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HTP Elite Ultra ELU-150WBN Installation, Start-Up, Maintenance, Parts, Warranty

High efficiency condensing wall-hung gas boilers
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Installation
Start-Up
Maintenance
Parts
Warranty
ELU-150WBN / ELU-199WBN / ELU-199WCN Models
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.
The manufacturer reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe
Drinking Water Act, Section 1417.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd.
Elite Ultra
High Efficiency Condensing
Wall-Hung Gas Boilers
DANGER
!
WARNING
!
NOTICE
New Bedford, MA 02745
Heat Exchanger Bears the ASME "H" Stamp
www.htproducts.com
LP-719 Rev. 000 Rel. 000 Date 6.25.20
TM

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  • Page 1 Elite Ultra High Efficiency Condensing Wall-Hung Gas Boilers Installation Start-Up Maintenance Parts Warranty ELU-150WBN / ELU-199WBN / ELU-199WCN Models Heat Exchanger Bears the ASME “H” Stamp DANGER 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.
  • 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 Installation should be made in accordance with the regulations of SPECIAL ATTENTION BOXES the Authority Having Jurisdiction, local code authorities, and utility The following defined terms are used throughout this manual to companies which pertain to this type of water heating equipment. bring attention to the presence of hazards of various risk levels or Authority Having Jurisdiction (AHJ) –...

  • Page 4: Table Of Contents

    In accordance with Section 325 (f) (3) of the Energy Policy and a nationally recognized testing agency to conform to UL 353; Conservation Act, HTP has provided this boiler with multiple they work to shutoff the fuel supply when the system water features designed to save energy by reducing the boiler water temperature reaches the preset operating temperature;...

  • Page 5: Part 1 - General Safety Information

    G. Exhaust Vent and Intake Pipe Installation C. Important Notice Maintenance Notes H. Applications Customer Installation Record Form 1. Direct Vent Installation of Exhaust and Intake 2. Venting Through an Existing System 3. Power Venting, Indoor Combustion Air in Confined or Unconfined Part 1 - General Safety Information Space This boiler is approved for indoor installations only and is not intended...

  • Page 6: Improper Combustion

    DO NOT alter or modify the appliance or appliance controls. This boiler must be installed by a qualified service technician. Altering any HTP boiler with parts not manufactured by HTP WILL Improper installation and/or operation can cause a potentially INSTANTLY VOID the boiler warranty and could result in property hazardous situation, which if not avoided will void the warranty and damage, personal injury, or death.

  • Page 7: Boiler System

    If you suspect that your water is contaminated in any way, CH applications. discontinue use of the appliance and contact an authorized NOTE: HTP DOES NOT WARRANT THE BOILER AGAINST FREEZE- technician or licensed professional. RELATED DAMAGE. The boiler control is equipped with freeze protection that activates based on internal water temperature.

  • Page 8: Water Temperature Adjustment And Scalding

    Freeze Protection Operation Condition Events Time Until the NTC1 and The water temperature • The internal pump operates at high speed. NTC2 temperature detected probes • The 3-Way Valve alternately switches positions - 1 minute on heating mode to Stage 1 is greater than NTC1 or NTC2 ranges 1 minute on DHW mode...

  • Page 9: Part 2 - Before You Start

    speed to control boiler output. This allows the boiler to deliver only Part 2 - Before You Start the amount of heat energy required and nothing more. NOTICE The control can be set to monitor outdoor temperature through an outdoor sensor or through internet weather (with optional WiFi UNCRATING THE BOILER - Any claims for damage or shortage in connection), use an optional room sensor, or use both outdoor temperature and an optional room sensor to regulate boiler set...

  • Page 10: Optional Equipment

    B. Optional Equipment Circulators suitable for DHW applications must be used. Optional equipment available from HTP (and Part #): Failure to take precautions could result in property damage, • Indirect Sensor (7250P-325) severe personal injury, or death.

  • Page 11: Leveling

    WARNING Do not introduce toxic chemicals, such as antifreeze or appliance treatments, into any piping meant for potable water purposes. Do not connect DHW connections to any heating systems or components that have been previously used for nonpotable applications. Ensure that all piping and components connected to the appliance are suitable for potable water applications.

