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Boiler and Heating System Piping

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FTV I&O Manual

52

Labeling

- Label all wires prior to disconnecting them when servicing controls. Wiring

errors can cause improper and dangerous operation. Failure to follow instructions may
result in property damage or personal injury.

Continuity

- Before connecting the line voltage wiring, perform a continuity check

between all wires and ground to make sure that there are no electrical leaks that could
blow a fuse or damage electrical components. Also check the polarity of the line and
neutral wires. Line must measure 120VAC to ground; neutral must measure zero. Failure
to follow instructions may damage the unit.

Figure 12-2 Field Wiring

Remove jumper

when installing

an Aux. Limit

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Содержание FTV110

Страница 1: ...0 TROUBLESHOOTING 75 19 0 PARTS LIST 78 HAZARD SYMBOLS AND DEFINITIONS Danger Sign Indicates a hazardous situation which if not avoided will result in serious injury or death Warning Sign Indicates a...

Страница 2: ...he burner by hand 4 Turn the manual gas valve to the OFF position Remove front access panel 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP...

Страница 3: ...it the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management sy...

Страница 4: ...th LP gas be provided with an approved means of removing unburned gases from the room Check your local codes for this requirement Natural Gas to LP Conversion Kit Model Natural Gas to LP Conversion Ki...

Страница 5: ...print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS plate included with boiler 4 INSPECTION The state or local gas inspector of the side wall horiz...

Страница 6: ...o people to lift the boiler into place Failure to follow these instructions may result in property damage or personal injury High Altitude Operation The FTV is designed to operate at its maximum liste...

Страница 7: ...d in Table 3 1 must be provided Closet Installations For closet installations it is necessary to provide two ventilation air openings as shown in Figure 3 1 each providing a minimum area equal to 1 in...

Страница 8: ...Clearances listed in Table 3 1 Top ventilation opening Max 6 below ceiling top Ventilation air opening 1in 2 per 1000 Btu hr min 100in 2 Removable surface closet door Ventilation air opening 1in 2 per...

Страница 9: ...away from the wall Mount the boiler to the wall by aligning the two wall mount brackets Top Bracket A with the Bottom bracket B Slide the top bracket fastened to the boiler down over the wall mounted...

Страница 10: ...ings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Verify that there is no blockage restriction leakage corrosion or other deficiencies which...

Страница 11: ...ated Sources to Avoid Antistatic fabric softeners bleaches detergents cleaners Laundry facilities Perchloroethylene PCE hydrocarbon based cleaners Dry cleaning facilities Chemical fertilizer herbicide...

Страница 12: ...the pipe is fully inserted into universal appliance adapter Failure to follow these instructions may result in serious injury or death PVC CPVC Piping Ensure the upper gasket of the universal applianc...

Страница 13: ...l use with CPVC PVC for Air inlet 2 36 CPVC PVC 3 46 PP 4 17 SS CPVC PP SS Exhaust Pipe With 1 8 bevel to prevent damage to gasket When venting with PVC use 5 long CPVC Transition Pipe factory supplie...

Страница 14: ...tory supplied CPVC Transition Pipe is mandatory when venting with PVC PVC Coupling Air inlet Adapter factory supplied PVC Air inlet Pipe PVC Exhaust Vent Swing Joint to attain slope in horizontal runs...

Страница 15: ...pter factory supplied CPVC Transition Pipe is mandatory when venting with PVC PVC Coupling Air inlet Adapter factory supplied PVC Air inlet Pipe PVC Exhaust Vent PP Elbow w offset angle to account for...

Страница 16: ...F891 cellular core CPVC or Radel polyphenolsulfone in the exhaust venting system is prohibited Failure to follow these instructions may result in property damage personal injury or death Covering non...

Страница 17: ...ge or where condensate or vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment Extra precaution must be taken to adequately support the weig...

Страница 18: ...ailed assembly and installation instructions 2 Clearance requirements in this manual supersede those of the instructions included with the vent terminal 3 Piping MUST be secured to the vent terminal d...

Страница 19: ...rmination Sidewall Location of exhaust and air inlet connections vary between models see Figure 4 3 Exhaust Inlet Location of exhaust and air inlet connections vary between models see Figure 4 3 Exhau...

Страница 20: ...mination Roof Location of exhaust and air inlet connections vary between models see Figure 4 3 Exhaust Inlet Exhaust Inlet Location of exhaust and air inlet connections vary between models see Figure...

Страница 21: ...e or snow level Exhaust Air inlet Exhaust Air inlet around perimeter Min 12 above grade or snow level Exhaust center Air inlet bottom Exhaust Air inlet Gas Vent Directly Below Keep Free of Obstruction...

Страница 22: ...in 12 above grade or snow level Vent Screen Vent pipe piece to retain vent screen Exhaust center Air inlet around perimeter Flashing Refer to documentation included with termination kit for complete i...

