HTP Elite XL ELX-400 Installation, Start-Up, Maintenance, Parts, Warranty
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HTP Elite XL ELX-400 Installation, Start-Up, Maintenance, Parts, Warranty

Commercial boilers
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Installation
Start-Up
Maintenance
Parts
Warranty
ELX-400 / 500 / 650 / 800 / 1000 / 1500 / 2000 Models*
*"B" Denotes Boiler Models,
"N" Denotes Natural Gas, "LP" Denotes Propane,
and "F" Denotes Floor Mount Models
Example Model: ELX-1000FBN
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.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.
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.
DANGER
!
WARNING
!
NOTICE
New Bedford, MA 02745
Elite XL®
Commercial Boilers
Heat Exchanger Bears the ASME "H"
lp-666 Rev. 003 Rel. 001 Date 2.25.20
Stamp
www.htproducts.com

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Summary of Contents for HTP Elite XL ELX-400

  • Page 1 California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. NOTICE 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.
  • Page 2 WARNING WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. • Do not store or use 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: For The Installer

    AHJ. DANGER indicates an imminently hazardous situation which, if NOTE: HTP reserves the right to modify product technical specifications not avoided, will result in serious personal injury or death. and components without prior notice.

  • Page 4: Table Of Contents

    In accordance with Section 325 (f) (3) of the Energy Policy and D. Clearances for Service Access Conservation Act, HTP has provided this boiler with multiple E. Residential Garage and Closet Installations features designed to save energy by reducing the boiler water F.

  • Page 5: Part 1 - General Safety Information

    Testing the Internal LWCO severe personal injury, or death. Part 12 - Boiler Monitoring Altering any HTP boiler with parts not manufactured by HTP WILL A. Status Screens INSTANTLY VOID the boiler warranty and could result in property B. History Screens damage, personal injury, or death.

  • Page 6: Improper Combustion

    CH applications. result in property damage, serious personal injury, or death. NOTE: HTP DOES NOT WARRANT THE BOILER AGAINST FREEZE- RELATED DAMAGE. B. Gas Should overheating or gas supply fail to shut off, turn off the manual The boiler control is equipped with freeze protection that activates gas control valve to the boiler.

  • Page 7: Optional Equipment

    HTP Link The high grade stainless steel burner uses premixed air and gas to HTP Link allows the installer to connect the boiler to WiFi, providing provide a wide range of firing rates. the user / installer with tools to remotely monitor the system, optimize Spark Ignition efficiency, and aid in troubleshooting.

  • Page 8: Part 3 - Prepare The Boiler

    Part 3 - Prepare the Boiler Remove all sides of the shipping crate to allow the boiler to be moved • Ensure a minimum 1” clearance around hot water and into its installation location. The boiler is heavy. At least two individuals exhaust vent pipes and special equipment (pallet jack, forklift, etc.) are needed to properly NOTE: To prevent condensing in the fan, it is recommended to...

  • Page 9: Flooring

    WARNING Use extreme care not to drop the boiler or cause bodily injury while lifting the boiler. Failure to follow these instructions could result in property damage, severe personal injury, or death. B. Flooring WARNING TURN WHEEL TO THE RIGHT TO LOWER 400 - 1000 Models ONLY are approved for installation on RUBBER FOOT combustible flooring, but must never be installed on carpeting.

  • Page 10: Clearances For Service Access

    D. Clearances for Service Access E. Residential Garage and Closet Installations WARNING CAUTION Check with your local Authority Having Jurisdiction for The space must be provided with combustion / ventilation air requirements when installing the boiler in a garage or closet. openings correctly sized for all other appliances located in the same Please read the entire manual before attempting installation.

  • Page 11: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    Different vent terminals can be used to simplify and eliminate is installed in areas where indoor air is contaminated (see Table 1) multiple penetrations in the building structure (see Optional it is imperative that the boiler be installed as direct vent so that all Equipment in Venting Section).

