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ELITE FT
INSTALLATION
START-UP
MAINTENANCE
PARTS
Models*
EFT-55 / 80 / 110 / 155 / 199 / 285 / 399
*A suffix of “LP” denotes propane gas
*A suffix of “N” denotes natural gas
Heat Exchanger Bears the ASME “H” Stamp
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
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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 BOILER.
Do not try to light any boiler.
Do not touch any electrical switch.
WHAT TO DO IF YOU SMELL GAS
Do not use any phone in your building.
Immediately call your g as supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department. Installation and service must be provided by a qualified installer, service agency, or the gas supplier.
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The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.
DANGER
indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE
NOTICE
is used to address practices not related to personal injury.
FOREWORD
This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the
National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.
Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.
Authority Having Jurisdiction (AHJ)
–
The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or
others having statutory authority
. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ.
NOTE:
HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.
FOR THE INSTALLER
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.
This boiler must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National
Fuel Gas Code, ANSI Z223.1-2002.
INSTALLATIONS MUST COMPLY WITH:
Authority Having Jurisdiction, 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. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100,
Mississauga, Ontario, Canada L4W 5N6.
LP-387 REV. 3.4.15
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Code for the installation of Heat Producing Boilers (latest version), from American Insurance Association, 85 John Street, New York, NY
11038.
The latest version of the National Electrical Code, NFPA No. 70.
NOTE:
The gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in
ANSI Z21.13
– latest edition.
The hydronic supply and return connections of these products are for installation in closed loop systems ONLY!
Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death. Damage or failure of this product (or the system in which it is installed) due to unauthorized use
IS NOT
COVERED BY WARRANTY
.
NOTICE
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, HTP, Inc. has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases.
These features include:
A modulating combustion system that adjusts firing rate based on heat demand.
Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor. The outdoor sensor is supplied by HTP, Inc. with this boiler.
This boiler does not include a standing pilot.
This boiler is designed and shipped to assure the highest efficiency operation possible. Such high efficiency is achieved by limiting heating circuit water temperature to 140°F when there is no anticipated heat load, based upon the outdoor sensor and the Outdoor Reset Curve (sensor response curve) in the boiler software.
This feature may be over-ridden as described below in specific installations:
The boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems (for systems with total input of 300,000 BTU/hr or greater).
See statement below for an important notice on the use of the override.
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.
This boiler is not used for space heating.
This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.
This boiler is equipped with a tankless coil.
NOTICE
The CSD-1 ASME Code, Section CW-400 requires that hot water heating and supply boilers have a) a UL 353 temperature control device, b) at least one (1) temperature-actuated control to shut off the fuel supply when system water reaches a preset operating temperature, c) a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout, and d) its own sensing element and operating switch.
Certain AHJs, locales, and states will require that commercial boiler installations meet the CSD-1 ASME Code, Section CW-400. To meet this code, HTP, Inc. has integrated a temperature control system into the 926 control provided with this heating appliance. This control system complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature difference between the inlet and the outlet sensor, which is affected by boiler water flow. If this temperature difference exceeds 55°F (typically because of low water flow or very low heat load), the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F, the control will effectively sense there is little or no water flow or heat load and shut the boiler down. The controller will restart automatically once the temperature difference has dropped below 55°F and the minimum off time (anticycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 199°F, the boiler is put into a hard lockout and requires manual reset to restart.
Installers should review the regulations of the AHJ, local and state code authorities, and utility companies which pertain to this type of boiler BEFORE performing installation.
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TABLE OF CONTENTS
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LP-387 REV. 3.4.15
PART 1 – GENERAL SAFETY INFORMATION
A. PRECAUTIONS
This boiler is for indoor installations only. Clearance to combustible materials: 6
” top, bottom, and sides, 0” back. Left side has all boiler mechanical connections.
Front must have room for service, 24” recommended. (A combustible door or removable panel is acceptable front clearance.) This boiler has been approved for closet installation. Do not install this boiler directly on carpeting. For installation on combustible flooring. Category IV vent systems only.
8
INSTALLER
–
Read all instructions in this manual before installing. Perform steps in the order given.
USER
–
This manual is for use only by a qualified heating installer/service technician. Have this boiler serviced/inspected by a qualified service technician annually.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS BOILER SERVICED/INSPECTED ANNUALLY
CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
NOTE:
When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.
DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER.
Immediately call a qualified service technician. The boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged boiler could result in property damage, severe personal injury, or death.
NOTE:
Boiler damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.
Be sure to disconnect electrical power before opening boiler cabinet or performing service. Failure to do so could result in an electrical shock that could result in property damage, serious personal injury, or death.
