HTP Elite EL-80 Installation Manual
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HTP Elite EL-80 Installation Manual

Installation start-up maintenance parts elite series
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See also: Installation Start-up Maintenance Parts
Elite
INSTALLATION
START-UP
MAINTENANCE
PARTS
Elite Models*
EL-80 / 110 / 150 / 220 / 299 / 399
*A suffix of "LP" denotes propane gas
*A suffix of "N" denotes natural gas
This manual must only be used by a qualified heating installer/service technician. Read all instructions in this
manual before installing. Perform steps in the order given. Failure to comply could result in substantial property
damage, severe personal injury, or death.
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.
120 Braley Rd. P.O. Box 429
East Freetown, MA 02717-0429
www.htproducts.com
LP- 293 REV. 3.29.12

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Summary of Contents for HTP Elite EL-80

  • Page 1 Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: 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.
  • Page 3 AHJ. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.

  • Page 4: Table Of Contents

    INSTALLATIONS MUST COMPLY WITH: Local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131. In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3.
  • Page 5 F. PREVENT COMBUSTION AIR CONTAMINATION ......................17 G. REMOVING A BOILER FROM A COMMON VENT SYSTEM ..................18 H. UNCRATING THE BOILER ............................... 18 PART 4 – BOILER PIPING ............................19 A. GENERAL PIPING INFORMATION ..........................19 B. RELIEF VALVE ................................. 20 C.
  • Page 6 C. CHECK INLET GAS PRESSURE ............................. 52 D. BOILER GAS VALVE ................................ 54 PART 7 – FIELD WIRING ............................55 A. INSTALLATION MUST COMPLY WITH: ........................... 55 B. FIELD WIRING TERMINATIONS ............................55 C. FIELD WIRING .................................. 55 D. LINE VOLTAGE WIRING FOR STANDARD BOILER ....................... 56 E.

  • Page 7: Part 1 - General Safety Information

    BOILER START-UP REPORT ..........................91 MAINTENANCE REPORT ............................92 MAINTENANCE NOTES ............................96 HTP CUSTOMER INSTALLATION RECORD FORM ..................97 PART 1 – GENERAL SAFETY INFORMATION A. PRECAUTIONS This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back.

  • Page 8: Improper Combustion

    Due to the low water content of the boiler, improper sizing of the boiler with regard to heating system load will result in excessive cycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.

  • Page 9: Boiler Water Chemistry

    Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Consider boiler piping and installation when determining boiler location. NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty.

  • Page 10: How Boiler Operates

     Pressure Relief Valve (Part #7250P-219 for EL80/110/150, #7350P-065 for EL220/299/399)  Indirect Sensor  Outdoor Sensor  Intake PVC Tee with Screens  Exhaust PVC Coupling with Screens  Outlet Combination Fitting (1” - Part #7450P-134 for EL80/110/150/220, 1.25” - #7450-135 for EL299, 1.5”...

  • Page 11: Optional Equipment

    II system controls the temperature to each zone by employing three way mixing valves. The Vision II also controls the output temperature of the boiler to assure accurate temperature delivery to all connected zones. C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP. These additional options may be purchased through your HTP distributor: ...

  • Page 12: Part 3 - Prepare Boiler Location

    PART 3 – PREPARE BOILER LOCATION Carefully consider installation when determining boiler location. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury. A.

  • Page 13: Leveling And Dimensions

    4. Gas control system components must be protected from dripping water during operation and service. 5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as:  System leaks  Location that could cause the system and boiler to freeze and leak. ...

  • Page 14: Clearances For Service Access

    C. CLEARANCES FOR SERVICE ACCESS See Figure 2 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the boiler without removing it from the space. Space must provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the boiler.
  • Page 15 Figure 3...

  • Page 16: Residential Garage Installation

    Figure 4 D. RESIDENTIAL GARAGE INSTALLATION PRECAUTIONS If the boiler is located in a residential garage, per ANSI Z223.1:  Mount the bottom of the boiler a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor.

  • Page 17: Exhaust Vent And Intake Air Vent

    E. EXHAUST VENT AND INTAKE AIR VENT Vents must be properly supported. The boiler intake and exhaust connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the boiler and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’...