  • Page 12: Prevent Combustion Air Contamination

    Approved Carbon Monoxide Detectors: Each carbon monoxide 3. If practical, close all building doors, windows, and doors between detector as required in accordance with the above provisions shall the space in which the boiler remains connected to the common comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certified. venting system and other spaces in the building.
  • Page 13 does not contain corrosive chemicals or elements that can damage 4. A corrosion inhibitor approved for use with stainless steel the heat exchanger. heat exchangers (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner If you suspect that your water is contaminated in any way, recommended by the manufacturer.
  • Page 14 ELX400 - 1000 ELX1500 - 2000 LP-666-P 08/23/19 MODEL # ELX400-500 40.7 41.0 26.0 17.9 35.0 10.1 10.5 12.6 16.1 20.5 22.0 25.8 35.0 2.8* ELX650-1000 56.5 ELX1500 66.5 60.8 31.8 39.2 44.8 51.2 11.9 14.4 24.4 31.8 22.7 39.1 ELX2000 79.0 Figure 9 - ELX Specifications and Dimensions - NOTE: All Dimensions Are Approximate - *FOR REFERENCE ONLY...

  • Page 15: Technical Specifications

    K. Technical Specifications Model 1000 1500 2000 Installation Indoor, Floor Standing, Fully Condensing 100,000 / 150,000 / 200,000 / Minimum / Maximum Input (Btu/Hr) 39,900 / 399,000 50,000 / 500,000 65,000 / 650,000 80,000 / 800,000 1,000,000 1,500,000 2,000,000 Heating Capacity (MBH) 1,455 1,940 Flue System...

  • Page 16: Part 4 - Piping

    Do not pipe discharge to any location where freezing could may be connected to an indirect water heater to supply domestic occur. hot water. HTP offers indirect water heaters in either stainless steel • No valve may be installed between the relief valve and boiler or glass-lined construction.

  • Page 17: Circulators

    CAUTION Model Heat Exchanger Volume (Gallons) Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler. Failure to follow this instruction can lead to premature failure of the boiler system. Such failures ARE NOT covered by warranty. The boiler should not be operated as a potable hot water heater.

  • Page 18: Circulator Sizing

    G. Circulator Sizing In addition, the boiler heat exchanger has a minimum total water flow rate that must be taken into account when sizing the circulator. Pressure drops are listed in the table below. Model Ft / Hd Ft / Hd Ft / Hd 12.0 11.4...

  • Page 19: Check / Control Water Chemistry

    of 12 PSI. H. Check / Control Water Chemistry 6. Install a circulator as shown in piping details (this section). Make NOTE: Boiler failure due to improper water chemistry is not sure the circulator is properly sized for the system and friction loss. covered by warranty.

  • Page 20: Zoning With Zone Valves

    increase from 32 F to 180 F, while water increases 3% over the same temperature rise. Allowances must be made for this expansion in the system design. 4. A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.

  • Page 21: Applications

    5. Piping shown is Primary/ PRESSURE GAUGE Secondary. SYSTEM CIRCULATOR 6. The minimum pipe size for BOILER CIRCULATOR connecting an HTP indirect TO SYSTEM fired water heater is 1”. 7. DO NOT down size the boiler MAKE-UP heating loop connections.

  • Page 22: Part 5 - Venting

    Part 5 - Venting DANGER 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 23: 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 Pipe and Fittings Approved for Intake ONLY ABS* ANSI/ASTM D2661 ANSI/ASTM D2661 PVC Schedule 40/80 ANSI/ASTM D1785 PVC-DWV Schedule 40/80 ANSI/ASTM D2665 PVC, CPVC, and PP Venting Pipe Approved for Must be ULC-S636 Certified.

