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Archer Highlander HLR-3-070NT Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for
Highlander
Models:
• HLR-3-070NT
• HLR-4-105NT
• HLR-5-140NT
• HLR-6-175NT
• HLR-7-210NT
Manual Contents
1.
Read Before Proceeding . . . . . . . . . . . . . . . . . . . . .3
3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4. Locating the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . .6
5. Preparing Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6. Air for Combustion and Ventilation . . . . . . . . . . . . .9
7.
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8. Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
9. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
10. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
11. Start-up and Checkout . . . . . . . . . . . . . . . . . . . . . .30
12. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
13. Before Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . .36
14. Service and Maintenance . . . . . . . . . . . . . . . . . . . .37
15. How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
16. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .44
17. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Appendix B: Instructions for High Altitude
Installations (US Only) . . . . . . . . . . . . . . . . . . . . . .59
Appendix C: Low Return Water . . . . . . . . . . . . . . . . .
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Appendix D: Special Requirements For Side- Wall
Vented Appliances In The Commonwealth of
Massachusetts . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
111953-01 - 1/23
• HLR-3-063PT
• HLR-4-095PT
• HLR-5-126PT
• HLR-6-158PT
• HLR-7-189PT
Installation, Operating & Service Manual
Highlander
Attention Installer - Affix these instructions
Page
adjacent to boiler. Provide model number and
serial number when seeking information and
support.
Attention Building Owner - Retain these
instructions for future reference. Contact a
qualified installer, service agency or gas
supplier for all issues and support.
Read these instructions carefully before
installing. This boiler must only be installed,
serviced, or repaired by a qualified installer,
service agency, or gas supplier. Improper
installation, adjustment, alteration, service or
maintenance can cause severe personal injury,
death, or substantial property damage. For
assistance or additional information, consult
a qualified installer, service agency, or gas
supplier.
. . . . . .
• Water Boiler
• Cast Iron
• Induced Draft
• Gas Fired
!
WARNING
!
WARNING
9700609
1

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Summary of Contents for Archer Highlander HLR-3-070NT

  • Page 1: Table Of Contents

    Installation, Operating & Service Manual Highlander Installation, Operating and Service Instructions for Highlander • Water Boiler Models: • Cast Iron • HLR-3-070NT • HLR-3-063PT • HLR-4-105NT • HLR-4-095PT • Induced Draft • HLR-5-140NT • HLR-5-126PT • Gas Fired • HLR-6-175NT •...
  • Page 2 Highlander Installation, Operating & Service Manual The city of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved these boilers. See the Massachusetts Board of Plumbers and Gas Fitters website https://licensing.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

  • Page 3: Qualified Installer, Service Agency Or Gas Supplier

    Installation, Operating & Service Manual Highlander Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding NOTICE: DANGER 1. Size boiler properly. A grossly oversized boiler Asphyxiation Hazard, Burn Hazard, Electrical will cycle excessively leading to premature Shock Hazard. failure of boiler and its components. Warranty •...

  • Page 4: User/Homeowner Read Before Proceeding

    Highlander Installation, Operating & Service Manual User/Homeowner Read Before Proceeding WARNING CAUTION Asphyxiation Hazard. Fire Hazard. Burn Hazard. • A qualified installer, service agency or gas Keep children and pets away from hot surfaces supplier should annually inspect boiler. of the boiler including boiler piping, vent piping, and vent terminals.

  • Page 5: Specifications

    Installation, Operating & Service Manual Highlander Specifications Table 3-1: Ratings Model Number Fuel AFUE% Input (MBH) Heating Capacity (MBH) Net AHRI Rating, Water (MBH) HLR-070-NT Nat. Gas 85.0 HLR-105-NT Nat. Gas 85.0 HLR-140-NT Nat. Gas 85.0 HLR-175-NT Nat. Gas 85.0 HLR-210-NT Nat.

  • Page 6: Locating The Boiler

    Highlander Installation, Operating & Service Manual Locating Boiler Code Requirements Table 4-1: Corrosive Combustion Contaminants and Sources 1. Installations must conform to requirements of Contaminants to avoid: authority having jurisdiction or, in the Spray cans containing chloro/fluorocarbons (CFC’s) absence of such requirements, to National Fuel Permanent wave solutions Gas Code, ANSI Z223.1/NFPA 54.
  • Page 7 Installation, Operating & Service Manual Highlander Locating Boiler (continued) Before Removing Existing Boiler 3. Insofar as is practical, close all building doors and windows and all doors between the space Take pictures and measure and/or mark existing in which the appliances remaining connected steam and condensate return piping to ensure to the common venting system are located and proper re-piping of new boiler.

