HTP EL-80 Installation Start-Up Maintenance Parts
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HTP EL-80 Installation Start-Up Maintenance Parts

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See also: Installation Manual
Installation
Start-Up
Maintenance
Parts
Warranty
EL-80 / EL-110 / EL-150 / EL-220
EL-299 / EL-301 / EL-399
Models*
* "N" Denotes Natural Gas Operation
"LP" Denotes Propane Gas Operation
This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe
personal injury, or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause
property damage, severe personal injury, or death.
HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical
errors in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd.
Commercial Boilers
New Bedford, MA 02745
Elite
Residential and
Heat Exchanger Bears the ASME "H" Stamp
www.htproducts.com
LP-293 Rev. 9.24.15

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Summary of Contents for HTP EL-80

  • Page 1 Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death. HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
  • Page 2 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS •...
  • Page 3 AHJ. levels or to important product information. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. DANGER indicates an imminently hazardous situation...

  • Page 4: Table Of Contents

    In accordance with Section 325 (f) (3) of the Energy Policy heat load), the control will reduce the maximum fan speed. and Conservation Act, HTP, Inc. has provided this boiler with If the temperature difference exceeds 60°F, the control multiple features designed to save energy by reducing the will effectively sense there is little or no water flow or heat boiler water temperature as heating load decreases.
  • Page 5 N. Multiple Boilers Part 11 - Troubleshooting O. Applications* A. Boiler Error and Fault Codes Part 5 - Venting and Condensate Removal B. Boiler Error A. General C. Boiler Fault B. Approved Materials for Exhaust Vent and Intake Pipe 25 D.

  • Page 6: Improper Combustion

    HTP recommends a suction strainer assembly. in this type of system. Altering any HTP, Inc. boiler with parts not manufactured by • Do not use petroleum-based cleaning or sealing HTP, Inc. WILL INSTANTLY VOID the boiler warranty and could compounds in boiler system.

  • Page 7: How The Boiler Operates

    C. Optional Equipment connected boilers. Each cascaded boiler will have its own Optional equipment available from HTP (and Part #): • Wall Mount Bracket (7450P-211) pump to provide maximum flow and control heat exchanger flow rate.

  • Page 8: Part 3 - Prepare The Boiler

    • Flow Switch Kit (EL-80/110/150/220 - 7450P-213, EL- 299/301 - 7450P-214, EL-399 - 7450P-215) This boiler has a condensate disposal system that may • Vision II (7250P-322) freeze if exposed to sustained temperatures below 32 NOTE: When using an optional system sensor, pipe insulation...

  • Page 9: Flooring

    6. Clean and flush system when reinstalling a boiler. D. Clearances for Service Access NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the boiler model and serial number.

  • Page 10: Direct Vent Of Exhaust And Intake

    NOTE: The venting options described here (and further must be taken to utilize uncontaminated combustion air. To detailed in the Venting section, this manual) are the lone prevent combustion air contamination, see Table 1. venting options approved for this boiler. Failure to vent the 2. Indoor Combustion Air in Confined or Unconfined Space boiler in accordance with the provided venting instructions This boiler requires fresh, uncontaminated air for safe...

  • Page 11: Removing A Boiler From A Common Vent System

    Garages and workshops detergents, and cleaning solvents equipment. HTP recommends having water quality professionally analyzed to determine whether it is necessary Adhesives used to fasten building to install a water softener. It is important that the water...
  • Page 12 • Chlorine concentration less than 100 ppm *NOTE: It is recommended to clean the heat exchanger at • Using chlorinated fresh water should be acceptable as least once a year to prevent lime scale buildup. To clean the levels are typically less than 5 ppm. heat exchanger, follow the maintenance procedure in this manual.
  • Page 13 Figure 5 - Boiler Dimensions - NOTE: All Dimensions Are Approximate LP-293 Rev. 9.24.15...

  • Page 14: Part 4 - Piping

    The boiler may be connected to an indirect water heater to FAILURE TO COMPLY WITH THE ABOVE GUIDELINES supply domestic hot water. HTP offers indirect water heaters in COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, a wide range of gallon sizes in either stainless steel or glass-lined RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY construction.