  • Page 18: Removing A Boiler From A Common Vent System

    G. REMOVING A BOILER FROM A COMMON VENT SYSTEM Do not install the boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

  • Page 19: Part 4 - Boiler Piping

    Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to an indirect water heater to supply domestic hot water. HTP offers indirect water heaters in a wide range of gallon sizes in either stainless steel or glass-lined construction.

  • Page 20: Relief Valve

    All piping methods shown in this manual use primary/secondary connection to the boiler loop. This is to avoid the possibility of inadequate flow through the boiler. For other piping methods, consult your HTP representative or refer to separate Piping Details, Section J, in this manual.

  • Page 21: Circulators

    EXPANSION TANK SIZING EL-80 1.4 Gallons EL-110 1.7 Gallons EL-150 2.0 Gallons EL-220 2.6 Gallons EL-299 3.1 Gallons EL-399 3.7 Gallons Table 2 Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added.

  • Page 22: Hydronic Piping With Circulators, Zone Valves, And Multiple Boilers

    On a boiler installed above radiation level, some states and local codes require a low water cut off device, which is an optional part available through HTP (Part # 7450P-225). Check with local codes for additional requirements. If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle.
  • Page 23 Figure 6 – LP-293-L 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. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4.
  • Page 24 Figure 7 – LP-293-Q 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. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4.
  • Page 25 Figure 8 – LP-293-O 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. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained above the minimum flow rates published on p.
  • Page 26 Figure 9 – LP-293-P 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. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained above the minimum flow rates published on p.

  • Page 27: Piping Installation

    H. PIPING INSTALLATION This boiler should not be operated as a potable hot water heater. It should not be used as a direct hot water heating device. Basic steps are listed below that will guide you through the installation of the boiler. 1.

  • Page 28: Circulator Sizing

    I. CIRCULATOR SIZING The heat exchanger has a pressure drop that must be considered in your system design. Refer to Table 3 for pressure drop through the heat exchanger. HEAT EXCHANGER PRESSURE DROP CHART Flow Rate Δ P’ Model Flow Rate EL-80 2.5’...

  • Page 29: Check/Control Water Chemistry

    MULTIPLE BOILER MANIFOLD PIPING Flow Rate (GPM) Pipe Dia. (Inches) 2½ 2½ 2½ 2½ 2½ 2½ 2½ 2½ 2½ Table 5 Multiple Boiler Manifold Piping Combined Boiler Water Flow (GPM) Figure 10 MULTIPLE BOILER MANIFOLD PIPING Flow Rate (GPM) Pipe Dia. (In.) Table 6 J.
  • Page 30 2. Do not use the boiler to directly heat swimming pool or spa water. 3. Do not fill boiler or operate with water containing chlorine in excess of 100 ppm. Hardness: 7 grains Chloride levels: 100 ppm pH levels: 6-8 TDS: 2000 ppm Sodium: 20 mGL Clean system to remove sediment*...

  • Page 31: Fill And Purge Heating System

    MINIMUM PIPE SIZES 1” NPT or Copper EL 80, EL 110, EL 150, EL 220 1 ¼” NPT or Copper EL 299 1 ½” NPT or Copper EL 399 Table 7 K. FILL AND PURGE HEATING SYSTEM 1. Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain. 2.

  • Page 32: Zoning With Zone Valves

    It is highly recommended that you carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.) You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer coefficients.

  • Page 33: Part 5 - Venting, Combustion Air, And Condensate Removal

    PART 5 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL The boiler must be vented as detailed in this Venting Section. Ensure exhaust and intake piping complies with these instructions regarding vent system. Inspect finished combustion air intake and exhaust piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as with the instructions provided in this manual.

  • Page 34: Approved Materials For Exhaust And Intake Air Vents

    When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the boiler vent connection, and at the termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

  • Page 35: Requirements For Installation In Canada

    C. REQUIREMENTS FOR INSTALLATION IN CANADA 1. Installations must be made with a vent pipe system certified to ULC-S636. IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. Additionally you may use AL29-4C stainless steel venting to comply with Canadian requirements. 2.