Страница 23: ...ack to the boiler a minimum of in per linear foot of vent For applications where excessive condensation is possible in per linear foot is recommended 9 Vent Supports Where required Vent and Air inlet...

Страница 24: ...sting Chimney Chase Way It is permissible to use an existing chimney as a chase way to run the Vent Air inlet piping as long as 1 The chimney is not being used by any other boiler 2 Flue gases do not...

Страница 25: ...rty if adjacent 12 7 ft 2 13 m 7 ft 2 13 m R Above a public walkway X X X X S Above a sidewalk or paved driveway that is located between two single family dwellings and services both dwellings X X X X...

Страница 26: ...e 5 2 Sidewall Termination See Table 5 1 G Letter represents a specific Termination Position Refer to Table 5 1 for corresponding termination clearances Concentric Vent Termination Q Two Pipe Terminat...

Страница 27: ...s factory supplied with the boiler and must be field installed 1 Inspect Condensate Trap Assembly Inspect the Condensate Trap to ensure all parts were shipped with the assembly see Figure 6 1 The Cond...

Страница 28: ...te Drain Piping Inlet Gasket Outlet Corrugated Outlet Tube Outlet Retaining Nut Outlet Gasket Inlet Cleanout Cap Condensate Trap Inlet Retaining Nut firmly tightened Corrugated Outlet Tube routed to h...

Страница 29: ...ing approved flexible gas piping if acceptable by local codes to connect the boiler to the gas supply see Figure 7 1 for details You plan the installation so the piping does not interfere with the ven...

Страница 30: ...nternal and external to the boiler for leaks Failure to follow these instructions may result in fire property damage serious injury or death Union Drip Leg Manual Gas Shutoff Valve Should overheating...

Страница 31: ...itch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire departm...

Страница 32: ...9 0 for details 4 Perform at least three ignitions in succession to ensure proper operation 5 After the three successive ignitions unplug the flame sensor and allow the unit to cycle again The flame s...

Страница 33: ...FTV I O Manual Lighting the Boiler 33 Turning Off the Boiler 1 Set the thermostat to the lowest setting and then turn off all power to the boiler 2 Turn the gas shutoff valve to the off position...

Страница 34: ...alue listed in Table 9 1 while the unit is operating at the maximum modulation rate see Table 9 2 8 Continue observing the gas line pressure until the completion of the combustion analyses in case adj...

Страница 35: ...g procedure using a calibrated combustion analyzer capable of measuring CO2 and CO from Natural and Propane Gas burning boilers 1 Operate the unit at the maximum modulation rate see Table 9 2 NOTICE t...

Страница 36: ...nd Burner Set up FTV I O Manual 36 Figure 9 1 Gas Valve and Venturi Assembly FTV150 Illustrated DO NOT Adjust Gas Valve Manifold Pressure Test Port Throttle Input Adjustment Screw Line Pressure Test P...

Страница 37: ...w boiler Use magnetic dirt separators on systems containing large amounts of iron Use Dirt Separators to remove debris from system water Where possible treat boiler feed water Repair system leaks imme...

Страница 38: ...ing or sealing Inhibitors should be used for all installations in both new and existing heating systems Follow the instructions provided by the inhibitor manufacturer when adding to the system to ensu...

Страница 39: ...res 10 2 b 10 2 c and 10 2 d Auto Air Vent Install the factory supplied auto air vent directly above the outlet fitting on the top of the unit as illustrated in Figure 10 2 a Open the auto air vent s...

Страница 40: ...e factory supplied Tee Fitting Typical field supplied Boiler Inlet 30 PSI Relief Valve factory supplied Auto Air Vent factory supplied in Brass Street Elbow factory supplied x x in Brass Tee factory s...

Страница 41: ...HW PUMP output is not used on Combi models 2 CH PUMP operates during a Central Heat CH demand 3 BOILER PUMP operates during any demand The internal pump for Combi models is factory wired to the BOILER...

Страница 42: ...V Combi Only Figure 10 4 Available Pump Head FTV Combi Internal Pump Notes 1 Graph depicts available pump head of FTV Combi internal pump after boiler internal flow losses Manual Bypass Valve set to M...

Страница 43: ...of the system as well as the firing rate of the appliance It is important to locate the expansion tank and make up water fill on the inlet side of any circulator in the system as doing so will guaran...

Страница 44: ...ity of the installing contractor and system designer to determine which system best meets the need of the installation and to consider all aspects of a proper system design Contractor modifications to...

Страница 45: ...45 Figure 10 7 Plumbing Schematic Multiple Central Heating Circulators non Combi Figure 10 7 illustrates the basic plumbing requirements for a non Combi FTV boiler installation with multiple Central H...