  • Page 24: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location INSIDE CORNER DETAIL FIXED OPERABLE CLOSED FIXED CLOSED OPERABLE LP-179-CC 03/28/17 Intake Pipe Terminal Exhaust Vent Terminal Area Where Intake Terminal Is Not Permitted Figure 13 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DESCRIPTION CANADA Clearance above grade, veranda, porch, deck, or balcony...

  • Page 25: Exhaust Vent And Intake Pipe Sizing

    4. When using PVC or CPVC pipe, all joints must be properly cleaned, E. Exhaust Vent and Intake Pipe Sizing primed, and cemented. Use only cement and primer approved for use 1. The exhaust vent and intake pipe size is 4”, 6”, or 8”, depending on with the pipe material.

  • Page 26: Applications

    b. In the absence of specific ordinances, snow levels shall be G. Applications calculated from the average monthly maximum depth of snow 1. Direct Vent Installation of Exhaust and Intake accumulation as indicated by the National Weather Service’s 10 If installing a direct vent option, combustion air must be drawn year statistics for the installation location/geographical area.
  • Page 27 Two Pipe Sidewall Venting EXTERIOR WALL with Intake (Elbow) and Coupling (Exhaust) 1" MIN. 400 - 1000 Models ONLY 12" MIN. EXHAUST Insert Intake/Exhaust Screen into Coupling MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER (TYP) INTAKE LP-505-A...

  • Page 28: Power Venting, Room And Indoor Combustion Ventilation Requirements

    2. Power Venting, Room and Indoor Combustion Ventilation Combustion air supply must be completely free of any flammable Requirements vapors that may ignite, or chemical fumes which may be corrosive to the boiler. See Table 1 for a list of combustion air contaminants. These When using an indoor combustion air installation, the mechanical chemicals, when burned, form acids which quickly attack the stainless room MUST be provided with properly sized openings, and/or be...

  • Page 29: Part 6 - Condensate Removal

    Condensate from the boiler is slightly acidic with a pH of 3.2 - 4.5. To avoid long term damage to the drainage system and to meet local code requirements, HTP recommends neutralizing condensate with a Condensate Neutralizer Kit (Part # 7350P-611). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the condensate.

  • Page 30: Part 7 - Wiring - 400 - 1500 Models

    CONDENSATE NEUTRALIZER CONDENSATE NEUTRALIZER WITHOUT PUMP WITH PUMP PIPE HANGER PIPE HANGER ASSEMBLIES ASSEMBLIES FOR SUPPORT FOR SUPPORT SWEAT PVC TEE OPEN TO ATMOSPHERE (TO PREVENT VACUUM) SWEAT PVC TEE OPEN TO FLOOR DRAIN ATMOSPHERE (TO PREVENT VACUUM) CONDENSATE CONDENSATE PUMP NEUTRALIZER HORIZONTAL LINES...

  • Page 31: Line Voltage Wiring For Standard Boiler

    1. The boiler will operate an indirect fired water heater with either 12. Connect the Earth Ground of the externally provided 120VAC to a thermostat type aquastat installed in the indirect tank, or an HTP the Earth Ground input of the DHW pump.

  • Page 32: Cascade Master System Pump And Sensor Wiring

    Avoid running communication cables parallel and close to 9. Connect the Neutral of the externally provided 120VAC to the or against high voltage (120 volt or greater) wiring. HTP recommends NEUTRAL input of the DHW pump. that the maximum length of 10.