  • Page 12: Wall Mounting Considerations

    alcove. Provided these conditions are met, the boiler requires no extra ventilation air openings to the space. If these conditions are not met, follow the requirements for Closet Installations. D. Wall Mounting Considerations These boilers are wall mounted. Use only the wall mounting instructions included with this boiler.

  • Page 13: Exhaust Vent And Intake Pipe

    Precautions 2. Power Venting, Indoor Combustion Air in Confined or If the boiler is located in a residential garage, per ANSI Z223.1: Unconfined Space • Mount the bottom of the boiler a minimum of 18” above the This boiler requires fresh, uncontaminated air for safe operation and must floor of the garage to ensure the burner and ignition devices be installed in a mechanical room where there is adequate combustion are well off the floor.

  • Page 14: Prevent Combustion Air Contamination

    days to comply with the above requirements; provided, however, J. Removing a Boiler from a Common Vent System that during said thirty (30) day period, a battery operated carbon DANGER monoxide detector with an alarm shall be installed. WARNING Do not install the boiler into a common vent with any other appliance.

  • Page 15: Technical Specifications

    K. Technical Specifications Model ELU-150WBN ELU-199WBN ELU-199WCN Type Boiler Combi Installation Indoor, Wall Hung, Fully Condensing 19,700 / 197,000 19,700 / 197,000 Minimum / Maximum Input (Btu/Hr) 15,000 / 150,000 19,200 / 192,000 19,200 / 192,000 DOE AFUE 1, 2 Heating Capacity (MBH) Net AHRI Rating, Water (MBH)
  • Page 16 4 " 4 " 4 " 8 " 8 " 8 " 4 " B C D 2 " 4 " 4 " 3" 8 " 8 " 4 " 3" 2 " Figure 7 - Boiler Dimensions - NOTE: All Dimensions Are Approximate Model Boiler Models Model...
  • Page 17 Model Components Pressure relief valve Circulation Pump Air purge valve DHW Flow Sensor (Combi Models Only) Boiler outlet temperature sensor Water pressure switch Air pressure switch Modulating Fan Flue gas temperature sensor Boiler inlet temperature sensor Main heat exchanger Frame Flame detection electrode Ignition electrode Silencer...
  • Page 18 Combi Models Boiler Models Pressure relief valve Air purge valve Boiler outlet temperature sensor DHW Temperature Sensor Flue gas temperature sensor Main heat exchanger Flame detection electrode Silencer DHW heat exchanger (Combi Models Only) Condensate trap Gas valve Circulation Pump DHW Flow Sensor (Combi Models Only) Water pressure switch Modulating Fan...

  • Page 19: Part 4 - Water Piping

    Model Heat Exchanger Volume (Gallons) hot water. HTP offers indirect water heaters in a wide range of gallon sizes in either stainless steel or glass-lined construction. 199 / 199C A.
  • Page 20 Boiler Models Combi Models A. CH Supply 1-1/4” A. CH Supply 1-1/4” B. Supply to Indirect Water Heater 3/4" (Cap if not in use) B. DHW Outlet 3/4" C. Gas Inlet 3/4" C. Gas Inlet 3/4" D. N/A D. DHW Inlet 3/4" E.

  • Page 21: Internal Circulation Pump

    DHW Loop (Combi Models) E. Internal Circulation Pump The DHW piping must be provided with a DHW pressure relief valve that complies with local codes, but not less than valves certified To calculate the size of the heating installation refer to the graph below. as meeting the requirements of Relief Valves for Hot Water Supply Graph Representing the Available Circulation Pump Head Systems, ANSI Z21.22 / CSA4.4 by a nationally recognized lab that...