  • Page 8: Preparing Boiler

    Highlander Installation, Operating & Service Manual Preparing Boiler Unpack boiler DANGER 1. Move boiler to approximate installed position. Use precautions and appropriate rigging 2. Remove all crate fasteners. apparatus when moving heavy objects. 3. Lift outside container and remove with all other inside protective spacers and bracing.

  • Page 9: Air For Combustion And Ventilation

    Installation, Operating & Service Manual Highlander Air for Combustion and Ventilation The National Fuel Gas Code does describe some NOTICE: Although this boiler is supplied with other acceptable techniques for bringing outdoor a direct vent conversion kit shown in Table 3-3, combustion air to the boiler room, but these should this kit does not need to be installed if adequate rarely be needed and are not discussed here.
  • Page 10 Highlander Installation, Operating & Service Manual Air for Combustion and Ventilation (continued) • If the total volume of both the boiler room Example: A 105,000 BTU/hr input boiler and a and the room to which the openings connect is less than 50 cubic feet per water heater are to be installed in a room measuring 6 ft.

  • Page 11: Venting

    Installation, Operating & Service Manual Highlander Venting A. Approved Vent Systems - Use only one of DANGER the approved vent systems shown in Table Asphyxiation Hazard. 7-7. These systems are made of a special stainless steel alloy (AL29-4C) for protection •...
  • Page 12 Highlander Installation, Operating & Service Manual Vent System Design (continued) Table 7-1: Summary Of Venting Options Using Indoor Combustion Air (See Appendix A for Options Using Outdoor Air) Classification Used in this Manual Horizontal Direct Exhaust Vertical Direct Exhaust Vent Option # Illustrated in Figure Structure Penetration Wall...
  • Page 13 Installation, Operating & Service Manual Highlander Vent System Design (continued) 7-7) Figure 7-2: Horizontal Direct Exhaust Vent System (Vent Option 1, 2) Figure 7-3: Tee Terminal Figure 7-4: Optional Miter Terminal 111953-01 - 1/23...
  • Page 14 Highlander Installation, Operating & Service Manual Vent System Design (continued) • If possible, install the terminal on a wall Vertical Vent Terminal Locations (Vent Option away from the prevailing wind. Reliable 3, 4) - The lowest discharge opening on operation of this boiler cannot be the cap must be at least 2 feet above any guaranteed if the terminal is subjected to object located within 10 feet.
  • Page 15 Installation, Operating & Service Manual Highlander Vent System Design (continued) Figure 7-6: Vertical Direct Exhaust System (Vent Option 3, 4) 111953-01 - 1/23...
  • Page 16 Highlander Installation, Operating & Service Manual Vent System Design (continued) Table 7-7: Permissible Vent Systems And Principle Vent Components CONDENSATE WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE TRAP THIMBLES TERMINATION TERMINATION 7393GC 9321 TEE: 7390TEE 7393GCS 5300CI (NOTE 2) SAF-T VENT 5391CI HEAT FAB EZ SEAL...
  • Page 17 Installation, Operating & Service Manual Highlander Vent System Design (continued) Figure 7-9a: Location of Vent Terminal Relative to Windows, Doors and Grades Figure 7-9b: Location of Vent Terminal Relative to Meters and Forced Air Inlets 111953-01 - 1/23...
  • Page 18 Highlander Installation, Operating & Service Manual Vent System Design (continued) Max. Overhang 0 - 12 in. NOT PERMITTED 12 - 48 in. 17 - 29 in. X minus 7 in. Greater than 48 in. 17 - 29 in. 36 in. Note: Overhang may not be ventilated if 'Y' is less than 48 in.
  • Page 19 Installation, Operating & Service Manual Highlander Removing Boiler From Common Chimney 2. Removing Boiler From Common Chimney of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or the Natural Gas and Propane When an existing boiler is removed from a Installation Code, CAN/CSA B149.1.
  • Page 20 Highlander Installation, Operating & Service Manual Removing Boiler From Common Chimney (continued) F. Une fois qu’il a été déterminé, selon la 3. Vent System Assembly méthode indiquée ci-dessus, que chaque A. General Assembly Notes: appareil raccordé au système d’évacuation est i.
  • Page 21 Installation, Operating & Service Manual Highlander Vent System Assembly (continued) iv. On the male end of the pipe, apply a ¼ in. D. Complete the rest of the vent system in wide bead of high temperature silicone accordance with the vent manufacturer’s approximately ½...