NOTE:
If the boiler is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman:
1. FIRE
2. DAMAGE
3. WATER
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
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.
B. IMPROPER COMBUSTION
Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. Failure to keep the vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.
C. GAS
Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the boiler.
D. WHEN SERVICING THE BOILER
To avoid electric shock, disconnect electrical supply before performing maintenance.
To avoid severe burns, allow boiler to cool.
E. BOILER SYSTEM
Thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. HTP recommends a suction strainer in all systems.
LP-387 REV. 3.4.15
Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.
Do not use “homemade cures” or “boiler patent medicines”. Substantial property damage, damage to boiler, and/or serious personal injury may result.
Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen from make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once.
F. BOILER WATER CHEMISTRY
Sodium less than 20mGL.
Water pH between 6 and 8 o
Maintain water pH between 6 and 8. Check with litmus paper or have it chemically analyzed by water treatment company. o
If the pH differs from above, consult local water treatment company for treatment needed.
Hardness less than 7 grains o
Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).
Chlorine concentration less than 100 ppm o
Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm. o
Do not connect the boiler to directly heat swimming pool or spa water. o
Do not fill boiler or operate with water containing chlorine in excess of 100 ppm.
NOTE:
It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup. To clean the heat exchanger, follow the maintenance procedure in Part 13, Section B of this manual.
ACIDITY
CONDUCTIVITY
CHLORIDE
6 to 8 pH
Less than 400 uS/cm at 25 o
C
IRON
COPPER
SODIUM
Less than 100 ppm
Less than 0.5 mg/L
Less than 0.1 mg/L
Less than 20 mg/L
HARDNESS
Table 1
– Water Quality Requirements
Less than 7 Grains
G. FREEZE PROTECTION FLUIDS
9
NEVER
use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems, with this boiler. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. 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.
PART 2 – BEFORE YOU START
A. WHAT’S IN THE BOX
Also included with the boiler:
Temperature and Pressure Gauge (Part #7500P-098)
Pressure Relief Valve (Part #7250P-080 for EFT-55/80/110/155/199, #7350P-066 for EFT-285/399)
Wall Mount Bracket (Part # 7600P-021 for EFT-55/80/110, #7600P-121 for EFT-155/199/285, #7600P-221 for EFT-399)
Indirect Sensor (Part # 7250P-325)
Outdoor Sensor (Part # 7250P-319)
Intake PVC Tee with Screens
Exhaust PVC Coupling with Screens
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Installation Manual
Warranty
CSD-1 Form
H-2 Data Sheet
NAT to LP Conversion Kit (Included with NAT models)
B. HOW BOILER OPERATES
ELITE FT
®
condensing technology intelligently delivers hydronic heating while maximizing efficiency. Outlined below are the features of the system and how they operate:
Stainless Steel Heat Exchanger
- The highly efficient stainless steel heat exchanger is designed to extract all available heat from the supply line before it is exhausted.
Modulating Combustion System
- The combustion system will modulate the output of the burner during operation to match the system demand and achieve the control set point while in operation. The set point can change by internal or external signals which enhance the overall performance of the system.
Control
– The integrated control system monitors the system and regulates fan speed to control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more.
The control can be set up to monitor outdoor temperature through an outdoor sensor to regulate boiler set point. The system can be further enhanced by installing an indirect water heater to provide domestic hot water.
The control can regulate the output of multiple boilers through its cascade system function. The cascade system is capable of connecting up to eight boilers together in such a way that they function as one boiler system. This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize efficiency.
The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating input from the connected boilers. Each cascaded boiler will have its own pump to provide maximum flow and control heat exchanger flow rate.
Text Display and Operational LED Light Indicators
– The display allows the user to change system parameters and monitor system outputs.
Gas Valve
– Senses suction from the blower, allowing gas to flow only if powered and combustion air is flowing.
All Metal Integrated Venturi
– Controls air and gas flow into the burner.
Burner
– Constructed of high grade stainless steel, the burner uses premixed air and gas fuel and provides a wide range of firing rates.
Spark Ignition
– The burner is ignited by applying high voltage through the system spark electrode. This causes the spark from the electrode to ignite mixed gas off of the burner.
Supply Water Temperature Sensor
– This sensor monitors boiler outlet water temperature (System Supply). The control adjusts boiler firing rate so the supply temperature will match boiler set point.
Return Water Temperature Sensor
– This sensor monitors the boiler return water temperature (System Return).
Flue Sensor
– Monitors flue temperature and adjusts firing rate.
Temperature and Pressure Gauge
– Allows the user to monitor system temperature and pressure.
Electrical field connections with terminal strips
– The electrical cover allows easy access to the line voltage and low voltage terminals strips which are clearly marked to facilitate wiring of the boiler.