  • Page 22: Air Elimination Device

    WARNING RE-INSPECTION OF RELIEF VALVES: Relief valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a licensed plumbing contractor or qualified service technician to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.
  • Page 23 Cap this fitting when not in use Primary/Secondary Piping Shown - See Note 2 Figure 14 - Boiler with Single Central Heating Circulator NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the appliance to prevent gravity circulation.
  • Page 24 WARNING For direct (not primary / secondary) piping applications, the expansion vessel must be placed on the return side of the boiler as illustrated. Placement of flow resticting de- vices, such as check valves, is prohibited between the boiler return and the expansion vessel.
  • Page 25 Cap this fitting when not in use Primary/Secondary Piping Shown - See Note 2 Figure 16 - Boiler with Multiple Central Heating Circulators NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the appliance to prevent gravity circulation.
  • Page 26 Primary/Secondary Piping Shown - See Note 2 Figure 17 - Combi Boiler with Single Central Heating Circulator NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the appliance to prevent gravity circulation.
  • Page 27 WARNING For direct (not primary / secondary) piping applications, the expansion vessel must be placed on the return side of the boiler as illustrated. Placement of flow resticting de- vices, such as check valves, is prohibited between the boiler return and the expansion vessel.
  • Page 28 In mixed temperature applications, a mixing valve is required for the protection of low temperature loops. Primary/Secondary Piping Shown - See Note 2 Figure 19 - ELUWCN with Multiple Central Heating Circulators NOTE: In piping applications utilizing a single zone, it is recommended that the installer use flow / check valves with weighted seats at or near the appliance to prevent gravity circulation.

  • Page 29: Floor Drying Function

    J. Floor Drying Function The Floor Drying Function is a special function that allows the installer, through a dedicated heating cycle, to use the boiler for drying a freshly poured radiant floor during a floor system installation. The installer can set parameter 2.7.4 (Floor Drying Cycle) and choose the cycle‘s operation (Functional Heating, Curing Heating, a combination of Functional and Curing Heating, or Manual Heating).

  • Page 30: 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 31: 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 UL-1738 or ANSI/ASTM D1785 PVC-DWV Schedule 40/80 UL-1738 or ANSI/ASTM D2665 UL-1738 or ULC-S636 Pipe Approved for...

  • Page 32: 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 Exhaust Vent Terminal Intake Pipe Terminal Area Where Intake Terminal Is Not Permitted Figure 20 - 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 33: Exhaust Vent And Intake Pipe Sizing

    When preparing pipe for installation: E. Exhaust Vent and Intake Pipe Sizing • Ensure cuts are square. 1. All models ship with 3” diameter vent pipe exhaust vent and intake • Bevel cut edges by 1/16” - 1/8”. Deburr the pipe. air pipe connections.
  • Page 34 14. In vacant chimney applications, install and seal a rain cap over The following table lists optional exhaust/intake terminations available existing chimney openings. from HTP: 15. All piping must be fully supported. Use pipe hangers at a Description Stock Code minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

  • Page 35: Applications

    Vent Option Availability Vent Supplier Vent Material Description Figure Size Part Number Compatibility Roof Wall 2” 196984 24, 28 IPEX (or Equivalent) Low Profile (Wall) 3” 196985 24, 28 2” 196125 25, 29, 36, 40 PVC/CPVC IPEX (or Equivalent) Concentric 196116 25, 29, 36, 40 4, 5, 6, 7...
  • Page 36 Sidewall Venting Options - Direct Vent Installation Low Profile Termination Two Pipe Termination WARNING WARNING Exhaust must terminate a minimum of 18” above the air intake 3” IPEX Low Profile Termination illustrated. See Figure 28 for more termination. See Figure 27 for more details. details.
  • Page 37 Sidewall Venting Options - Direct Vent Installation Low Profile Termination Two Pipe Termination WARNING 4 in min. Refer to documentation included with termination kit for complete installation instructions. Gas Vent Directly Gas Vent Below Keep Free of Directly Obstructions Below Keep Free of Obstructions Figure 28 - Low Profile Sidewall Termination (with Optional IPEX Kit)
  • Page 38 Snorkel Venting (Two Pipe Sidewall Venting Terminations Venting Below Grade Beneath an Overhang) For installations that exit the wall below grade: Excavate the site to a point where the pipes are to exit as shown in Figure 32. Ensure the wall is fully sealed where the pipes penetrate. The exhaust vent / air intake piping MUST be secured to the side of the building above grade, as shown, to provide rigidity.
  • Page 39 Roof Venting Options - Direct Vent Installation Unbalanced Termination (Roof Exhaust / Sidewall Intake) Two Pipe Termination WARNING WARNING Exhaust must terminate a minimum of 18” above the air intake Exhaust must terminate a minimum of 12” above snow level. See termination.
  • Page 40 Roof Venting Options - Direct Vent Installation Unbalanced Venting - Roof Exhaust Termination Two Pipe Termination WARNING Figure illustrates two options for exhaust termination only. Neither vent pipe illustrated is intended for combustion air intake. 4 in min. Figure 38 - Two Pipe Roof Venting Detail Concentric Termination Figure 39 - Unbalanced Venting - Roof Exhaust Termination Options WARNING...