  • Page 33: Optional 0-10 Volt Building Control Signal

    pump input wire to 0-10VA+, and the negative wire to 0-10VA-. P. Optional Low Gas Pressure Switch NOTE: When making wiring connections, ensure proper polarity or 1. If an optional low gas pressure switch is used, it should be installed the system will not operate properly.
  • Page 34 GREEN (GROUND) POWER WHITE (NEUTRAL) SWITCH 400-1500 HIGH VOLTAGE LP-666-X BLACK (HOT) 09/20/19 BLOWER CUSTOMER CONNECTION BOARD LINE VOLTAGE SINGLE BOILER AND CASCADE MASTER IN 120VAC BLK/BLU BLACK SWITCH 120V LINE 120V NEUT SYSTEM PUMP 120V GND PUMP RELAY 5V DC (USB) PUMP PUMP POWER...
  • Page 35 Figure 27 - Cascade Termination Plug Detail ELX 400-2.0 LOW VOLTAGE ELX 400-2.0 LOW VOLTAGE CUSTOMER CONNECTION BOARD CUSTOMER CONNECTION BOARD CASCADE FOLLOWER SINGLE BOILER AND CASCADE MASTER CASCADE BUS CASCADE BUS CASCADE BUS CASCADE BUS TERMINATION PLUG TERMINATION PLUG INSTALLED HERE INSTALLED HERE IN FINAL CASCADED BOILER...
  • Page 36 ELX-400-1500 WIRING DIAGRAM 120 VAC LINE NEUTRAL P1-1 J7-2 J7-3 P1-2 POWER SWITCH HMI DISPLAY P1-3 DUAL FLUE SENSOR X11-1 X11-4 X11-2 X5-15 X5-16 PROTECTED BY AN INTERNAL X6-10 6.3 AMP FUSE X6-6 X6-11 +24V X6-7 LWCO DUAL SUPPLY SENSOR PROBE HALL X7-3...

  • Page 37: Part 8 - Wiring - 2000 Models

    Ground goes to the G terminal. Neutral goes to N. The three Hot legs Part 8 - Wiring - 2000 Models connect to the L1-L3 terminals. 3. A line voltage fused disconnect switch may be required to be WARNING externally mounted and connected according to local wiring codes. To avoid electrical shock, turn off all power to the boiler prior CH Pump Wiring to opening an electrical box within the unit.

  • Page 38: Low Voltage Connections For Standard Boiler

    Avoid running communication cables parallel and 1. The boiler will operate an indirect fired water heater with either a close to or against high voltage (120 volt or greater) wiring. HTP thermostat type aquastat installed in the indirect tank, or an HTP recommends that the maximum length of communication bus 7250P-325 tank sensor.

  • Page 39: Cascade Follower Pump And Sensor Wiring

    5. Connect the other NO relay CONTACT to the LINE input of the M. Variable Speed Pumping boiler pump. Variable speed pump support is available on the primary loop of all 6. Connect the Neutral of an externally provided 120VAC service to models.

  • Page 40: Optional Low Gas Pressure Switch

    2. Insert the control probe into the control well. P. Optional Low Gas Pressure Switch 3. Secure the high limit manual reset box to the control well. 1. If an optional low gas pressure switch is used, it should be installed 4.
  • Page 41 2000 MODEL HIGH VOLTAGE BOILER CUSTOMER CONNECTION BOARD PUMP CASCADE FOLLOWER LINE IN EXTERNAL RELAY LINE IN BLUE (HOT) LINE RED (HOT) VOLTAGE IN 208VAC 3 PH BLACK (HOT) WHITE (NEUT) GREEN (GRND) ALARM LP-666-X4 09/20/19 Figure 33 - Cascade Follower High Voltage Wiring - 2000 Model lp-666 Rev.
  • Page 42 Figure 34 - Cascade Termination Plug Detail ELX 400-2.0 LOW VOLTAGE ELX 400-2.0 LOW VOLTAGE CUSTOMER CONNECTION BOARD CUSTOMER CONNECTION BOARD CASCADE FOLLOWER SINGLE BOILER AND CASCADE MASTER CASCADE BUS CASCADE BUS CASCADE BUS CASCADE BUS TERMINATION PLUG TERMINATION PLUG INSTALLED HERE INSTALLED HERE IN FINAL CASCADED BOILER...
  • Page 43 Figure 37 - Internal Connection Diagram - 2000 Models lp-666 Rev. 003 Rel. 001 Date 2.25.20...