Страница 46: ...nual 46 Figure 10 8 Plumbing Schematic Multiple Central Heating Circulators Combi Figure 10 8 illustrates the basic plumbing requirements for an FTV Combi boiler installation with multiple Central Hea...

Страница 47: ...bing Schematic Single Central Heating Circulator Primary Secondary Combi Figure 10 9 illustrates the basic plumbing requirements for an FTV Combi boiler installation with a single Central Heating circ...

Страница 48: ...10 illustrates the basic plumbing requirements for an FTV Combi boiler installation piped Direct to Zones Limited to zone valve or non zone circulator distribution systems with small flow requirement...

Страница 49: ...static mixing valve is not used or is set too high Be sure to follow the adjustment instructions provided with the thermostatic mixing valve Failure to follow these instructions may result in serious...

Страница 50: ...t the backflow will cause a momentary forward flow of water through the flow sensor when the cold water draw has ended and the water pressure increases This forward flow of water will momentarily acti...

Страница 51: ...l panel cover see Figure 12 1 Field wiring enters the cabinet through holes located on the bottom of the boiler cabinet then must be routed through holes in the bottom of the control panel protect the...

Страница 52: ...al injury Continuity Before connecting the line voltage wiring perform a continuity check between all wires and ground to make sure that there are no electrical leaks that could blow a fuse or damage...

Страница 53: ...s 7 and 8 Switch must be an isolated end switch 8 Table 12 1 b Field Connections Line Voltage Connection Location Description EXT LIM 9 120V Safety Limit Circuit Factory jumpered wire the output conta...

Страница 54: ...ity to cascade lead lag stage up to 16 FTV boilers without the use of an external controller Use the instructions detailed in this section to set up and install the cascade system FTV Combi cascades h...

Страница 55: ...actory supplied LL Header is employed in this case the external circulator is operated via the CH PUMP output terminal 12 CH Pump System the Managing Boiler can control the System s Central Heating Pu...

Страница 56: ...cations of Units FTV110 FTV150 FTV190 Pipe Size 2 1 1 4 1 1 2 2 3 1 1 2 2 2 4 2 2 2 1 2 5 2 2 1 2 2 1 2 6 2 1 2 2 1 2 3 7 2 1 2 3 3 8 2 1 2 3 3 9 2 1 2 3 3 10 3 3 4 11 3 3 4 12 3 4 4 13 3 4 4 14 3 4 4...

Страница 57: ...FTV I O Manual Wiring Schematics 57 14 0 WIRING SCHEMATICS Figure 14 1 FTV Connection Diagram...

Страница 58: ...Wiring Schematics FTV I O Manual 58 Figure 14 2 FTV Ladder Logic Diagram...

Страница 59: ...gas shut off valve to the ON position 2 Turn Power on to the boiler 3 Set Controller to the desired settings 4 Turn thermostat up Ignition will occur Operational Checklist 1 System is free of gas lea...

Страница 60: ...service work in the combustion chamber Take all necessary precautions and use recommended personal protective equipment as required Cleaning Checklist 1 Remove the demand for heat allow the post purge...

Страница 61: ...This boiler contains materials that have been identified as carcinogenic or possibly carcinogenic to humans Table 16 1 Handling Instructions for Refractory Ceramic Fibers RCF Reduce the Risk of Exposu...

Страница 62: ...and personal injury Figure 17 1 de Air Sequence Main Screen Following power up of the boiler after the de air sequence or after 60 seconds of inactivity no buttons pressed the boiler defaults to the M...

Страница 63: ...etails Figure 17 3 User Menu Navigation Item ID 14 parameters can be viewed from the User Menu 1 01 to 1 14 see Table 17 1 for description of each Units if applicable Value of displayed parameter Down...

Страница 64: ...ng from outdoor temperature sensor NTI p n 83604 NOTICE when sensor is open not connected display indicates 40 F C or OPEn when sensor is shorted display indicates 176 F 80 C or OPEn See Table 18 1 Th...

Страница 65: ...ss the OK button to enter save the new value At this point the value will stop flashing 4 Repeat for the next setting Once complete return to the Main Screen by holding the RESET button Figure 17 4 In...

Страница 66: ...entral heat demand Only applicable when an outdoor sensor is used i e CH modes 1 2 Target temperature will not exceed CH setpoint setting 2 01 Range 0 to 36 F NOTICE Boost feature does not function wh...

Страница 67: ...postpurge length of time the DHW Boiler Pumps remain powered at the end of a DHW demand Timer commences following the combustion fan postpurge Range 0 255seconds 10 sec 2 20 Cascade boiler address as...

Страница 68: ...ror History From this screen the display indicates how long ago the most recent error occurred see Figure 17 5 a 2 Press the OK button to display the most recent error and the time between it and the...

