Lochinvar FTXL 400 Installation & Operation Manual
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Lochinvar FTXL 400 Installation & Operation Manual

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See also: Service Manual , Instruction Manual
FTXL-I-O_100059358_2000005000 Rev E
Installation & Operation Manual
Models: 400, 500, 600, 725,
& 850
Th is manual must only be used by a
WARNING
qualifi ed 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.

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  • Page 1 FTXL-I-O_100059358_2000005000 Rev E Installation & Operation Manual Models: 400, 500, 600, 725, & 850 Th is manual must only be used by a WARNING qualifi ed heating installer / service technician. Read all instructions, including this manual and the FTXL Service Manual, before installing.

  • Page 2: Table Of Contents

    Contents HAZARD DEFINITIONS ............ 2 6. HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING ......3 System Water Piping Methods ......... 37 THE FTXL -- HOW IT WORKS........4-5 Low Water Cutoff Device ..........37 RATINGS ................6 Chilled Water System ............37 1.

  • Page 3: Please Read Before Proceeding

    Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including WARNING DO NOT install units in rooms or WARNING this manual and the FTXL Service Manual, environments that contain corrosive before installing. Perform steps in the contaminants (see Table 1A on page 10).

  • Page 4: The Ftxl - How It Works

    Installation & Operation Manual The FTXL - How it works... 1. Stainless steel heat exchanger 21. Low voltage connection board Th e connection board provides easy access for connecting Allows system water to fl ow around specially designed tubes for external low voltage devices.
  • Page 5 Installation & Operation Manual The FTXL - How it works... (continued) Models 400 - 850 Front View Rear View Left Side (inside unit) Right Side (inside unit)

  • Page 6: Ratings

    Installation & Operation Manual Ratings FTXL Boiler Other Specifi cations AHRI Rating Input Model Number Boiler Gross AHRI Vent Water Water Output Ratings Size Content Connections Connections Size (Note 4) Water, Note: Change “N” to Gallons “L” for L.P. gas models. (Note 1) (Note 2) (Note 3)

  • Page 7: Determine Boiler Location

    Installation & Operation Manual Determine boiler location Installation must comply with: Th is appliance is certifi ed as an indoor WARNING appliance. Do not install the appliance • Local, state, provincial, and national codes, laws, outdoors or locate where the appliance will regulations, and ordinances.
  • Page 8 Installation & Operation Manual Determine boiler location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, CLOSET INSTALLATION WARNING polypropylene or stainless steel 1/4" (6 MM) MINIMUM CLEARANCE vent material MUST BE used in AROUND HOT WATER PIPES 1"...

  • Page 9: Provide Air Openings To Room

    Installation & Operation Manual Determine boiler location Provide air openings to room: Residential garage installation FTXL alone in boiler room Precautions Take the following precautions when installing the appliance 1. No air ventilation openings into the boiler room are in a residential garage. If the appliance is located in a needed when clearances around the FTXL are at least residential garage, it should be installed in compliance with equal to the SERVICE clearances shown in FIG.’s 1-1...

  • Page 10: Corrosive Contaminants And Sources

    Installation & Operation Manual Determine boiler location (continued) When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new boiler: Products to avoid: Failure to follow all instructions can result WARNING Spray cans containing chloro/fl uorocarbons in fl ue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions...

  • Page 11: Removing A Boiler From Existing Common Vent

    Installation & Operation Manual Determine boiler location (continued) When removing a boiler from existing common vent system: Do not install the FTXL into a common g. Any improper operation of the common venting DANGER vent with any other appliance. Th is system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ will cause fl ue gas spillage or appliance...

  • Page 12: Combustion And Ventilation Air

    Installation & Operation Manual Determine boiler location Combustion ventilation 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.
  • Page 13 Installation & Operation Manual Determine boiler location (continued) Under no circumstances should the If a single combustion air opening is provided to bring CAUTION equipment room ever be under negative combustion air in directly from the outdoors, the pressure. Particular care should be taken opening must be sized based on a minimum free area where exhaust fans, attic fans, clothes dryers, of one square inch per 3000 Btu/hr (7 cm...