  • Page 44: Part 9 - Gas Connections

    WARNING Part 9 - Gas Connections Do not use Teflon tape on gas line pipe thread. Use a pipe compound WARNING rated for use with natural gases. Apply sparingly on male pipe ends, leaving the two end threads bare and flow unobstructed. Failure to Failure to follow all precautions could result in fire, explosion, follow these instructions could result in gas leakage or blockage, and severe injury, or death.

  • Page 45: Check Inlet Gas Pressure

    Natural Gas Supply Piping Capacity Chart - Schedule 40 metallic pipe size in nominal inches (0.6 Specific gravity gas; 0.5” WC pressure drop) Capacity in Cubic Ft. Hr. by Length of Pipe in Straight Feet Pipe Size (Inches) 1 1/4 1390 1 1/2 2090...

  • Page 46: Boiler Gas Valve

    Do not do a gas conversion on this boiler without an officially Adjustments to the throttle screw or offset may only be made by approved conversion kit and instructions supplied by HTP. Failure to a qualified gas technician using a calibrated combustion analyzer use a conversion kit when converting the boiler to fire on Natural capable of measuring CO2 and CO.

  • Page 47: Part 10 - Start-Up Preparation

    B. Check for Gas Leaks Part 10 - Start-Up Preparation WARNING WARNING Before starting the boiler, and during initial operation, smell near Thoroughly clean and flush any system that has used glycol before the floor and around the boiler for gas odorant or any unusual odor. installing the boiler.

  • Page 48: Check Thermostat Circuit(S)

    HTP (554200). This If you discover any evidence of a gas leak, shut down the boiler pump is equipped with two leads that can be connected to an alarm at once.

  • Page 49: Navigation Of The Touch Screen Display

    HTP Logo and Home Tapping the HTP Logo or Home will return the installer / user to the Home Screen. The Home Screen allows the installer / user quick access to appliance internal operating temperatures, external temperature sensor readings, current CH and DHW setpoints and actual temperatures, appliance modulation percentage, operation details, and a Reset key.

  • Page 50: Purge Air From The System

    that the control goes into lockout, it will show a diagnostic code on C. Purge Air from the System the display, illuminate the red indicator, and close the alarm relay To purge air from the system: contacts to aid in recognition of the condition, diagnosis, and repair. a.

  • Page 51: Cascade System Programming

    6. If any boiler fails to start refer to the troubleshooting section in the G. Cascade System Programming back of this manual. 1. If the boiler is used alone, skip this section. 2. Programming the Master Boiler: a. Make sure there is no demand for heat being supplied to the boiler.

  • Page 52: Programming User Settings

    I. Programming User Settings User Setting Program Access NOTE: Programming the boiler control is not possible when the boiler is firing. Make sure any input which can create a demand on the boiler, such as the tank thermostat, is turned off so the boiler will remain idle to allow programming. NOTE: To change User Settings enter Access Code 600 when prompted.
  • Page 53 Boiler Settings 2 User Screen 2 - DHW Settings Use the Sliders to select DHW Setpoint settings 119ºF 32ºF 190ºF Slider 1 181ºF 95ºF Setpoint Slider 2 145ºF Di erential 32ºF 190ºF 135ºF 155ºF Press SAVE to Outdoor Temperature º 33 º...

  • Page 54: Programming Installer Settings

    J. Programming Installer Settings Installer Setting Program Access NOTE: Programming the boiler control is not possible when the boiler is firing. Make sure any input which can create a demand on the boiler, such as the tank thermostat, is turned off, so the boiler will remain idle to allow programming. NOTE: To change Installer Settings enter Access Code 925 when prompted.
  • Page 55 Installer - Installer Menu The Installer Menu provides the installer with a number of settings to customize system operation. These settings are as follows: Installer - Installer Menu Installer Menu Possible Values Current Values Installer # Description Units Mode INDIRECT DHW Tank Max Temp 95 to 185 180.5...
  • Page 56 Factory Default: NORMAL MOD (Range: NORMAL MOD / MINIMUM MOD). Allows for a non HTP boiler to be controlled when the cascade output has risen above the percent Extra Boiler Mode of the cascade firing rate set in this parameter.
  • Page 57 • Addresses 248 – 256 are not available for use. The baud rate (communication speed) can be set on the control display to either 9600 or 19200 baud. All HTP appliances, as well as any other device on the same bus and the Modbus/BACnet Baud Rate master, must have the same baud rate setting.