  • Page 36: Exhaust Vent And Intake Air Vent Pipe Location

    D. EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION You must insert the provided intake and exhaust screen at your vent termination to prevent blockage caused by debris or birds. NOTE: SEE ADDITIONAL REQUIREMENTS FOR MASSACHUSETTS IN THE BACK OF THIS MANUAL. 1.
  • Page 37 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 the condensate with a Condensate Neutralizer Kit (Part # 7450P-212 for EL-80/110/150/220/299, 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 water vapor.
  • Page 38 Figure 12 – Condensate Piping NOTES: 1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line.

  • Page 39: Exhaust Vent And Intake Air Vent Sizing

    E. EXHAUST VENT AND INTAKE AIR VENT SIZING 1. The exhaust vent and intake air vent pipes are 3” for the Elite EL-80/110/155/220 and 4” for the EL-299/399. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 200 feet.

  • Page 40: Longer Vent Runs

    c. You should keep a minimum combined equivalent length between the intake air vent pipe and the exhaust vent. The minimum combined equivalent length is 32 combined equivalent feet. d. The size of venting can also be reduced in order to accommodate existing vent sizes. When reducing down to a 2”...
  • Page 41 14. A screened straight coupling is provided with the appliance for use as an outside exhaust termination. 15. A screened inlet air tee is provided with the appliance to be used as an outside intake termination. The following information on Table 11 lists optional intake air/exhaust vent terminations available from HTP: DESCRIPTION STOCK CODE 3”...

  • Page 42: Sidewall Venting

    H. SIDEWALL VENTING Figure 14 – Sidewall Venting with Tee (Intake) and Coupling (Exhaust) – LP-293-E NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.

  • Page 43: Vertical Venting

    I. VERTICAL VENTING Figure 15 – Vertical Venting - LP-293-F NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.

  • Page 44: Horizontal Venting

    J. HORIZONTAL VENTING Figure 16 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]).

  • Page 45: Unbalanced Flue / Vertical Vent

    K. UNBALANCED FLUE / VERTICAL VENT Figure 17 – LP-293-T – Unbalanced Flue/Vertical Vent - NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.

  • Page 46: 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 concentric vent kits (2” Part # KGVAT0501CVT, 3" Part # KGAVT0601CVT). Refer to Concentric Vent Kit installation manual (Part # LP-166) for further concentric venting information and instructions.
  • Page 47 Figure 18 – 1, 18 – 2 Concentric Venting NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]).

  • Page 48: Venting As A Chase

    2. VENTING AS A CHASE When venting as a chase, follow all instructions included in Part 5 – Venting, Sections A – G of this manual, as well as the previous Concentric Venting section. See Figure 19 for chase venting demonstration.

  • Page 49: Indoor Combustion Air Installation In Confined Or Unconfined Space

    M. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE NOTE: This installation is intended for commercial applications. For residential applications, it is recommended to pipe intake combustion air from the outdoors. 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.
  • Page 50 NOTE: It is always recommended to isolate the boiler installation room from the rest of the building and bring uncontaminated air in from the outside for combustion and ventilation. Figure 21 – 1, 21 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

  • Page 51: Part 6 - Gas Piping

    PART 6 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" w.c. (3.5 kPa), and a minimum of 3.5" w.c. (.87 kPa).

  • Page 52: Check Inlet Gas Pressure

    2. Locate and install manual shutoff valves in accordance with state and local requirements. 3. In Canada, the Manual Shutoff must be identified by the installing contractor. 4. It is important to support gas piping as the unit is not designed to structurally support a large amount of weight. 5.
  • Page 53 10 Section D). In service mode, monitor pressure to assure it does not drop below 1 inch from its idle reading. If gas pressure is out of range or pressure drop is excessive, contact the gas utility, gas supplier, qualified installer, or service agency to determine correct action that is needed to provide proper gas pressure to the unit.

  • Page 54: 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 LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.

  • Page 55: Part 7 - Field Wiring

    PART 7 – FIELD WIRING To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death.

  • Page 56: Line Voltage Wiring For Standard Boiler

    D. LINE VOLTAGE WIRING FOR STANDARD BOILER 1. Connect 120V / 60Hz / 15 AMP incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V, Neutral, Ground (shown in Figure 26). 2. A line voltage fused disconnect or service switch may be required, externally mounted and connected according to local codes that may apply.

  • Page 57: Outdoor Sensor

    1. The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or an HTP 7250P-325 tank sensor. When a tank sensor is used, the boiler control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user set point by more than the user selectable offset.