  • Page 14: Prepare Boiler

    Installation & Operation Manual Prepare boiler Remove boiler from wood pallet Models 400 and 500 Only (Venturi w/LP Orifi ces) 1. Aft er removing the outer shipping carton from the boiler, remove the parts box. 1. Remove the top bezel from the unit (no tools required for removal).

  • Page 15: Models 600 - 850

    Installation & Operation Manual Prepare boiler (continued) Models 600 - 850 Figure 2-2A 400 Model_Venturi with LP Orifi ce 1. Lift the top bezel (prop the bezel up for service). BLOWER 2. Remove the cover on top of the gas valve (FIG. 2-3). O-RING 3.

  • Page 16: General Venting

    Installation & Operation Manual General venting Direct venting options - Sidewall Vent IMG01061 IMG01060 PVC/CPVC Concentric Sidewall Models 400 - 600 Only Two Pipe Sidewall See page 28 for more details See page 24 for more details Direct venting options - Vertical Vent IMG01062 IMG01063 IMG01064...

  • Page 17: Install Vent And Combustion Air Piping

    Installation & Operation Manual General venting (continued) Install vent and combustion air piping Th e FTXL boiler must be vented and Th e FTXL boiler vent and air piping can be installed through DANGER supplied with combustion and ventilation the roof or through a sidewall. Follow the procedures in this air as described in this section.

  • Page 18: Requirements For Installation In Canada

    PVC, CPVC, Polypropylene or ABS material to comply with this requirement. Dryer Vent or Sealed Flexible Duct (not recommended for Th e 4" Concentric Vent Kit available from Lochinvar (see rooft op air inlet) Section 4 – Sidewall Termination – Optional Concentric Galvanized steel vent pipe with joints and seams sealed as Vent) and the 4"...

  • Page 19: Optional Room Air

    Installation & Operation Manual General venting (continued) Th e PVC, CPVC, or ABS air inlet pipe should be cleaned and When utilizing the single pipe method, WARNING provisions for combustion and ventilation sealed with the pipe manufacturer’s recommended solvents air must be in accordance with Air for and standard commercial pipe cement for the material used.

  • Page 20: Pvc/Cpvc

    FTXL boilers connected to the common vent must all be of the same size. 4” 100056141 4” 100056141 Each FTXL boiler must have a Lochinvar supplied fl ue damper installed (see Table 3D). 6” 100056142 6” 100056142 Only vertical direct vent, positive pressure, Category...
  • Page 21 Installation & Operation Manual General venting (continued) Table 3E PVC/CPVC Vent Pipe, and Fittings Dry fi t vent or air piping to ensure proper fi t up before assembling any joint. Th e pipe should go Approved PVC/CPVC Vent Pipe and Fittings a third to two-thirds into the fi tting to ensure Item Material...

  • Page 22: Polypropylene

    Installation & Operation Manual General venting Th e installer must use a specifi c vent starter NOTICE adapter at the fl ue collar connection. Th e adapter is supplied by the vent manufacturer Polypropylene to adapt to its vent system. See Table 3F Th is product has been approved for use with polypropylene for approved vent adapters.

  • Page 23: Stainless Steel Vent

    Installation & Operation Manual General venting (continued) Stainless steel vent Figure 3-6 Near Boiler Stainless Steel Venting Models Th is product has been approved for use with stainless steel 400 - 600 using the manufacturers listed in Table 3H. Use only the materials, vent systems, and WARNING terminations listed in Tables 3G and 3I.

