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Lochinvar FTxl 725 User Manual

Lochinvar FTxl 725
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Installation & Operation Manual
Models: 400, 500, 600, 725,
& 850
is manual must only be used by a
quali 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.
WARNING
Save this manual for future reference.
FTXL-I-O_100059358_2000005000 Rev E

Table of Contents

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Lochinvar FTxl 725 Specifications

General IconGeneral
ModelFTxl 725
Input BTU/hr725, 000
Fuel TypeNatural Gas or Propane
Water Connection Size2" NPT
Modulation Ratio10:1
Width30 in.
Depth30 in.
Electrical Supply120V, 60Hz, 1Ph

Summary

Hazard Definitions

DANGER

Imminent hazard, death or serious injury.

WARNING

Potential hazard, death or serious injury.

CAUTION

Potential hazard, minor or moderate injury.

Please Read Before Proceeding

Installer Instructions

Read all instructions, including manuals, before installing.

Boiler Operation Safety

Warnings for operation, maintenance, and potential hazards.

What to Do If You Smell Gas

Emergency steps for gas leaks.

The FTXL - How it Works

Stainless Steel Heat Exchanger

Water flow around tubes for heat transfer and corrosion protection.

Blower

Mixes air and gas for combustion.

Gas Valve

Controls gas flow based on blower pressure.

Ratings

AHRI Rating

Boiler performance ratings confirmed by AHRI.

Other Specifications

Boiler dimensions, connections, and technical data.

Determine Boiler Location

Installation Compliance

Adherence to local, state, and national codes.

Closet and Alcove Installations

Specific requirements for confined spaces.

Determine Boiler Location

Residential Garage Installation

Precautions for installing appliances in garages.

Prevent Combustion Air Contamination

Avoiding corrosive air sources for combustion.

Determine Boiler Location

Corrosive Contaminants and Sources

Table listing substances that can damage the boiler.

Determine Boiler Location

Removing a Boiler from Existing Common Vent System

Procedures for safely removing a boiler from a common vent.

Determine Boiler Location

Combustion and Ventilation Air Requirements

Guidelines for air supply to the equipment room.

Prepare Boiler

Remove Boiler from Wood Pallet

Steps to safely remove the boiler from its packaging.

Gas Conversions

Procedures for converting to LP gas.

General Venting

Direct Venting Options

Sidewall and vertical vent configurations.

Install Vent and Combustion Air Piping

Connecting vent and air pipes.

General Venting

Requirements for Installation in Canada

Canadian certification and installation standards.

Sizing

Combustion air and vent piping size requirements.

General Venting

Common Venting

Criteria for connecting multiple FTXL boilers to a common vent.

PVC/CPVC Vent Pipe and Fittings

Approved materials and installation for PVC/CPVC venting.

General Venting

Polypropylene Vent Pipe and Fittings

Approved materials and installation for polypropylene venting.

Stainless Steel Vent Pipe and Fittings

Approved materials and installation for stainless steel venting.

Sidewall Direct Venting

Vent/air termination – sidewall

Guidelines for terminating vent and air pipes through a sidewall.

Determine location

Factors for choosing the vent/air termination location.

Sidewall Direct Venting

Prepare wall penetrations

Procedures for creating openings in walls for vent/air.

Multiple vent/air terminations

Terminating multiple vent/air connections.

Sidewall Direct Venting

Sidewall termination – optional concentric vent

Using a concentric vent kit for sidewall termination.

Vertical Direct Venting

Vent/air termination – vertical

Guidelines for terminating vent and air pipes vertically through a roof.

Determine location

Factors for choosing the vent/air termination location.

Vertical Direct Venting

Prepare roof penetrations

Procedures for creating openings in roofs for vent/air.

Multiple vent/air terminations

Terminating multiple vent/air connections vertically.

Vertical Direct Venting

Optional concentric vent: Models 400 - 600 Only

Using a concentric vent kit for vertical termination.

Vertical Direct Venting

Existing vent as a chase

Using an existing vent system as a chase for vent and air.

Hydronic Piping

System water piping methods

Closed loop system design and pressure requirements.

Freeze protection

Using glycol for freeze protection.

General piping information

Basic steps for system piping installation.

Hydronic Piping

Relief valve and temperature and pressure gauge installation

Installing safety and monitoring devices.

Near boiler piping components

Components for piping near the boiler.

Hydronic Piping

Circulator sizing

Selecting appropriate circulators.