  • Page 58: Optional Ul353 Low Water Cut-Off Interface Kit

    Do not run unprotected cables across the floor where they may become wet or damaged. Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet.

  • Page 59: Cascade Master Pump And Sensor Wiring

    Figure 27 M. CASCADE MASTER PUMP AND SENSOR WIRING 1. Connect the system pump hot wire to the terminal marked 8. 2. Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal. 3.
  • Page 60 Note that in a cascade system the alarm output of the boiler addressed as #1 will also be active if the master boiler has a lockout condition. The alarm output of boilers addressed as 2-7 will only activate an alarm if a lockout condition occurs on that specific boiler.
  • Page 61 Figure 29...
  • Page 62 Figure 30...

  • Page 63: Part 8 - Start-Up Preparation

    PART 8 – START-UP PREPARATION Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used. A. CHECK / CONTROL WATER CHEMISTRY Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also affect efficiency.

  • Page 64: Check For Gas Leaks

    2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3. Flush system until water runs clean and you are sure piping is free of sediment. *NOTE: It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup.

  • Page 65: Purge Air From Water System

    1. Fill the system only after ensuring water chemistry meets the requirements listed in this manual. 2. Close the manual and automatic air vents and boiler drain valve. 3. Fill to the correct system pressure. Correct pressure will vary with each application. a.

  • Page 66: Check Thermostat Circuit(S)

    HTP (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow, which, if not corrected, could cause property damage.

  • Page 67: Final Checks Before Starting Boiler

    H. FINAL CHECKS BEFORE STARTING BOILER 1. Read Start-Up Procedure, Part 9 in this manual, for proper steps to start boiler. (See Start-Up Report to record steps for future reference.) 2. Verify the boiler and system are full of water and all system components are correctly set for operation. 3.

  • Page 68: Lockout Condition

    J. LOCKOUT CONDITION If any boilers, including the master boiler in the cascade system, are in a lockout condition, the master control will recognize the lockout condition and skip over the boiler in the firing sequence. Each boiler in the cascade system is responsible for its own safety functions.

  • Page 69: Navigation Of The Display

    B. NAVIGATION OF THE DISPLAY The display includes a two-line backlit LCD readout to provide informative messages about the operation of the boiler. Many operating parameters can be viewed and adjusted by using the six buttons on the display. The func- tion of each button is described below.

  • Page 70: Programming Boiler Settings

    6. If the boilers fail to start, refer to the troubleshooting section in the back of this manual. D. PROGRAMMING BOILER SETTINGS Boiler 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.

  • Page 71: Programming The System Setting

    Function: Allows the user to switch to European date format (2009/08/28) from US format (08/28/2009). CLOCK DATE MODE 08/28/2009 Fr 10:01A Function: Adjusts the year setting. CLOCK YEAR 08/28/2009 Fr 10:01A Function: Adjusts the month setting. CLOCK MONTH 08/28/2009 Fr 10:01A The clock is set.
  • Page 72 Function 9 Max Supply Temp Sets the maximum design supply temperature based on the minimum outdoor design temperature. Default: MAX SUPPLY TEMP F (Range: 77 F to 190 Function 10 Max Outdoor Temp Sets the maximum outdoor design temperature for the system design. Default: 68 F (Range 32 F to 190 MAX OUTDOOR TEMP...

  • Page 73: Resetting The Maintenance Schedule

    Extra Boiler Mode EXTRA BOILER MODE Allows for a non HTP boiler to be controlled when the cascade output has risen above the percent of the cascade firing rate set in this parameter. Factory Default: Off (Range: 50% - 100%).

  • Page 74: Part 10 - Start-Up Procedures For The Installer

    PART 10 – START-UP PROCEDURES FOR THE INSTALLER Table 20 – NOTE: It is important to note that the user can adjust the heat curve down by lowering the central heating temperature. A. BOILER CONTROL STATUS MENU The boiler control also has the ability to review the status of the system. To access the status screens, simply press the right arrow .
  • Page 75 This screen displays the domestic hot water temperature set point on the top line. The actual temperature measured by the tank or return line sensor (HTP 7250P-325) is displayed on the bottom DHW SET line. If a mechanical aquastat is used in place of the recommended sensor, the second line will display ‘OFF’...