  • Page 24: Determine Location

    Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Do not terminate above any door or window. Condensate can freeze, causing ice formations. Locate or guard vent to prevent condensate damage Follow instructions below when WARNING to exterior fi nishes. determining vent location to avoid possibility of severe personal injury, death, Figure...
  • Page 25 Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Do not terminate closer than 4 feet (1.2 m) horizontally from any electric meter, gas meter, Figure 4-2A PVC/CPVC/ Polypropylene Sidewall regulator, relief valve, or other equipment. Never Termination Models 400 - 850 w/Field Supplied Fittings terminate above or below any of these within 4 feet (1.2 m) horizontally.

  • Page 26: Sidewall Direct Venting Vent/Air Termination - Sidewall

    Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall 3. Use a sidewall termination plate as a template for correct Figure 4-4A Clearance to Forced Air Inlets w/Field location of hole centers. Supplied Fittings 4. Follow all local codes for isolation of vent pipe when passing IF LESS through fl oors or walls.

  • Page 27: Multiple Vent/Air Terminations

    Installation & Operation Manual Sidewall direct venting (continued) Multiple vent/air terminations Mount and secure the vent plate to the wall using stainless steel screws. 1. When terminating multiple FTXL’s terminate Seal all gaps between the pipes and wall. Seal around the each vent/air connection as described in this manual plate to the wall assuring no air gaps.

  • Page 28: Sidewall Termination - Optional Concentric Vent

    Sidewall termination – optional concentric vent: Models 400 - 600 Only Description and usage Lochinvar off ers an optional concentric combustion air 3. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 and vent pipe termination kit (#100140484 for 4" (102 mm) installations into the structure to install the termination kit.
  • Page 29 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 400 - 600 Only Figure 4-9 Concentric Vent Dimensional Drawing - Models 400 - 600 "A" "B" DIA. "C" DIA. "D" 3" (76 MM) "E" "G"...
  • Page 30 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent: Models 400 - 600 Only Figure 4-11 Concentric Vent Sidewall Attachment STRAP (FIELD SUPPLIED) ELBOW (FIELD SUPPLIED) COMBUSTION AIR COMBUSTION AIR VENT VENT Multiventing sidewall terminations DO NOT use fi eld-supplied couplings CAUTION to extend pipes.

  • Page 31: Vertical Direct Venting

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when WARNING Figure 5-1A PVC/CPVC/Polypropylene Vertical determining vent location to avoid Termination of Air and Vent possibility of severe personal injury, death or substantial property damage. ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED Determine location...

  • Page 32: Prepare Roof Penetrations

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Prepare roof penetrations Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as Figure 5-2 Vertical Terminations with Multiple Boilers close as desired to the air pipe outside diameter. 12"...

  • Page 33: Vertical Termination - Optional Concentric Vent

    Description and usage 2. Cut one (1) hole (7 inch (178 mm) diameter for #100140484 Lochinvar off ers an optional concentric combustion air and installations) into the structure to install the termination vent pipe termination kit. Both combustion air and vent kit.
  • Page 34 Installation & Operation Manual Vertical direct venting Vertical termination – optional concentric vent: Models 400 - 600 Only Do not operate the appliance with DO NOT use fi eld-supplied couplings WARNING CAUTION the rain cap removed or recirculation to extend pipes. Airfl ow restriction will of combustion products may occur.

  • Page 35: Alternate Vertical Concentric Venting

    Installation & Operation Manual Vertical direct venting (continued) Alternate vertical concentric venting Th is appliance may be installed with a concentric vent Figure 5-8 Concentric Vent Example 1 arrangement where the vent pipe is routed through an FLUE EXHAUST existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.
  • Page 36 Installation & Operation Manual 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...

  • Page 37: Hydronic Piping

    Installation & Operation Manual General piping information Hydronic piping All boiler piping must contain an oxygen IMPORTANT System water piping methods barrier. Th is will help prevent any excess oxygen from entering the system. Th e FTXL is designed to function in a closed loop system Basic steps are listed below along with illustrations on the pressurized to not less than 12 psi (83 kPa).

  • Page 38: Relief Valve Installation

    Installation & Operation Manual Hydronic piping Relief valve temperature Figure 6-1 Flow Switch, Relief Valve and Temperature and pressure gauge installation 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.