  • Page 58: Resetting The Maintenance Schedule

    K. Resetting the Maintenance Schedule It is highly recommended to call for service when the Home Screen center pane turns yellow on the display. After service is performed, reset the schedule for the next required service by using the following steps. Press Installer.

  • Page 59: Part 12 - Boiler Monitoring

    Part 12 - Boiler Monitoring A. Status Screens The boiler control has the ability to review system status. To access the Status screens, tap Status in the display Navigation Bar. Tap NEXT or PREVIOUS to swap between the screens. Tap Home in the display Navigation Bar to exit the Status screens. Status Screen 1 Status Fan Speed Settings...
  • Page 60 F3 / F4 Flue B). Displays the actual temperature measured by the tank or return sensor (HTP 7250P-325). If a mechanical Indirect aquastat is used in place of the recommended sensor, it will display “N/C” if the aquastat is open because the DHW tank is satisfied.
  • Page 61 S tatu s I n p uts & O utp uts Status Screen 2 Inputs Internal External Room Thermostat CH Enable Ch Boost Outdoor Temperature Lock: 210ºF 0-10V In 33 º F 90ºF Safeties System Temperature Water Closed 112 º F Block Vent Closed Lock: 194ºF...

  • Page 62: History Screens

    Outputs Table Display Description Gas Valve Displays whether the gas valve is on or off. Spark Displays whether the spark is on or off. Ionization Displays the current flame ionization current. Pump CH Displays whether the CH Pump is on or off. Pump DHW Displays whether the DHW Pump is on or off.
  • Page 63 Appliance History Table Display Description Control Displays control details, including the Comfort and Safety firmware revisions programmed into the control. Parameters Displays the programmed appliance model number parameter set. Serial Number Displays the appliance serial number. Production Date Displays the appliance production date. Programming Date Displays when the appliance was last programmed.

  • Page 64: Graphics Screen

    C. Graphics Screen Tap Graphics in the display Navigation Bar to open the Graphics function. The Graphics function allows the installer / user to select, record, and view real time system analytics. This function helps the installer / user fine tune system operation and aids in troubleshooting. Graphics Graphics Screen Supply...

  • Page 65: Actual Temperature

    Sensor code are shown here. The Cascade Mode rotation hours are shown here. The operating percentages of connected appliances is shown towards the bottom of the screen, along with whether the SYS, DHW, or CH pumps are enabled and whether the system is meeting a CH or DHW demand.