  • Page 15: Potable Expansion Tank

    HTP (Part # 7450P-225). Check with local of the expansion tank. codes for additional requirements. If the boiler supplies hot...
  • Page 16 Heat Exchanger Pressure Drop Flow Rate in GPM and Corresponding Pressure Drop in Feet (Δ P’) Model EL-80 10’ 14’ 17’ 21’ 26’ EL-110 15’ 17’ 22’ 25’ 33’ EL-150 12’ 15’ 17’ 19’ 22’ 27’ EL-220 8’ 10’ 11.5’ 13’ 15’ 16.5’ 17’ 19’ EL-299 13’ 14’ 15’ EL-301 EL-399...

  • Page 17: Check / Control Water Chemistry

    The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit. To size, simply add up the number of boilers and the required flow rates for the system design temperature. Example: (5) EL-220 boilers with a design of 20°Δt degree temperature rise with each boiler having an individual flow rate of 22 GPM.

  • Page 18: Plumbing

    Minimum Pipe Sizes from flowing. Disconnect the hose and connect it to next zone to be purged. EL-80 / 110 / 150 / 220 1” NPT 5. Repeat this procedure for additional zones (one at a time). EL-299 / 301 1 1/4”...

  • Page 19: Zoning With Zone Valves

    • Glycol in hydronic applications should include inhibitors that prevent the glycol from attacking metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level. • The glycol solution should be tested at least once a year or as recommended by the glycol manufacturer.

  • Page 20: Applications

    O. Applications* *NOTE: Systems shown are primary/secondary piping systems. These recommended systems have a primary (boiler) loop, and secondary circuits for heating. The primary loop and secondary circuits have separate circulators. The use of other near boiler piping configurations could result in improper flow rates, leading to inadvertent boiler high limit shutdowns and poor system performance.
  • Page 21 Secondary Circuit Primary Loop Primary Loop Figure 8 - Cascaded Boilers with Indirect Priority on a Single Boiler NOTES: 1. This drawing is meant to show system piping concept only. 2. A mixing valve is recommended if the DHW temperature is set above 119 3.
  • Page 22 Secondary Circuit Primary Loop Figure 9 - Space Heating NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Piping shown is Primary/Secondary. 4.
  • Page 23 Secondary Circuit Primary Loop Primary Loop Figure 10 - Cascaded Space Heating NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Piping shown is Primary/Secondary. 4.

  • Page 24: Part 5 - Venting And Condensate Removal

    Part 5 - Venting and Condensate Removal The boiler must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual.

  • Page 25: Approved Materials For Exhaust Vent And Intake Pipe

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada PVC Schedule 40/80 ANSI / ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV* ANSI / ASTM D2665 be ULC-S636 Certified. IPEX is Exhaust Vent or Intake an approved manufacturer in CPVC Schedule 40/80...

  • Page 26: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location Area Where Terminal Is Not Permitted Exhaust Vent Terminal Intake Pipe Terminal Figure 11 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION –...

  • Page 27: Exhaust Vent And Intake Pipe Sizing

    E. Exhaust Vent and Intake Pipe Sizing 1. The exhaust vent and intake pipe size is 3” for EL-80 - EL-220 models and 4” for EL299 - EL-399 models. 2. The maximum total equivalent length of exhaust vent and intake pipe should not exceed 200 feet.

  • Page 28: Applications

    16. Ensure the outdoor intake pipe termination is screened to prevent blockage caused by debris or birds. The following table lists optional exhaust/intake terminations 6/23/15 available from HTP: TWO PIPE SIDEWALL VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST) Description Stock Code 3”...

  • Page 29: Sidewall Venting

    Sidewall Venting with Kit Sidewall Venting with Concentric Vent SIDE VIEW FRONT VIEW Roof Venting with Concentric Vent FRONT VIEW Figure 14 - Venting with Optional Kits (NOT INCLUDED WITH THE BOILER) NOTE: These drawings are meant to demonstrate system LP-325-PP 03/03/11 venting only.