  • Page 39: Near Boiler Piping Components

    13. System temperature sensor: inadvertent high limit shutdowns and poor system Lochinvar supplies a system temperature sensor. Th e performance. Flow rates are based on a full fl ow sensor is to be installed in the heating loop downstream application.

  • Page 40: Near Boiler Piping Connections

    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 off ers the Multi- Temperature Loop Control Board Kit (100167843). Th e maximum allowable water fl ow rate...
  • Page 41 Installation & Operation Manual Hydronic piping (continued) Figure 6-4 Pressure Drop vs. Flow HEX Pressure Drop (Full Flow Application) FTX725-850 FTX400-600 15 ft 15 ft 14 ft 14 ft FTX725 - 850 13 ft 13 ft FTX400-600 12 ft 12 ft 11 ft 11 ft 10 ft...

  • Page 42: Piping Diagrams

    Installation & Operation Manual Hydronic piping Figure 6-5 Multiple Boilers - Alternate - Fixed or Variable Flow Primary System Piping Number of Units Model Manifold Pipe Sizes in Inches (mm) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254)
  • Page 43 Installation & Operation Manual Hydronic piping (continued) Figure 6-6 Single Boiler - Multiple Temperatures Mixing valves are required for the protection of low temperature loops. CAUTION Please note that these illustrations are meant to show system piping concept only, the installer is responsible NOTICE for all equipment and detailing required by local codes.
  • Page 44 Installation & Operation Manual Hydronic piping Figure 6-7 Single Boiler - Primary/Secondary Piping Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION 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 NOTICE for all equipment and detailing required by local codes.
  • Page 45 Installation & Operation Manual Hydronic piping (continued) Figure 6-8 Multiple Boilers - Multiple Temperatures Number of Units Model Manifold Pipe Sizes in Inches (mm) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102)
  • Page 46 Installation & Operation Manual Hydronic piping Figure 6-9 Multiple Boilers - Primary/Secondary Piping Number of Units Model Manifold Pipe Sizes in Inches (mm) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102) 5 (127) 6 (152) 6 (152) 8 (203) 10 (254) 3 1/2 (89) 4 (102)
  • Page 47 Installation & Operation Manual Hydronic piping (continued) Figure 6-10 Single Boiler - Multiple Temperatures with DHW Piped as a Zone Indirect water heaters are capable of transferring a limited number of Btu’s into the water. Ensure boiler CAUTION output does not exceed indirect water heater transfer capabilities. Mixing valves are required for the protection of low temperature loops.

  • Page 48: Gas Connections

    Installation & Operation Manual Gas connections Connecting gas supply piping 1. Remove the top access panel and refer to FIG.’s 7-1 and 3. Support piping with hangers, not by the boiler or its 7-2 to pipe gas to the boiler. accessories.

  • Page 49: Natural Gas

    Installation & Operation Manual Gas connections (continued) Natural gas: Failure to apply pipe sealing compound WARNING as detailed in this manual can result Pipe sizing for natural gas in severe personal injury, death, or substantial property damage. 1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per Use two wrenches when tightening gas WARNING...

  • Page 50: Check Inlet Gas Supply

    Installation & Operation Manual 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 specifi c gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4...

  • Page 51: Gas Pressure

    Installation & Operation Manual Gas connections (continued) Gas pressure When re-tightening the set screw, be sure WARNING to tighten securely to prevent gas leaks. Th e gas pressure must remain between 4 inches w.c. Do not check for gas leaks with an open (.99 kPa) minimum and 14 inches w.c.

  • Page 52: Field Wiring

    Installation & Operation Manual Field wiring Line voltage connections ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power 1. Connect 120 VAC power wiring to the line voltage terminal supply before making any electrical strip in the junction box, as shown in FIG. 8-1. connections to avoid possible electric 2.