  • Page 76: Boiler Test Mode

    Press the ▼ key once. This screen displays the seventh oldest lockout fault that occurred in the boiler controller. The top FAULT HISTORY line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line 08/28/2009 Fr 5:19A displays the date and time the fault occurred.

  • Page 77: Test Mode Access

    Press the ▼ key once. CASCADE SYST This screen shows the current system temperature sensor reading on the top line and the cascade CASCADE SET system temperature setting on the bottom. Press the ▼ key once. This screen shows the current cascade power demand output on a per connected boiler basis for BOILER 0 100% boilers addressed as 0 and 1.

  • Page 78: Boiler Error

    The Boiler will not start until a qualified technician has repaired the boiler and pressed the RESET button for more than 1 second. If there is an error message displayed on the readout, and the message “LOCKOUT” is not displayed and the FAULT light is not lit, then the message is the result of a temporary condition and will disappear when the problem corrects itself.

  • Page 79: User Interface Display

    If overheating occurs, or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve.
  • Page 80 Fault Code LOU 1. Check line voltage. It must be between 100 and 128 volts. 2. If available, connect PC, and using HTP service software 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 81 Fault Code F03 This display indicates that the return temperature 1. Check circulator pump operation. sensor of the boiler has failed. This code indicates a 2. Assure that there is adequate flow through the serious safety issue and the boiler will not restart boiler by accessing the status menu and assuring that until the sensor is replaced by a technician and he there is less than a 50°F rise from the return...
  • Page 82 Fault Code F09 1. Watch the igniter through the observation window provided. 2. If there is no spark, check the spark electrode for the proper .196” (5.0 mm ± 1mm) gap. 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.
  • Page 83 Fault Code F13 The fan is not running at the speed that the control 1. Check the combustion air fan wiring. has commanded it to run at. The fan speed had 2. Measure the DC voltage from the red fan wire to been more than 30% faster or slower than the ground while it is connected to the fan.

  • Page 84: Part 12 - Maintenance

    Table 27 PART 12 – MAINTENANCE A. MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the boiler.

  • Page 85: Combustion Chamber Coil Cleaning Instructions For Boiler

    The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”...

  • Page 86: Cleaning Water Side Of Heat Exchanger

    i. Pull the entire burner plate assembly with blower still attached towards you. Remove or push aside any wiring to allow the removal of the assembly. 2. Using a spray bottle filled with the FDA approved lime scale remover, spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate system.
  • Page 87 Figure 33...
  • Page 88 Figure 34...
  • Page 89 Figure 35 – LP-293-A NOTE: Parts listed on the following page.
  • Page 90 ITEM# EL-80 EL-110 EL-150 EL-220 EL-299 EL-399 DESCRIPTION 7450P-039 7450P-039 7450P-039 7450P-039 7450P-065 7450P-065 JACKET - REAR 7450P-055 7450P-055 7450P-056 7450P-038 7450P-064 7450P-068 JACKET - BOTTOM 7450P-121 7450P-121 7450P-121 7450P-121 7450P-121 7450P-121 LEVELING FEET 7450P-057 7450P-059 7450P-060 7450P-036 7450P-061 7450P-066 JACKET - LEFT SIDE 7450P-058 7450P-123...

  • Page 91: Boiler Start-Up Report

    BOILER START-UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED ________________ 1) Fill the Check all piping and gas connections, heating verify all are tight system Pressurize system (12 – 15 psi) ____ PSI Add water to prime condensate cup Percentage of glycol in system (0 – ____ % 50%) Verify near boiler piping is properly...

  • Page 92: Maintenance Report

    MAINTENANCE REPORT 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! Allowing the boiler to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in boiler failure, property damage, personal injury, or death.
  • Page 93 Check gas pipe for Check piping for leaks. Verify that all are properly leaks supported. COMBUSTION CO/CO2 Levels Check CO and CO2 levels in Exhaust (See Start-up Procedures for ranges). Record at high and low fire. SAFETIES ECO (Energy Cut Check continuity on Flue and Water ECO.

  • Page 96: Maintenance Notes

    MAINTENANCE NOTES...

  • Page 97: Htp Customer Installation Record Form

    Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative. Distributor/Dealer: Please insert contact details.

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