  • Page 66: Part 13 - Troubleshooting

    Part 13 - Troubleshooting Unresponsive Screen - Ensure the screen is not installed too tightly into the housing, as the screen may be recording a continuous touch at the edges. Turn the boiler power off at the main power supply and loosen the screen slightly by backing out the nuts behind the housing. If the problem persists calibrate the screen.
  • Page 67 Description Possible Remedy Code Message The dual flue sensor contains two sensing elements within a single body. F01 indicates that one or both halves of the supply 1. Check the electrical connections to each half of the thermistor temperature sensor has failed OR the on the outlet manifold.
  • Page 68 Description Possible Remedy Code Message This display indicates that the boiler return temperature is excessive. This code indicates that the return sensor temperature has exceeded 210 F and a serious safety issue Blocking: exists when accompanied by the red center Return pane of the Home screen and displayed phrase 1.
  • Page 69 Description Possible Remedy Code Message The fan is not running at the speed determined 1. Check the combustion fan wiring. by the control. Fan speed has been more than 2. Measure DC voltage from the red fan wire (POS) to the light blue 30% slower than the commanded speed for wire (ground) while it is connected to the fan.
  • Page 70 Description Possible Remedy Code Message 1. Use an ohmmeter to check the burner door switch for continuity. First disconnect the switch and determine if it has tripped. If the switch has no continuity it has tripped: a. Check bolts on hx door. If door is not tight, a minor combustion leak will cause elevated door temperatures.
  • Page 71 Description Possible Remedy Code Message 1. Check outdoor sensor connections and wiring. Ensure the sensor and wiring are intact and that the sensor is connected to There is an issue with the outdoor sensor. It is Outdoor the boiler. shorted, damaged, or disconnected from the Sensor 2.

  • Page 72: Part 14 - Maintenance

    Indirect Sensor Flue Temp. Sensor Outdoor Sensor (7250P-319) Return Sensor (7100P-004) Supply Sensor (7700P-073) (7350P-325) (7550P-147) Temperature ( Resistance (ohms) Temperature ( Resistance (ohms) 171800 32624 129800 25381 98930 19897 76020 15711 58880 12493 45950 10000 36130 8056 28600 6530 22800 5324 18300...
  • Page 73 WARNING Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe boiler operation, substantial property damage, severe personal injury, or death. 2. Spray the coils liberally with the FDA approved liquid lime scale remover.

  • Page 74: Part 15 - Shutdown

    Part 15 - Shutdown 0.31” 400 - 1000 Model Igniter Detail (Gap from Burner Wall) A. Shutdown Procedure If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70 F and wait for the burner to shut off.