Condensation Collection System
– This boiler is a high efficiency boiler, and will produce condensate. The collection system has a float switch which monitors the condensation level and prevents condensation from backing up into the combustion system. Inside the collection system there is a built in trap which seals the combustion system from the connected drain. This condensate should be neutralized to avoid damage to the drainage system or piping.
Outdoor Sensor
– The outdoor sensor monitors outdoor temperature and adjusts boiler set point to provide greater efficiency.
0-10 Volt Input
– Allows Installer to connect a BMS (Building Management System) to control the boiler.
Condensate Flue Check System
– The check system prevents exhaust from the heat exchanger from backing up into cabinet.
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Pump Service Mode
– Allows manual operation of pumps to commission system and check pump operation.
The Vision II System (Optional)
– Allows the user to supply mixed temperatures in up to eight zones. The Vision 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:
System Sensor (Part # 7250P-324)
Indirect Tank Sensor (Part # 7250P-325)
3" PVC Concentric Vent Kit (Part # KGAVT0601CVT)
3” Stainless Steel Outside Termination Vent Kit (Part # V1000)
4” Stainless Steel Outside Termination Vent Kit (Part # V2000)
6” Stainless Steel Outside Termination Vent Kit (Part # V3000)
3” Polypro Vent Kit (Part # 8400P-001)
3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)
U.L. 353 Compliant Low Water Cut-Off Interface Kit with Manual Reset (Part # 7600P-104 for EFT-55/80/110, #7600P-990 for all other models)
Manual Reset High Limit (Part # 7450P-217)
Alarm System (Part # 7350P-602) (to monitor any failure)
PC Connection Kit (Part # 7250P-320)
Condensate Neutralizer (Part # 7450P-212)
Condensate Removal Pump (Part # 554200)
Flow Switch Kit (Part # 7450P-213)
Vision II (Part # 7250P-322)
NOTE:
When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system efficiency.
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. BEFORE LOCATING THE BOILER
Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the boiler installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.
Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty.
1. Installation Area (Mechanical Room) Operating Conditions
Ensure ambient temperatures are higher than 32 o
F/0 o
C and lower than 104 o
F/40 o
Avoid continuously high levels of humidity
C.
Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual, Part 3, Section F.
Never close existing ventilation openings
The service life of the boiler’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other boiler components. In these environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.
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This boiler is certified for indoor installations only. Do not install the boiler outdoors. Failure to install this boiler indoors could result in substantial property damage, severe personal injury, or death.
2. Check for nearby connections to:
System water piping
Venting connections
Gas supply piping
Electrical power
Condensate drain
3. Check area around boiler. Remove any combustible materials, gasoline, and other flammable liquids.
Failure to keep boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.
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.
Incorrectly-sized expansion tank
6. Clean and flush system when reinstalling a boiler.
NOTE:
When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the boiler model and serial number.
Gas conversion should be performed BEFORE the boiler is installed. Carefully follow the gas conversion instructions when performing the conversion. Failure to do so could result in property damage, severe personal injury, or death.
Consider boiler piping and installation when determining boiler location.
B. LEVELING
In order for the condensate to properly flow out of the collection system, the boiler must be installed level. The location must also support the boiler when it is full of water.
C. CLEARANCES FOR SERVICE ACCESS
service the boiler without removing it from the space.
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Figure 1
– Required Clearances
Space must be provided with combustion/ventilation air openings correctly sized for all other boilers located in the same space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the mechanical room. This is particularly important if the boiler is in a room with other boilers. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.
Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.
MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS
Hot water pipes
– at least 1” from combustible materials.
Exhaust vent pipe
– at least 1” from combustible materials.
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SPECIFICATIONS AND DIMENSIONS
14
Figure 2
– LP-387-K
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D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS
Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage, closet, or alcove. 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.
PRECAUTIONS
If the boiler is located in a residential garage, it should be installed per the latest edition of the National Fuel Gas Code, ANSI Z223.1, and CGA-B149 Installation Code in Canada.
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.
Locate or protect the boiler so it cannot be damaged by a moving vehicle.
For closet or alcove installations, a two pipe venting system must be used. Failure to follow this warning could result in substantial property damage, severe personal injury, or death.
The space must be provided with correctly sized combustion/ventilation air openings for all other boilers located in the space with the boiler. Do not install the boiler in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.
NOTE:
For installations using room air for combustion, refer to the boiler venting section, Part 6 in this manual.
E. EXHAUST VENT AND INTAKE PIPE
The appliance is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.
NOTE: The venting options described here (and further detailed in the Venting section of this manual) are the lone venting options approved for this appliance. Failure to vent the appliance in accordance with the provided venting instructions will void the warranty.