  • Page 30: Venting Through An Existing System

    NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.

  • Page 31: Indoor Combustion Air In Confined Or Unconfined Space

    Concentric Venting Through an Existing System Concentric Venting Through an Existing System Chase Venting Through an Existing System INTAKE EXISTING VENT AIR INTAKE W/ SCREEN AIR INTAKE W/ SCREEN Figure 17 - 1, 2 - Concentric Venting Through an Existing System, 3, Chase Venting Through an Existing System NOTE: These drawings are meant to demonstrate system venting only.

  • Page 32: Condensate Removal System

    HTP recommends neutralizing condensate with a Condensate Neutralizer Kit (Part # 7450P-212 for EL-80/110/150/220/299/301, Part # 7350P-611 for EL-399). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the condensate.

  • Page 33: Part 6 - Wiring

    3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate It is of extreme importance that this unit be properly grounded. It line from freezing temperatures or any type of blockage. is very important that the building system ground is inspected by In installations that may encounter sustained freezing a qualified electrician prior to making this connection.

  • Page 34: Alarm Connections

    120 volts supplied, an external motor starter or tank or an HTP 7250P-325 tank sensor. When a tank sensor is contactor will be required. used, the boiler control will automatically detect its presence E.

  • Page 35: Optional 0-10 Volt Building Control Signal

    Avoid running communication cables parallel signal. When this and close to or against high voltage (120 volt or greater) wiring. input is enabled using HTP recommends that the maximum length of communication installer menu, bus cables not exceed 200 feet. building control 4.

  • Page 36: Cascade Master Pump And Sensor Wiring

    alarm contacts are rated 5 amps at 120 VAC. M. Cascade Master Pump and Sensor Wiring To connect an alarm device, connect the power for the device 1. Connect the system pump hot wire to the terminal marked 8. to the ALARM COM terminal. Connect the alarm device hot 2.
  • Page 37 Figure 26 - EL-80 - 150 Internal Connection Diagram LP-293 Rev. 9.24.15...
  • Page 38 ELITE 220 BOILER INTERNAL CONNECTION DIAGRAM 120 VAC NEUTRAL LINE J6-2 J6-1 POWER SWITCH DISPLAY BOARD ASSEMBLY J6-3 FLUE TEMPERATURE SENSOR X6-1 X6-4 X6-2 X4-12 X8-2 PROTECTED BY AN INTERNAL COMBINATION 6.3 AMP FUSE SUPPLY / HIGH WATER X4-13 TEMP. SENSOR J6-6 CH PUMP X8-1...
  • Page 39 ELITE 301 / 299 / 399 BOILER INTERNAL CONNECTION DIAGRAM 120 VAC LINE NEUTRAL J6-2 J6-1 POWER SWITCH DISPLAY BOARD ASSEMBLY J6-3 FLUE TEMPERATURE SENSOR X6-1 X6-4 X6-2 X4-12 X8-2 PROTECTED BY AN INTERNAL COMBINATION 6.3 AMP FUSE SUPPLY / HIGH WATER X4-13 TEMP.

  • Page 40: Part 7 - Gas Connections

    Union Drip Leg The gas connection on the boiler is 3/4” for the EL-80/110/150 Piping Support and 1” for the EL-220/299/301/399. It is mandatory that this Figure 29 - Gas Connection fitting is used for connection to a field fabricated drip leg as shown in the illustratioN per the National Fuel Gas Code.

  • Page 41: Check Inlet Gas Pressure

    Never use an open flame (match or lighter) to check for gas Ensure the pressure tap screw is properly tightened to prevent leaks. Use a soapy solution to test connection. Failure to use gas leaks. Failure to do so could cause substantial property a soapy solution test or check gas connection for leaks can damage, severe personal injury, or death.

  • Page 42: Boiler Gas Valve

    Do not do a gas conversion on this boiler without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the boiler to fire on Natural or Propane gas will result in extremely dangerous burner operation, leading to fire, explosion, severe personal injury, or death.