  • Page 22: Water Piping

    Highlander Installation, Operating & Service Manual Water Piping WARNING • Failure to properly pipe boiler may result in improper operation and damage to boiler or building. • Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) During appliance operation and service (circulator replacement, etc.).
  • Page 23 Installation, Operating & Service Manual Highlander Water Piping (continued) C. Expansion Tank (Required) - If this boiler is If a manual reset LWCO is required, it must replacing an existing boiler with no other be installed in the supply piping just above changes in the system, the old expansion tank the boiler in accordance with the LWCO can generally be reused.
  • Page 24 Highlander Installation, Operating & Service Manual Water Piping (continued) 2. Piping For Special Situations Certain types of C. Systems Containing Oxygen - Many hydronic heating systems have additional requirements. systems contain enough dissolved oxygen to cause severe corrosion damage to a cast Some of the more common variations follow: iron boiler such as this one.
  • Page 25 Installation, Operating & Service Manual Highlander Water Piping (continued) D. Piping with a Chiller - If the boiler is used WARNING in conjunction with a chiller, pipe the boiler Oxygen contamination of boiler water will cause and chiller in parallel. Use isolation valves to corrosion of iron and steel boiler components prevent chilled water from entering the boiler.

  • Page 26: Gas Piping

    Highlander Installation, Operating & Service Manual D. All above ground gas piping upstream from Gas Piping manual shut-off valve must be electrically continuous and bonded to a grounding WARNING electrode. Do not use gas piping as grounding • Shut off gas supply before servicing the boiler. electrode.

  • Page 27: Electrical

    Installation, Operating & Service Manual Highlander Electrical 1. Line Voltage (120 VAC) Field Connections – See WARNING Figure 10.1 for line voltage connections. Provide • All wiring and grounding must be done in a dedicated circuit for the boiler of 15A or greater. accordance with the authority having jurisdiction A service switch is recommended and is required or, in the absence of such requirements, with...
  • Page 28 Highlander Installation, Operating & Service Manual Electrical (continued) Figure 10-1: Line Voltage Connections 24V CH 8.8.8 Thermostat (by others) Hydrostat Temperature Limit/LWCO Green Ground Screw Internal J-Box BL WH Overcurrent Service Power Protection/ Switch Supply Disconnect (optional) 120/60/1 (By Installer) (By Installer) Green Ground Screw...
  • Page 29 Installation, Operating & Service Manual Highlander Electrical (continued) Power Supply 120/60/1 (By Installer) Overcurrent 24V CH Thermostat Protection/ (by others) Disconnect (By Installer) Hydrostat Service Switch Temperature (optional) Limit/LWCO (By Installer) Internal J-Box On/Off Switch Relay 1 R 1 L2 C2 C1 B1 B2 Internal J-Box...

  • Page 30: Start-Up And Checkout

    Highlander Installation, Operating & Service Manual Start-up and Checkout DANGER WARNING Explosion Hazard. Failure to follow the following procedure exactly Do not use matches, candles, open flames, or could result in over firing of boiler and a carbon other ignition sources to check for leaks. Failure monoxide hazard.
  • Page 31 Installation, Operating & Service Manual Highlander Start-up and Checkout (continued) Figure 11-2: Operating Instructions 111953-01 - 1/23...
  • Page 32 Highlander Installation, Operating & Service Manual 12. Check Pilot Burner Flame. Start-up and Checkout (continued) Natural Gas Only. Pilot produces single F. Read the manifold pressure. It should be set at: flame. Flame should be steady medium hard Natural Gas LP Gas blue enveloping 3/8 to 1/2 inch of igniter/ sensor tip.
  • Page 33 Installation, Operating & Service Manual Highlander Start-up and Checkout (continued) Figure 11-4: Main Burner Flame Figure 11-5: Natural Gas Pilot Flame Figure 10.6: Pilot Burner Flame (LP Only) Figure 11-6: LP Gas Pilot Flame 111953-01 - 1/23...