  • Page 41: Venting Through An Existing System

    NOTE: The following instructions refer only to venting through This boiler may be vented through an existing unused vent system. an existing vent system, and not to venting with HTP’s optional The inner diameter of the existing vent system is utilized for the concentric vent kits.

  • Page 42: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    3. Power Venting, Indoor Combustion Air in Confined or Unconfined Space This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 6.

  • Page 43: Part 6 - Installing The Condensate Drain

    Condensate from the boiler will be slightly acidic (pH from 3.2 to (p/n 7450P-212 available from HTP). Follow all the installation 4.5). Check with your local gas company to determine if combustion instructions included with the neutralizer.

  • Page 44: Part 7 - Connecting Electrical Service

    Part 7 - Connecting Electrical Service NOTE: For additional electrical protection, the use of a whole house WARNING surge protector is recommended. Damage caused by power surges IS NOT covered by the warranty. Install wiring and electrically ground boiler in accordance with the 1.

  • Page 45: Room Thermostat Wiring Connections

    CAUTION NOTE: Some newer thermostat models may draw too much Open the control panel cover to have access to the main PCB. power from the boiler and will require an additional power supply See Figure 49. to operate properly. Review the instructions provided with the thermostat to determine if an additional power supply is needed.

  • Page 46: Internal Wiring Details

    B. Internal Wiring Details POWER-IN DHW PUMP FUSE 5AT FUSE 5A CN16 CN22 CN26 CN12 CN20 CN19 Figure 52 - Electrical Wiring Diagram LP-719 Rev. 000 Rel. 000 Date 6.25.20...
  • Page 47 Figure 53 - Ladder Diagram LP-719 Rev. 000 Rel. 000 Date 6.25.20...
  • Page 48 Connector Description HT Selv No. of Location 120 VAC LIVE INPUT POWER SUPPLY 120 VAC NEUTRAL INPUT HT (120V~) AC PROTECTIVE EARTH 120 VAC EXT. PUMP2 INPUT / 120VAC LINE DIV1 EXTERNAL PUMP 2 / 120 VAC NEUTRAL Hi-V DIVERTER VALVE (DHW) 120 VAC EXT.
  • Page 49 Connector Description HT Selv No. of Location +24V ROOM THERMOSTAT SELV (24V) ROOM THERMOSTAT 1 SIGNAL NTC SYSTEM CASCADE NTC SENSOR SIGNAL NTC TANK SELV (5V) BOILER NTC SENSOR SIGNAL CN24 OUTDOOR SENSOR OUTDOOR NTC SENSOR SIGNAL +24V ROOM THERMOSTAT 2 SELV (24V) ROOM THERMOSTAT 2 SIGNAL EBUS2 SIGNAL...

  • Page 50: Part 8 - Gas Connections

    Part 8 - Gas Connections WARNING FIRE AND/OR EXPLOSION HAZARD To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional. Ensure the gas on which the boiler will operate is the same type specified on the rating plate (natural gas or LP gas). This boiler must be converted to propane operation.

