6 A condensate removal pump is requ...

Page 51: ...tem fill and make up water quantities should not exceed three 3 times the system volume 3 Consult local water treatment companies for hard water areas above the values listed in Table 10A Hardness lev...

Page 52: ...the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to corr...

Page 53: ...ave the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to each of the heat loop demand terminals on the connectio...

Page 54: ...ent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death q Check gas piping 1 Check around the boiler for gas odor following the procedure on page 42 of...

Page 55: ...o replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest set...

Page 56: ...a detailed explanation of this procedure Verify space heat circulator mode The Space Heating Mode controls both the system pump if connected and the boiler pump When the SMART SYSTEM control receives...

Page 57: ...ons to adjust the set points as shown in FIG 10 4 2 Once the set point has been adjusted to the desired setting press the Door Menu slider top left or the Setup button 3 Press the APPLY CHANGES button...

Page 58: ...ate to maintain the boiler outlet temperature or system supply temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in...

Page 59: ...sfied the boiler will provide 110 F water to the system SMART SYSTEM Multi temp loop control The FTXL boiler is capable of producing up to three 3 set point temperatures to meet different space heatin...

Page 60: ...ual 60 Programmable controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default If a system supply sensor is connected the control automatically uses...

Page 61: ...mperature difference exceeds 80 F 44 C the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 70 F 39 C and the minimum off time has...

Page 62: ...as described on this page under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations The FTXL is equipped with adjustable automatic reset an...

Page 63: ...the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a DHW call the Leader control will take that boiler out of the Cascade sequence If anothe...

Page 64: ...onds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS signal 8 If the space heating call for heat is active and the...

Page 65: ...screen and displays both factory installed and field installed sensor including Outdoor Air Hot Water Temperature System Supply System Return Inlet Water Delta T Outlet Water Flue Temperature and Fla...

Page 66: ...ormance verification per Section 10 of this manual Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C a...

Page 67: ...inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line vent line condensate P...

Page 68: ...NCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and...

Page 69: ...YSTEM control module display to Parameter Mode and check all settings See Section 1 of the FTXL Service Manual Adjust settings if necessary See Section 1 of the FTXL Service Manual for adjustment proc...

Page 70: ...jury WARNING Cleaning boiler heat exchanger 1 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup Do not drain the boiler unless it will be expos...

Page 71: ...s when using diagrams to troubleshoot unit WIRING DIAGRAM LBL20426 REV C BOX DEPICTS OPTIONAL ITEMS CN2 2 CN2 3 DHW PUMP BOILER PUMP SYSTEM PUMP 120V SUPPLY L N GND L N X 7 BOX DEPICTS DUAL SENSOR SIN...

Page 72: ...ible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connect...

Page 73: ...73 Notes Installation Operation Manual...

Page 74: ...74 Notes Installation Operation Manual...

Page 75: ...Revision Notes Revision A PCP 3000052596 CN 500039338 initial release 100361229_2000617079_Rev A 08 22...

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