  • Page 34: Operation

    Highlander Installation, Operating & Service Manual Operation 1. Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. 2. Electronic Ignition Module See Figure 12-1 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 12-2 cross-references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams.
  • Page 35 Installation, Operating & Service Manual Highlander Operation (continued) a. Restore boiler power at circuit f. If needed, adjust pilot flame breaker or fuse box. by turning the gas valve pilot b. Set thermostat to call for heat. adjustment screw clockwise to decrease or counterclockwise to c.

  • Page 36: Before Leaving Jobsite

    Highlander Installation, Operating & Service Manual Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water  Performed gas leak test  Checked pilot burner flame  Checked main burner flames  Checked gas input rate  Checked gas inlet pressure ...

  • Page 37: Service And Maintenance

    Installation, Operating & Service Manual Highlander Service and Maintenance http://www.cdc.gov/niosh/homepage.html 111953-01 - 1/23...
  • Page 38 Highlander Installation, Operating & Service Manual Service and Maintenance (continued) CAUTION WARNING Label all wires prior to disconnection when This boiler should be serviced by a qualified servicing controls. Wiring errors can cause installer, service agency, or gas supplier. improper and dangerous operation. Verify Inspections should be performed at intervals proper operation after servicing.
  • Page 39 Installation, Operating & Service Manual Highlander Service and Maintenance (continued) WARNING Soot deposits in the flue passages are a sign that the boiler may be operating at high carbon monoxide (CO) levels. After cleaning the boiler of soot deposits, check the CO level in the flue gas to insure that the boiler is operating properly.
  • Page 40 Highlander Installation, Operating & Service Manual Service and Maintenance (continued) 2. Heat Exchanger Cleaning Procedure M. Put a light in the combustion chamber and look through the flue passages from the top to verify A. Turn off electrical power and gas supply to the that they have been thoroughly cleaned.
  • Page 41 Installation, Operating & Service Manual Highlander Service and Maintenance (continued) Figure 14-3a: Pressure Switch Connections Figure 14-3b: Measuring Pressure Across Pressure Switch 111953-01 - 1/23...

  • Page 42: How It Works

    Highlander Installation, Operating & Service Manual How It Works Hydrostat 3200 contains features such as high limit switch, Low Water Cut- Off and circulator relay. Energy is saved by using a thermal target feature which adjusts boiler target temperature depending on heat required. Dual sensor for boiler temperature control and protection against potentially damaging low water conditions in boiler.
  • Page 43 Installation, Operating & Service Manual Highlander How It Works (continued) 111953-01 - 1/23...

  • Page 44: Troubleshooting

    Highlander Installation, Operating & Service Manual Troubleshooting 1. Before Troubleshooting 2. Temperature Limit/LWCO Control When troubleshooting the following should be Refer to the HydroStat 3200 Installation kept in mind: Instructions and Operating Manual included with these instructions for additional troubleshooting A.
  • Page 45 Installation, Operating & Service Manual Highlander Troubleshooting (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 46: Service Parts

    All Highlander Service Parts may be obtained through your local Archer Boilers Wholesale Distributor. Should you require assistance in locating an Archer Distributor in your area or have questions regarding the availability of Archer products or service parts, please contact Customer Service at (888) 432-8887.
  • Page 47 Installation, Operating & Service Manual Highlander Service Parts (continued) WARNING If base must be replaced, there is a good chance pilot assembly and pilot tubing will need to be replaced as well. Replacement pilot assemblies are shown on page 48. Also check condition of manifold and gas valve and replace if they show any signs of heat,...
  • Page 48 Highlander Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description 3 Section 4 Section 5 Section 6 Section 7 Section Gas Valve (Natural Gas), 110404-01 [1] VR8204C6000 Gas Valve (Natural Gas), 110405-01 VR8304P4553 Gas Valve (LP Gas), 110406-01 [1] VR8204C6018 Gas Valve (LP Gas),...
  • Page 49 Installation, Operating & Service Manual REVISIONS Highlander REV. DATE DESCRIPTION 3/4/2020 INITIAL RELEASE Service Parts (continued) MATERIAL: UNLESS OTHERWISE NOTED: THIRD ANGLE DES: JP SCALE ALL DIMENSIONS IN INCHES. PROJECTION ITEM NUMBER: TOLERANCES: CHK: JP SIZE: C X.X ±.1 X.XXX ±.005 FIRST USE: X.XX ±.03 ANGLE ±1°...
  • Page 50 Highlander Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description 3 Section 4 Section 5 Section 6 Section 7 Section 110402-03 110402-04 110402-05 110402-06 110402-07 Burner Cover (Natural Gas Only) 111953-01 - 1/23...
  • Page 51 Installation, Operating & Service Manual Highlander Service Parts (continued) Part Number [Quantity] Key No. Description 3 Section 4 Section 5 Section 6 Section 7 Section Resideo S8670E EI Module 100959-01 [1] Resideo Relay Module 80160096 [1] Hydrostat 3200 w/ Sensor 105161-01 [1] 6D, 4C, Air Pressure Switch w/ Tubing...
  • Page 52 Highlander Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description 3 Section 4 Section 5 Section 6 Section 7 Section Left Jacket Panel 111824-01 [1] Right Jacket Panel Rear Jacket Panel Vestibule Jacket Panel Top Jacket Panel 111821-03 [1] 111821-04 [1] 111821-05 [1]...
  • Page 53 Installation, Operating & Service Manual Highlander Service Parts (continued) Part Number [Quantity] Description 3 Section 4 Section 5 Section 6 Section 7 Section Water Manifold 109614-01 [1] Temperature/Pressure Gauge 105894-01 [1] 3/4 in. Safety Relief Valve 109038-01 [1] (30 psi) Boiler Drain Valve Obtain Locally (3/4 in.