  • Page 43: Check For Gas Leaks

    maintenance procedure to clean the heat exchanger in the 3. Fill to the correct system pressure. Correct pressure will vary Maintenance Section of this manual. with each application. a. Typical cold water fill pressure for a residential system is 12 Test/replace freeze protection fluid psi.

  • Page 44: Check Thermostat Circuit(S)

    This may be done by the installer or determines that a dangerous or unsafe condition has occurred, you may purchase a condensate neutralizer from HTP (7450P- the control may lock out the boiler and prevent it from igniting 212).

  • Page 45: Setting Up A Cascaded System

    system will ignite simultaneously when there is a demand, and J. Setting Up a Cascaded System each boiler will individually regulate firing rates to maintain the If the boiler is part of a cascaded system the operation is master set point temperature (supply temperature set point + somewhat different.

  • Page 46: Part 9 - Start-Up Procedure

    ENTER – The ENTER key is used to access parameter Part 9 - Start-Up Procedure programming mode. To access this mode, hold down the ENTER key for more than 4 seconds. The readout will change ENTER MENU CODE FOR YOUR OWN SAFETY READ BEFORE OPERATING 1.

  • Page 47: Programming Boiler Settings

    D. Programming Boiler Settings CLOCK HOUR Allows the user to adjust the hour Boiler Setting Program Access 08/28/2009 Fr 10:01A setting. Note: Programming the boiler control is not possible when CLOCK MINUTE the boiler is firing. Make sure any input which can create a Adjusts the minute setting.
  • Page 48 Screen Description Function 16 Optional Inputs Function 6 DHW Post Pump Time Allows the user to select optional inputs to control or monitor the The indirect pump has the ability to OPTIONAL INPUT system. Default: RETURN (Range: post purge energy from the boiler RETURN SEN Off / Booster Board / 0-10 Volt / DHW to run the pump after the set point...

  • Page 49: Resetting The Maintenance Schedule

    Function 30 Extra Boiler Mode SERVICE SCHEDULE selected the run hour function, you MONTH 00/00/2000 Allows for a non HTP boiler to be will need to program 10,000 hours, if controlled when the cascade output has required. EXTRA BOILER MODE...

  • Page 50: Part 10 - Start-Up Procedures For The Installer

    The actual temperature measured by the tank or return sensor (HTP 7250P-325) is displayed on the DHW SET bottom line. If a mechanical aquastat is used in place of the recommended sensor, the second line will display ‘OFF’...
  • Page 51 This screen displays boiler flame This screen displays the third oldest FLAME 0.0uA current on the top line. The second boiler control lockout fault. The top FAN SPEED 3497 RPM line displays boiler fan speed. line will alternate between the words FAULT HISTORY ‘FAULT HISTORY’...

  • Page 52: Cascade Menu

    This screen displays information about cascade status. The TT in the center This screen displays the tenth oldest of the top line shows that cascade boiler control lockout fault. The top demand is coming from the TT contact line will alternate between the words being closed.

  • Page 53: Boiler Test Mode

    readout, call a technician immediately, since the message may C. Boiler Test Mode indicate a more serious problem will occur soon. This function is intended to simplify gas adjustment. The following tables include recommended combustion settings B. Boiler Error by fuel type and boiler fan speeds. Automatic modulation does The controller will display an error code and message when not take place while the controller is in Test Mode.

  • Page 54: User Interface Display

    D. User Interface Display Cascade Control Fault Codes Screen Description Possible Remedy Disconnect the system sensor from the wiring and measure it’s resistance. Compare the measured resistance E03 indicates a problem with the system to the table in this manual to see if it corresponds to the sensor circuit.
  • Page 55 1. Check line voltage. It must be between 100 and 128 volts. 2. If available, connect a PC and use HTP service software to check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be no greater than 250.
  • Page 56 F03 indicates the return temperature sensor of the boiler has failed. The boiler will not 1. Check circulator pump operation. restart until a technician replaces the sensor 2. Ensure adequate flow through the boiler by accessing RETURN SENSOR F03 and pushes RESET on the display. This is the status menu and determining there is less than a 50 PUMP ON a serious safety issue as indicated by the...
  • Page 57 1. Watch the igniter through the observation window. 2. If there is no spark, check the spark electrode for the proper .196” (5.0 mm ± 1mm) gap. See below. 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.