  • Page 75: Part 16 - Replacement Parts

    Part 16 - Replacement Parts ELX-400, 500 ONLY ITEM# PART# DESCRIPTION ITEM# PART# DESCRIPTION 7550P-057 GASKET - DISPLAY - 7" 7550P-215 COMBUSTION BLOWER w/GASKET, SCREWS (400) 7550P-209 COMBUSTION BLOWER w/GASKET, SCREWS (500) 7550P-060 TOUCH SCREEN BRACKET 7550P-210 COMBUSTION BLOWER w/GASKET, SCREWS (650-1000) 7500P-087 POWER SWITCH 7250P-478 SCREWS (400/500)- COMBUSTION BLOWER...
  • Page 76 LP-666-U 12/06/19 ITEM# PART# DESCRIPTION 7550P-218 PRESSURE RELIEF VALVE - 50 PSI 7250P-211 TEMPERATURE/PRESSURE GAUGE 6070P-009 DRAIN VALVE 7550P-147 FLUE TEMPERATURE SENSOR 7550P-148 RUBBER GROMMETT 7550P-226 CONDENSATE ASSEMBLY 7550P-222 HOSE - CONDENSATE 7250P-210 HOSE CLAMP (2) 7350P-063 SCREWS - #10 X 1/2" SELF TAPPING 7550P-225 GAS PIPING ASSY - 1"...
  • Page 77 ITEM# PART# DESCRIPTION 7550P-372 CLAMP - VENT ADAPTER 4" 7550P-373 CLAMP - VENT ADAPTER 6" 7550P-374 GASKET - VENT ADAPTER 4" 7550P-375 GASKET - VENT ADAPTER 6" 7550P-376 CERAMIC REFRACTORY (w/CLIP, SCREW) BACK OF MODULE 7550P-377 CERAMIC REFRACTORY KIT, BURNER DOOR (w/SCREW & CLIP) 7550P-378 BURNER DOOR (w/SCREWS, WASHERS, GASKET) 7550P-379...
  • Page 78 7550P-337 BOARD (1500) 7550P-442 AIR/GAS MIXER (2000) 7550P-309 AIR/GAS MIXER (1500) 7550P-998 HTP LINK WI-FI DONGLE KIT 6300P-072 GASKET - FLANGE TO VENTURI 7550P-140 SCREW- HEX HEAD M8X16, 6 PER (2000) 7550P-548 SCREW- HEX HEAD M8X10, 6 PER (1500) 7550P-162...
  • Page 79 LP-666-U 12/17/19 ITEM# PART# DESCRIPTION 7550P-531 8" INTAKE ADAPTER 7550P-137 SCREW - 10-32 X 1/2" LONG 7550P-072 VENT ADAPTER 7550P-052 HIGH VOLTAGE BOARD 1 8800P-108 CONTACTOR 7550P-119 COVER - HIGH VOLTAGE BOX 7550P-216 EXTERNAL SPARK TRANSFORMER 7550P-541 SPARK LEAD (NOT SHOWN) 7550P-085 BACK PANEL 7550P-150...
  • Page 80 LP-666-U 12/16/19 ITEM# PART# DESCRIPTION 7550P-192 GAS PIPE ASSEMBLY 7550P-197 WATER SUPPLY ASSEMBLY (2000) 7550P-532 WATER SUPPLY ASSEMBLY (1500) 7550P-199 WATER RETURN ASSEMBLY 7350P-089 LOW WATER CUT-OFF PROBE 7550P-063 HIGH TURNDOWN FLOW SWITCH 7700P-073 DUAL TEMPERATURE SENSOR - HIGH LIMIT 7100P-004 HIGH TEMPERATURE SENSOR 7550P-175 PRESSURE RELIEF VALVE 7250P-211 PRESSURE GAUGE...
  • Page 81 ITEM# PART # DESCRIPTION 7550P-410 GASKET - VENT ADAPTER 7550P-411 CERAMIC REFRACTORY - BACK OF MODULE 7550P-412 CERAMIC REFRACTORY KIT - BURNER DOOR 7550P-413 SIGHT GLASS (w/SCREWS) 7550P-414 BURNER DOOR (w/SCREWS, WASHERS) 7550P-415 SCREWS, WASHERS - BURNER DOOR 7550P-416 SPARK ELECTRODE (w/SCREWS, GASKET) 7550P-417 FLAME RECTIFICATION PROBE (w/SCREWS, GASKET) 7550P-580...

  • Page 82: Part 17 - Installation Checklist

    Part 17 - Installation Checklist Light Off Activities Date Completed: Check all piping and gas connections. Verify all are tight. Pressurize system (12 - 15 psi). 1. Fill the Heating System Add water to prime condensate cup. Verify near boiler piping is properly supported. Percentage of glycol in system (0 - 50%) Leak test using locally approved methods (con- sult jurisdictional code book).
  • Page 83 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 pipes Near boiler piping are properly supported. Check condition of all vent pipes and joints. Ensure the vent piping Vent terminations are free of obstructions and blockages.

  • Page 84: Elx Boiler Limited Warranty

    Ten year warranty to assure your complete satisfaction. HTP warrants this boiler and its components to be free from defects in material and workmanship according to the following terms, conditions, and time periods. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original consumer purchaser (herinafter “Owner”) of this boiler, and is non-transferable.
  • Page 85 During the claims process a product that must be replaced will be given a 18. Damages, malfunctions, or failures caused by abuse, accident, fire, flood, designation of either a) field scrap, or b) return to HTP. If the product must be freeze, lightning, electrochemical reaction, acts of God and the like.

  • Page 86: Maintenance Notes

    Maintenance Notes lp-666 Rev. 003 Rel. 001 Date 2.25.20...

  • Page 87: Customer Installation Record Form

    Customer Installation Record Form The following form should be completed by the qualified installer / service technician 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:

Elite xl elx-650Elite xl elx-500Elite xl elx-1500Elite xl elx-800Elite xl elx-2000Elite xl elx-1000

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