Hydronic Piping

Variable speed pump option

Setup for variable speed pumps.

SMART SYSTEM / Multi-temperature loop control option

Controlling multiple temperature loops.

Hydronic Piping

Sizing Information for Temperature Rise Applications

Table for sizing based on temperature rise.

Hydronic Piping

Multiple Boilers - Alternate - Fixed or Variable Flow Primary System Piping

Piping for multiple boilers in a primary/secondary system.

Hydronic Piping

Single Boiler - Multiple Temperatures

Piping for a single boiler with multiple temperature loops.

Hydronic Piping

Single Boiler - Primary/Secondary Piping

Piping for a single boiler in a primary/secondary system.

Hydronic Piping

Multiple Boilers - Multiple Temperatures

Piping for multiple boilers with multiple temperature loops.

Hydronic Piping

Multiple Boilers - Primary/Secondary Piping

Piping for multiple boilers in a primary/secondary system.

Hydronic Piping

Gas Connections

Connecting gas supply piping

Installing gas supply lines to the boiler.

Natural Gas

Specific requirements for natural gas.

Gas Connections

Propane Gas

Specific requirements for propane gas.

Check inlet gas supply

Verifying gas supply pressure and integrity.

Gas Connections

Gas pressure

Required gas pressures for operation.

Gas valve replacement

Procedures and warnings for gas valve replacement.

Field Wiring

Line voltage connections

Connecting the 120 VAC power supply.

Low voltage connections

Routing and connecting low voltage wires.

Thermostat

Connecting room thermostats and zone controls.

Field Wiring

Outdoor temperature sensor

Installing sensor for outdoor reset operation.

DHW (Domestic Hot Water) thermostat

Connecting DHW controls.

DHW tank sensor

Connecting the tank sensor for DHW control.

Field Wiring

Wiring of the cascade

Connecting multiple boilers in a cascade.

Condensate Disposal

Condensate drain

Managing condensate from the appliance.

Start-up

Fill water

Ensuring proper water quality and filling the system.

Freeze protection

Using glycol for freeze protection.

Oxygen prevention

Preventing oxygen-related corrosion.

Start-up

Boiler water

Precautions for boiler water chemistry.

Purge air from water system

Removing air from the system.

Start-up

Check for gas leaks

Verifying gas connections for leaks.

Check thermostat circuit(s)

Verifying thermostat wiring.

Start-up

Check flame and combustion

Verifying burner operation and combustion.

Check system and boiler

Final checks before boiler operation.

Start-up

Set space heating operation

Configuring heating operation.

Start-up

Set DHW boiler target temperature

Setting the domestic hot water temperature.

Configuration of the cascade

Setting up boilers for cascade operation.

Operating Information

General

Overview of boiler operation.

How the boiler operates

Basic process of boiler functioning.

DHW priority

Prioritizing domestic hot water calls.

Operating Information

Boiler and system pump control

Managing pump operation.

Outdoor air reset

Adjusting set points based on outdoor temperature.

Boost function

Increasing set point based on continuous demand.

Operating Information

Night setback

Programming reduced set points for savings.

Freeze protection

Boiler's built-in freeze protection features.

Protection features

Over-temperature and flue temperature limits.

Operating Information

Boiler temperature regulation

Controlling boiler temperature.

High limit operations

Automatic and manual reset high limits.

High limit test procedure

Testing high limit controls.

Operating Information

Sequence of the cascade

Operating order for boilers in a cascade.

Operating Information

Control Panel Overview

Description of the control panel interface.

Operating Information

Status Display Screens

Information displayed on the control panel.

Maintenance

Service and Maintenance Schedules

Tables for maintenance tasks.

Address reported problems

Steps for resolving reported issues.

Inspect boiler area

Checking the area around the boiler.

Maintenance

Clean condensate trap

Cleaning the condensate trap.

Check all piping for leaks

Verifying all piping is leak-free.

Maintenance

Flue vent system and air piping

Inspecting vent and air piping.

Check boiler relief valve

Inspecting and testing the relief valve.

Maintenance

Inspect ignition and flame sense electrodes

Inspecting and cleaning electrodes.

Check burner flame

Inspecting the burner flame.

Maintenance

Cleaning boiler heat exchanger

Procedure for cleaning the heat exchanger.

Diagrams

Wiring Diagram

Electrical wiring schematic for the boiler.

Diagrams

Ladder Diagram

Control logic diagram for boiler operation.

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