  • Page 53: Outdoor Temperature Sensor

    0 - 10V input on the boiler pump speed control. Th e tank sensor included with the Lochinvar Squire® indirect Rate output DHW tanks (100170544) is the only sensor suitable for use with the SMART SYSTEM control.

  • Page 54: Wiring Of The Cascade

    Installation & Operation Manual Field wiring Connect the system supply sensor and outdoor air sensor (if See the FTXL Service Manual for instructions on how to used) to the Leader boiler. For the Cascade system to work use the inlet sensor as the controlling sensor. When the properly the system supply sensor must be installed.
  • Page 55 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections...

  • Page 56: Condensate Disposal

    Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. Th e FTXL is a high effi ciency appliance that produces authority, PVC and CPVC pipe must comply condensate.

  • Page 57: Startup

    Installation & Operation Manual Start-up Freeze protection Fill water Check/control fi ll water chemistry Ethylene glycol is toxic, DO NOT use as WARNING your freeze protection. Ethylene glycol has a Conduct water quality testing prior to IMPORTANT sweet aroma which children and pets could installing the appliance.
  • Page 58 Installation & Operation Manual Start-up Oxygen prevention Fill and test water system 1. Fill system only aft er ensuring the water meets the Eliminate all system leaks. Continual CAUTION requirements of this manual. fresh makeup water will reduce boiler life. Minerals can build up in the 2.

  • Page 59: Check For Gas Leaks

    Installation & Operation Manual Start-up (continued) Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the propane Before starting the boiler, and during to make its presence detectable. In some WARNING initial operation, smell near the fl oor and instances, the odorant can fade, and the around the boiler for gas odorant or any gas may no longer have an odor.

  • Page 60: Start The Boiler

    Installation & Operation Manual Start-up Final checks before starting the boiler  Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air  Read the FTXL Service Manual to familiarize yourself with piping, and vent piping. SMART SYSTEM control module operation.

  • Page 61: For Your Safety Read Before Operating

    Installation & Operation Manual Start-up (continued) Figure 10-2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. •...
  • Page 62 Installation & Operation Manual Start-up Check fl ame and combustion Set space heating operation (continued) 4. Place the boiler into the active position by pressing the Determine controlling sensor RIGHT SELECT [ON] key (FIG. 11-1, page 71). 5. Locate the pinhole button above the RESET button on For space heating systems, the temperature control can be the display board (FIG.
  • Page 63 Installation & Operation Manual Start-up (continued) Set domestic hot water (DHW) operation Verify DHW mode Turn the NAVIGATION dial to adjust the minutes. Press Th ere are two (2) modes of operation for DHW. In Normal the NAVIGATION dial. Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and Turn the NAVIGATION dial to adjust the month.

  • Page 64: Operating Information General

    (3) heat/loop demands boiler fi ring rate. Th e gas valve senses the amount of air (reference Lochinvar kit 100167843). fl owing into the boiler and allows only the right amount of gas to fl ow.

  • Page 65: Temperature Control

    Installation & Operation Manual Operating information (continued) Temperature control Programmable controlling sensor Th e control module is programmed to use the outlet Modulation sensor as the control sensor by default. If a system supply Th e FTXL is capable of modulating its fi ring rate from a sensor is connected, the control automatically uses it as minimum of 10% to a maximum of 100%.
  • Page 66 Installation & Operation Manual Operating information Freeze protection Night setback DO NOT install the boiler in a room likely to freeze. Th e controller may be programmed to reduce the space heating Th e following integral feature of the SMART SYSTEM control and DHW set points during certain times each week.
  • Page 67 Installation & Operation Manual Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for Th e FTXL is equipped with adjustable automatic reset and a fl ow switch and a louver proving switch. Th e SMART manual reset high limits.

  • Page 68: Cascade

    Installation & Operation Manual Operating information Low water cutoff protection Sequence of the cascade Th e SMART SYSTEM control module uses temperature To equalize the run time of all boilers on the Cascade, the fi ring sensing of both supply and return areas of the heat sequence will automatically be changed at set intervals.