  • Page 54: Appendix A: Direct Vent Installations

    Highlander Installation, Operating & Service Manual Appendix A: Direct Vent Installations This Appendix describes how to bring B. Vent System Design and Assembly – combustion air directly from outside to the boiler Vent system is assembled using installer supplied (direct venting) using the Direct Vent Conversion AL29-4C stainless steel vent components.
  • Page 55 Installation, Operating & Service Manual Highlander Appendix A Direct Vent Installations (continued) Table A.2: Summary Of Direct Vent Options (See Section 7 for Additional Details on Vent System Installation) Classification Used in this Horizontal Direct Vent Vertical Direct Vent Manual Vent Option # A.3, A.4 A.3, A.4...
  • Page 56 Highlander Installation, Operating & Service Manual Appendix A Direct Vent Installations (continued) Figure A-4: Horizontal Direct Venting (Vent Options 5-7) 3. Permitted Intake Terminals – 4. Horizontal terminal location – Install the intake terminal to either side of the a. Horizontal venting applications use the exhaust terminal as shown in Figure A-4.
  • Page 57 Installation, Operating & Service Manual Highlander Appendix A Direct Vent Installations (continued) Figure A-5: Horizontal Terminal Offsets Figure A-6: Vertical Direct Vent System (Vent Options 8-10) 111953-01 - 1/23...
  • Page 58 Highlander Installation, Operating & Service Manual Appendix A Direct Vent Installations (continued) D. Air Intake System Assembly - 4. If PVC is used for the intake system, the PVC will fit over the outside of the air intake collar 1. If PVC piping is used, use PVC cement to on the boiler.

  • Page 59: Installations (Us Only)

    Installation, Operating & Service Manual Highlander Appendix B: Instructions for High Altitude Installations (US Only) These instructions apply only to the following altitude ranges: Sea Level - 2,000 ft., 2,001-10,200 ft. These instructions contain specific information to setup your boiler to ensure proper operation. As with most gas appliances, special consideration Table B.1 lists the specific differences must be given to when this boiler is installed at...
  • Page 60 Highlander Installation, Operating & Service Manual Appendix B Instructions for High Altitude Installations (US Only) (continued) Figure B-2: Air Intake Terminal (Installed on Air Intake Collar) WARNING • Safe operation of this boiler depends upon the use of the correct burner orifice AND pressure switch for the altitude at which the boiler is to be installed.

  • Page 61: Temperatures

    Installation, Operating & Service Manual Highlander Appendix C: Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110°F and below return water temperatures will not cause thermal shock to our castings. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation but are not designed for extended condensation periods.
  • Page 62 Highlander Installation, Operating & Service Manual Appendix C Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow. Best Alternative: Slant/Fin offers a system by-pass kit [part number 107795-01] that addresses these situations.

  • Page 63: Massachusetts

    Installation, Operating & Service Manual Highlander Appendix D: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1.
  • Page 64 Highlander Installation, Operating & Service Manual Archer Boilers (888)432-8887 www.archerboiler.com 111953-01 - 1/23...

This manual is also suitable for:

Highlander hlr-3-063ptHighlander hlr-4-105ntHighlander hlr-4-095ptHighlander hlr-5-140ntHighlander hlr-5-126ptHighlander hlr-6-175nt ... Show all

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