  • Page 51: Additional Precaution For Excess Flow Valve (Efv)

    Leak test the gas line pipe before placing the boiler in WARNING Gas Outlet operation. Only use approved leak detector liquid solutions to check for leaks. DO NOT REMOVE OR ATTEMPT TO MAKE AN ADJUSTMENT TO Do not operate the boiler until all connections have been SCREWS 2 and 4 WITHOUT A CALIBRATED COMBUSTION ANALYZER.

  • Page 52: Part 9 - Controls

    Part 9 - Controls A. Control and Display Overview AUTO COMFORT ON OFF MENU PAR CODE Display Icon Description Digits Indicating: • Boiler Status • Temperature ( F) with bar level Figure 57 - Control and Display Overview • Error Codes (ERROR) •...

  • Page 53: Ignition Procedure

    NOTE: When set to AUTO - Automatic Temperature Control (e.g., B. Ignition Procedure Outdoor Reset), the CH Temperature Setpoint is calculated in accordance with the type of automatic temperature control Press the ON/OFF button on the control panel to power on the selected.

  • Page 54: Automatic Ch Temperature Control (Auto)

    2.2.4 = 1 via the technical menu. NOTICE In order for the boiler to detect changes in room temperature it is necessary to install an HTP Room Sensor. Other thermostats (not HTP) can only switch the boiler ON and OFF. Parameters of Automatic CH Temperature Control -13 °F...

  • Page 55: Type Of Temperature Control

    4 = Indoor and Outdoor Temp. Reset - The boiler target temperature automatically adjusts between the Min and Max Temperature Set- tings (4.2.6 and 4.2.5), based upon the input temperatures provided by an optional HTP Room Sensor AND the included Outdoor Sensor (or Internet Weather via WiFi connection), in accordance with the following formula: Boiler Target Temp = Min Temp (4.2.6) + Slope of Outdoor Reset Curve (4.2.2) X {Room Sensor Influence (4.2.4) X [Room Setpoint - Room Temp] + [Room...

  • Page 56: Parallel Shift Of Reset Curve

    H. Parallel Shift of Reset Curve 179 °F (e.g. Parameter 4.2.3 for Zone 1) When the Reset Curve results in a boiler target +25°F Increase parallel shift temperature that is too high or too low (i.e., heats the building too quickly or slowly), Parallel Shift can be used 0 °F Default to offset the curve up or down to increase or decrease...

  • Page 57: Technical Menu - Access And Navigation

    J. Technical Menu - Access and Navigation To access advanced setup and troubleshooting parameters, it is necessary to enter the Technical Menu. The Technical Menu includes a number of Quick Access Menus which allow easy access to commonly used parameters. See K. Technical Menu - Menu Structure. The Quick Access Menu option, “MENU”, provides access to all parameters.

  • Page 58: Technical Menu - Menu Structure

    Free parameters Only applicable with 0-10V / 4-20mA Reset Factory Settings Clip-In Board installed Other - 1 Other - 2 11 HTP Zone Controller Parameters 0 General 1 Diagnostics 25 Cascade Manager Parameters 0 General 1 System Settings 2 Domestic Hot Water...