  • Page 69: Sequence Of Operation

    Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW).
  • Page 70 Installation & Operation Manual Operating information Sequence of operation OPERATION DISPLAY 7. If fl ame is detected, it holds the fi ring rate steady for a few seconds to let the fl ame stabilize, then it begins to modulate the fi...

  • Page 71: Ftxl Control Module

    Installation & Operation Manual Operating information (continued) FTXL control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation. Figure 11-1 Control Panel DRIVE RESET CONNECTION SWITCH LEFT SELECT KEY RIGHT SELECT KEY NAVIGATION DIAL IMG01093 Th e information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the...

  • Page 72: Status Display Screens

    Installation & Operation Manual Operating information Figure 11-2 Status Display Screen (BOILER (CALL FOR STATUS) HEAT) (OPERATIONAL INFORMATION) (LEFT SELECT (RIGHT SELECT KEY) KEY) (NAVIGATION DIAL) Status Display Screens NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description...
  • Page 73 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description a. SYSTEM TEMP b. TANK TEMP c. OUTDOOR TEMP DETAILS SCREEN 1 d.
  • Page 74 Installation & Operation Manual Operating information Status Display Screens (cont’d) NOTE: All screens show burner status, heat demands, lockout/blocking, pump status, and soft keys. Section Display Description a. CASCADE STATUS CASCADE STATUS b. CASCADE POWER (Operational c. PRESENT Information a. TRIGGER 1 - Next Space Heat (SH) night setback trigger. cont.) NIGHT SETBACK b.

  • Page 75: Maintenance Maintenance And Annual Startup

    Installation & Operation Manual Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the FTXL User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •...

  • Page 76: Address Reported Problems

    Installation & Operation Manual Maintenance Follow the Service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

  • Page 77: Check Expansion Tank

    Installation & Operation Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire fl ue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage.

  • Page 78: Check Control Settings

    Installation & Operation Manual Maintenance Inspect ignition and fl ame sense Figure 12-2 Burner Assembly - Model 400 - 850 electrodes 1. Remove the ignition and fl ame sense electrodes from the FAN TOP PLATE boiler heat exchanger access cover. 2.

  • Page 79: Review With Owner

    Installation & Operation Manual Maintenance (continued) Check fl ame signal 7. Disconnect the condensate hose from the condensate trap and route to drain. 1. At high fi re the fl ame signal shown on the display should 8. Use a vacuum cleaner to remove any accumulation on the be at least 10 microamps.

  • Page 80: Diagrams

    Installation & Operation Manual Diagrams Figure 13-1 Wiring Diagram LOW VOLTAGE 120 VAC BOX DEPICTS OPTIONAL ITEMS HIGH VOLTAGE CONXUS BOX DEPICTS DUAL SENSOR SINGLE HOUSING RIBBON CABLE INTEGRATED CONNECTION BOARD CONTROL JUNCTION RELAY BOARD PUMP DAMPER FLUE DAMPER X1-3 CN2-4 CN1-5 RELAY...

  • Page 81: Ladder Diagram

    Installation & Operation Manual Diagrams (continued) Figure 13-2 Ladder Diagram 120VAC JUNCTION BOX NEUTRAL TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" BLOWER BLOWER GROUND RELAY SYSTEM ON / OFF PUMP SWITCH CONTACTS INTEGRATED CONTROL X1-6 X1-1 3.15A BLOWER SYSTEM RELAY...
  • Page 82 Installation & Operation Manual Notes...
  • Page 83 Installation & Operation Manual Notes...

  • Page 84: Revision Notes

    Revision Notes: Revision A (ECO #C15743) initial release. Revision B (ECO #C16066) refl ects updates made to the room air kit on page 19 along with updates made to the wiring and ladder diagrams. Revision C (ECO C17014) refl ects the standardization of pressure drop information on pages 49 and 50 as well as the the addition of the system supply sensor note on page 53.

This manual is also suitable for:

Ftxl 850Ftxl 600Ftxl 500Ftxl 725

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