  • Page 58: Part 12 - Maintenance

    The condensate trap is full. This is a serious safety issue as indicated by the illuminated 1. Check condensate lines for obstructions. red light and the word LOCKOUT flashing on 2. Check float switch in condensate reservoir. CONDENSATE FULL F20 the display.

  • Page 59: Combustion Chamber Coil Cleaning Instructions

    Supply Temperature Sensor (7250P-324) The combustion chamber insulation in this product contains Outdoor Sensor Boiler Sensor (7250P-319) (7250P-667) ceramic fiber material. Ceramic fibers can be converted Indirect Sensor to cristobalite in very high temperature applications. The (7350P-325) International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz Outside High / Low...

  • Page 60: Cleaning Water Side Of Heat Exchanger

    NOTE: Ensure all parts shown in Figure 33, Condensate Detail, are installed with the condensate trap. If any parts are missing, DO NOT reinstall the trap. Replace the entire assembly. Do not install the condensate assembly if a component is lost or missing.
  • Page 61 ½” to avoid blockage in condensate piping (for piping details, refer to condensate neutralizer installation instruction.) 9. Check condensate piping for sagging and/or leakage. Repair any sags or leaks before restoring power to the boiler. It is very important that the condensate piping be no smaller than ¾”.
  • Page 62 Figure 34 - Combustion System Replacement Parts - 80 - 220kBTU Models LP-293 Rev. 9.24.15...
  • Page 63 Figure 35 - Combustion System Replacement Parts - 299 - 399kBTU Models LP-293 Rev. 9.24.15...
  • Page 64 LP-293-A 05/27/15 ITEM# EL-80 EL-110 EL-150 EL-220 EL-299/301 EL-399 DESCRIPTION 7450P-039 7450P-065 JACKET - REAR 7450P-160 FIELD CONNECTION BOARD COVER 7450P-072 7450P-099 7450P-073 JACKET - TOP COVER, BACK 7450P-081 6-32 X 1/4 PAN HEAD SCREW - ACCESSORY PANELS 7450P-040 7450P-041...
  • Page 65 LP-293-CC 05/27/15 ITEM# ITEM# EL-80 EL-80 EL-110 EL-110 EL-150 EL-150 EL-220 EL-220 EL-299/301 EL-299/301 EL-399 EL-399 DESCRIPTION DESCRIPTION 7450P-282 7450P-282 7450P-292 7450P-292 7450P-157 7450P-157 CLAMP ALL - EXHAUST VENT ADAPTER CLAMP ALL - EXHAUST VENT ADAPTER 7450P-201 7450P-201 7450P-202 7450P-202...

  • Page 66: Part 13 - Installation Checklist

    Part 13 - Installation Checklist Light Off Activities Date Completed: Check all piping and gas connections. Verify all are tight. Pressurize system. 1. Fill the Heating System Add water to prime condensate cup. Verify near boiler piping is properly supported. Leak test using locally approved methods (consult jurisdictional code book).
  • Page 67 Inspection Activities Date Last Completed Piping 1st Year 2nd Year 3rd Year 4th Year* Check boiler and system piping for any sign of leakage; make sure Near boiler piping pipes are properly supported. Check condition of all vent pipes and joints. Ensure the vent piping Vent terminations are free of obstructions and blockages.

  • Page 68: Rev

    ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 69 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
  • Page 70 D. If HTP is unable to repair or replace an Elite™ boiler so as to connection, combustion air openings, electric service voltage, conform to this warranty after a reasonable number of attempts, wiring, or fusing.
  • Page 71 NOTE: Any parts or boilers returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied. If all warranty conditions are satisfied, HTP will provide replacement parts to the retailer.
  • Page 72 Maintenance Notes LP-293 Rev. 9.24.15...
  • Page 73 Customer Installation Record Form The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document. Customer’s Name Date of Installation Installation Address...

This manual is also suitable for:

El-110El-150El-220El-299El-301El-399 ... Show all

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