  • Page 59: Technical Menu - Complete Menu

    L. Technical Menu - Complete Menu Description Value ACCESS the Complete Menu “+” and “-” buttons for 5 seconds. T 222. Simultaneously press the he display shows 2. Press the “+” button to select 234 , the service code. 3. Press the OK button. PCB.
  • Page 60 Description Value 3 BOILER CH PARAMETERS - 1 Limited by the absolute values defined by parameters 2.3.3 and 1 Adjustable max CH power percentage 0 - 100 2.3.4, i.e., 0 = min power and 100 = max power. Absolute Max DHW power percentage 0 - 100 CANNOT BE MODIFIED RESERVED FOR TECHNICAL...
  • Page 61 Description Value 6 BOILER MANUAL SETTINGS Only to test components 0 Manual mode activation 0 = OFF, 1 = ON 1 Boiler pump control 0 = OFF, 1 = ON Set Parameter 260=1 2 Fan control 0 = OFF, 1 = ON Set Parameter 260=1 3 3 way valve control 0 = DHW, 1 = Heating...
  • Page 62 68 - 122 °F Parameter 4.2.0 = 0 Only applicable when using an 3 Zone Freeze Protection Temperature 36 - 59 °F HTP room sensor - Changes all zones 1 SUMMER/WINTER CHANGEOVER 0 S/W function activation 0 = OFF, 1 = ON 1 S/W temperature threshold 50 - 86 °F...
  • Page 63 Adjusts the influence of room temperature on target boiler temperature - a higher setting causes a greater increase to the boiler target temperature as the indoor temperature drops below room setpoint. Only applicable when using an optional HTP Room Sensor and when 4.2.1 = 2 or 4. 86 - 179 °F if Parameter 4.2.0 = 1...
  • Page 64 Adjusts the influence of room temperature on target boiler temperature - a higher setting causes a greater increase to the boiler target temperature as the indoor temperature drops below room setpoint. Only applicable when using an optional HTP Room Sensor and when 5.2.1 = 2 or 4. 86 - 179 °F if parameter 5.2.0 = 1...
  • Page 65 Adjusts the influence of room temperature on target boiler temperature - a higher setting causes a greater increase to the boiler target temperature as the indoor temperature drops below room setpoint. Only applicable when using an optional HTP Room Sensor and when 6.2.1 = 2 or 4. 86 - 179 °F if Parameter 6.2.0 = 1...
  • Page 66 Description Value 1 CH Supply Temperature (in °F) 2 CH Return Temperature (in °F) Not applicable to Non-Combi 3 DHW Outlet Temperature (in °F) models 4 Exhaust Flue Temperature (in °F) Only with outdoor sensor 5 Outdoor Temperature (in °F) connected 4 DHW TANK TEMPERATURE (ONLY ACTIVE WITH CONNECTED NTC TANK SENSOR) - Read Only Only with NTC tank sensor...

  • Page 67: 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 68: System Water Fill, Purge, And Test

    If the condensate outlet on the boiler is lower than the drain, you 2. Open hot water faucets in the DHW system. Start with the faucets must use a condensate removal pump, available from HTP (554200). nearest the boiler. This pump is equipped with two leads that can be connected to 3.

  • Page 69: Part 11 - Start-Up

    NOTE: It is recommended to run through the full initial purge cycle at Part 11 - Start-Up install. Do not cut the purge cycle short. NOTE: The AUTO button also engages / disengages Automatic WARNING Temperature Control. After purging, ensure Automatic Temperature Control is set according to system requirements.
  • Page 70 WARNING It is very important that the combustion system be set within the recommended CO measurements listed in Table 28. Visually looking at the burner does not determine combustion quality. Failure to measure combustion with a calibrated combustion analyzer and set the throttle within the recommended CO measurements could result in property damage, severe personal injury, or death.

  • Page 71: Checking Combustion Parameters

    D. Converting the Appliance from Natural Gas to Propane Operation HTP boilers are factory set to operate on Natural Gas. BEFORE OPERATING ON PROPANE the boiler must be converted to Propane using the included conversion kit specific to the boiler model.

  • Page 72: Part 12 - Installation Checklist

    Part 12 - Installation Checklist Before Installing Note Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? Are water and gas lines properly sized and set at proper pressures for the installation? Is boiler location as near the exhaust vent / intake pipe terminations as possible? Have combustible materials been cleared from the installation location? Is there a drain close to the boiler? Water Piping...

  • Page 73: Part 13 - Troubleshooting

    Wiring Note Has the power and control been wired per boiler wiring diagram, this manual? Is the main electrical connection polarity within boiler requirements? Does the power supply voltage agree with the boiler rating plate? 120V AC? Start-Up, Adjust, and Test Note Has the boiler been started? If necessary, has the boiler gas valve been adjusted?