Страница 69: ...t of the screen the specific error code number is displayed in large text to the right see Figure 17 7 Blocking errors are only displayed while a problem exists during which time the burner is not per...

Страница 70: ...sure below 7 PSI burner operation is inhibited and FILL is displayed on the screen see Figure 17 8 As long as the water pressure is above 3 PSI the circulators will be permitted to operate otherwise t...

Страница 71: ...1 External Limit if an external limit device i e LWCO is connected to EXT LIM at field wiring terminals 9 10 check to ensure it has not tripped and that it is wired correctly 2 Bad Electrical Connecti...

Страница 72: ...ure drops below 190 F 1 ensure there is water flow through the boiler 2 check for correct return sensor reading menu reading 1 09 3 check wiring to return sensor replace sensor see Figure 19 1 a item...

Страница 73: ...nk sensor is being used set DHW Mode setting 2 08 to the appropriate setting see Table 17 2 Att 6 Warm Weather Shutdown WWSD Active when the outdoor temperature menu reading 1 08 exceeds the WWSD sett...

Страница 74: ...ler Menu setting 2 11 make sure it matches the correct boiler model as per Table 17 4 Set the remainder of the control settings as desired Verify proper boiler operation for DHW and Central Heat deman...

Страница 75: ...Figure 18 1 If 120VAC is not present check wiring between the boiler and electrical panel for poor connections Check the electrical connection to the display connector is located behind display Only r...

Страница 76: ...irculator should be wired to DHW PUMP and L2 NEUTRAL boiler terminals 9 and 12 13 see Figure 12 2 o Verify plumbing is in accordance with Figure 10 4 or 10 4 Indirect Tank with Tank Thermostat o Verif...

Страница 77: ...22 50 3 603 4 20 96 761 131 55 2 986 14 10 55 218 140 60 2 488 32 0 32 650 149 65 2 083 41 5 25 390 158 70 1 752 50 10 19 900 167 75 1 481 59 15 15 710 176 80 1 258 68 20 12 490 185 85 1 072 77 25 10...

Страница 78: ...renced Building Owners Replacement parts are available from your stocking wholesaler Contact your local Installer or Wholesaler for assistance with parts Wholesalers Contact NY Thermal Inc directly wh...

Страница 79: ...FTV I O Manual Parts List 79 Figure 19 1 b Heat Exchanger Water Piping Sensors FTV110C FTV150C FTV190C 26 59 15 18 21 64 64 64 92 92 43 40 29 91 24 96 97 30 118 47 117 28 83...

Страница 80: ...Parts List FTV I O Manual Figure 19 1 c Heat Exchanger Water Piping Sensors FTV110 FTV150 FTV190 15 26 59 64 64 64 18 21 40 43 83 24 58...

Страница 81: ...FTV I O Manual Parts List 81 Figure 19 1 d Gas Train Burner Assembly All FTV 14 9 7 8 37 39 5 4 36 10 25 34 2 1 33 13...

Страница 82: ...wer Venturi Gas_Valve Assembly 5 85809 FTV190 FTV190C Blower Venturi Gas_Valve Assembly 5 85460 FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Blower w o Venturi Gas Valve 6 86091 FTV110 FTV110C FTV150...

Страница 83: ...to Air Vent NPT 20 83608 FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Flue Sensor Dual 21 85738 FTV110 FTV150 FTV190 Return Pipe FTV non combi 21 85740 FTV110C FTV150C FTV190C Return Pipe from Hydrobl...

Страница 84: ...inlet Assembly FTV150 190 C 40 83718 FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Hose Clamp 1 1 16 to 1 1 2 41 85132 FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Flue Outlet Adapter PP 3 42 85133 FT...

Страница 85: ...asket 67 84918 FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Fuse LFT 3 15 250V 70 TBD FTV110 FTV110C FTV150 FTV150C FTV190 FTV190C Control Panel Sheet Metal Only 71 83604 FTV110 FTV110C FTV150 FTV150C...

Страница 86: ...FTV150C FTV190C DHW Temperature Flow Sensor VFS 92 84749 FTV110C FTV150C FTV190C O ring large Hydroblock Inlet Outlet 4 x 17 mm 93 84921 FTV110C FTV150C FTV190C Retaining Clips Hydroblock Inlet Outle...

Страница 87: ...s 100M Screen 115 82368 FTV110C FTV150C FTV190C Compression Gasket Rubber 116 85110 FTV110C FTV150C FTV190C Low Loss Header Pipe 117 85294 FTV110C FTV150C FTV190C Auto Air Vent Hydroblock 118 84744 FT...

Страница 88: ...Parts List FTV I O Manual Visit us online NY Thermal Inc 30 Stonegate Drive Saint John NB E2H 0A4 Canada Technical Assistance 1 800 688 2575 Fax 1 506 432 1135 www ntiboilers com...

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