  • Page 74: Boiler Error Codes

    B. Boiler Error Codes Error Display Description Possible Remedies Type CH Circuit Press the Reset button to clear the Error Code. If Error happens again: Blocking 1 01* Overheat 1. Check for the correct functioning and positioning of the supply and return temperature probes. (Manual 2.
  • Page 75 Error Display Description Possible Remedies Type 1 P1 Insufficient circulation or missing water: Gradient T supply> 12.6 °F / sec Warning 1 P2 Insufficient circulation or missing water: T supply - T return> 99 °F Warning 1 P3 Inadequate circulation or missing water: T return - T supply> 18 °F Warning DHW Circuit Reset?
  • Page 76 Error Display Description Possible Remedies Type This Error Code will go away when the condition is remedied. If Error happens again disconnect the flame detection electrode. Then press Reset. Blocking Flame detected with gas valve 5 02 If the error does not happen again replace the flame detection (Auto closed electrode.
  • Page 77 1. The control has sensed a short circuit on the BUS connection – disconnect field wiring from BUS Incorrect wiring to BUS con- connection. nection 2. If connecting an HTP room sensor or zone controller to the BUS connection, check for correct polarity and short circuits of the wiring. EMERG (When in Emergency mode, 3.

  • Page 78: Part 14 - Maintenance

    Part 14 - Maintenance vent or intake pipe openings. If removing the debris does not DANGER allow the boiler to operate correctly, contact your qualified service The boiler must be inspected and serviced annually, preferably at technician to inspect the boiler and the vent system. the start of the heating season, by a qualified service technician.

  • Page 79: Maintenance Only To Be Performed By A Qualified Service Technician

    Check Water and Gas Piping C. Maintenance Only to be Performed by a Qualified Remove the boiler cover and perform a gas leak inspection Service Technician following Operating Instructions on page 2 of this manual. If gas odor or leak is detected, follow procedures on page 2. Call a Removing the Cabinet Cover and Inspecting the Boiler qualified service technician.
  • Page 80 Unscrew the two (2) nuts and remove the gas pipe. WARNING Water drained from the boiler could be scalding hot. Wait for the boiler to cool before draining water, and take precautions when draining water. Failure to do so could result in property damage, personal injury, or death.
  • Page 81 Clean the combustion chamber by spraying water or solution into the combustion assembly and monitor the flow through the combustion system. Liquid should flow freely through each tube. If there is an obstruction, increase the flow on the tube to force the blockage out.

  • Page 82: Replacing Components

    Clean the filter with a toothbrush and clean running water. WARNING Reinstall the DHW inlet filter. Refill the DHW circuit following the filling and purging Do not install the condensate assembly if a component is lost or instructions in this manual. missing.
  • Page 83 Replacing the Main Heat Exchanger Replacing the Fan Drain the boiler and remove the combustion assembly as 1. Remove the silencer and gas line as described in Cleaning the described in Cleaning the Heat Exchanger Combustion Heat Exchanger Combustion Chamber. Chamber.

  • Page 84: After Maintenance Is Complete

    Remove the six (6) fixing screws from the heat exchanger. If Remove the gas valve. accessing the screws on the left part of the heat exchanger is Reinstall the new gas valve in reverse order. difficult remove the lateral panel. BE SURE TO USE NEW SEALING RINGS.

  • Page 85: Part 15 - Maintenance Report

    Part 15 - Maintenance Report CAUTION In unusually dirty or dusty conditions, care must be taken to keep boiler cabinet door in place at all times. Failure to do so VOIDS WARRANTY! WARNING Allowing the boiler to operate with a dirty combustion chamber will hurt operation.
  • Page 86 INSPECTION ACTIVITIES DATE LAST COMPLETED 1 st YEAR 2 nd YEAR 4 th YEAR* PIPING 3 rd YEAR Near boiler piping Check boiler and system piping for any sign of leakage. Leaking pipes could cause property damage. Make sure all piping is properly supported.

  • Page 87: Part 16 - Shutdown

    Part 16 - Shutdown Supply/Return Temperature Sensors A. Shutdown Procedure Outdoor Sensor Indirect Sensor Turn the boiler off at the on/off power switch. Wait for the combustion DHW Outlet Sensor blower to stop, so all latent combustion gases are purged from the system.
  • Page 88 Maintenance Notes LP-719 Rev. 000 Rel. 000 Date 6.25.20...
  • Page 89 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...

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