Failure to vent the appliance properly will result in serious personal injury or death.
Vents must be properly supported. Appliance exhaust and intake connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the appliance and the balance at 4’ intervals. Appliance must be readily accessible for visual inspection for the first 3’ from the appliance.
1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE
If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.
Unbalanced Venting.
Be sure to locate the appliance such that the exhaust vent and intake piping can be routed through the building and properly terminated. Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional
Equipment in Venting Section). The exhaust vent and intake piping lengths, routing and termination methods must all comply with the methods and limits given in the Venting section of this manual.
When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air.
NOTE: To prevent combustion air contamination, see
Table 2
.
2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE
This appliance 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 2
.
Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the appliance input.
Never obstruct the supply of combustion air to the appliance.
If the
LP-387 REV. 3.4.15
16 appliance is installed in areas where indoor air is contaminated (see Table 2) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection.
Unconfined space
is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.
Confined space
is space with volume less than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.
When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening
2 should have a free area of one square inch per 1,000 Btu/hr (22cm than 100 square inches (645cm
2
).
/kW) of the total input of all appliances in the space, but not less
If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the
Venting Section of this manual.
When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.
Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty, and may result in severe personal injury or death.
Failure to provide an adequate fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death.
To prevent combustion air contamination, see
Table 2
.
F. PREVENT COMBUSTION AIR CONTAMINATION
Install intake piping for the boiler as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.
PRODUCTS TO AVOID
Spray cans containing fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric or Muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, laundry detergents, and cleaning solvents
Adhesives used to fasten building products
Table 2
AREAS LIKELY TO HAVE CONTAMINANTS
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages and workshops
You must ensure that intake air will not contain any of the contaminants listed in Table 2. For example, do not pipe intake vent near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death.
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NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO
CORROSIVE VAPORS IS NOT COVERED BY WARRANTY.
(Refer to the limited warranty for complete terms and conditions).
G. REMOVING AN BOILER FROM A COMMON VENT SYSTEM
Do not install the boiler into a common vent with any other boiler. This will cause flue gas spillage or boiler 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.
When removing an existing boiler, the following steps must be followed.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion or other deficiencies that
Figure 3
– CO Warning Label
could cause an unsafe condition.
3. If practical, close all building doors, windows and all doors between the common venting system and other spaces in the building.
Turn on clothes dryers and any boilers not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all fireplace dampers.
4. Place in operation the boiler being inspected. Follow the lighting instructions. Adjust the thermostat so the boiler will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette.
6. After it has been determined that each boiler remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning boiler to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas
Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.
PART 4 – PREPARE BOILER
UNCRATING BOILER
– Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Cold weather handling
– If boiler has been stored in a very cold location (below 0 o
F) before installation, handle with care until the plastic components come to room temperature.
A. REMOVE THE BOILER FROM PACKAGING
Remove all sides of the shipping crate, and the wooden block that holds the boiler in place during shipping. Slide the boiler from the mounting bracket, which is affixed to the skid (Figure 4 and 5). Remove the mounting bracket from the crate (Figure 5). Take care to place the boiler in a safe location prior to installation to prevent damage to the mechanical connections.
LP-387 REV. 3.4.15
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Figure 4
– Pallet with Mounting Bracket Affixed
Figure 5
–Boiler Mounted to Bracket
B. WALL MOUNTING CONSIDERATIONS
These boilers are wall mounted. Use only the wall mounting instructions included in this manual.
Ensure the wall that the boiler is intended to be mounted on is comprised of cement, brick, block, or wooden studs spaced 16” apart from center. Ensure the wall is capable of supporting at least 250 lbs (115 kg) for EFT-55
– 110 models, 300 lbs (136 kg) for EFT-155 –
285 models, and 500 lbs (227 kg) for EFT-399.
If flooding is possible, elevate the boiler to prevent floodwater from reaching the boiler.
Ensure the boiler is installed in a location that minimizes the risk of water damage due to leaking valves, pumps, unions, etc.
The mounting location must be capable of carrying the weight of the boiler and its related components. If the mounting location cannot support a minimum of 250 lbs. (115 kg), it is recommended to locate the boiler in a mounting location that can support the minimum weight. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.
C. WALL MOUNTING INSTRUCTIONS
This boiler is too heavy for one person to lift. It is highly recommended to install the boiler with two people. Use caution as to not drop the boiler, which could damage the boiler and cause property damage and/or severe personal injury. Verify that the boiler is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.
Figure 6
– Wall Mounting Bracket – NOTE: Drawing for Demonstration Purposes ONLY
This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.
DO NOT use the bolts included in shipping for wall mounting the boiler. Doing so may result in property damage, serious injury, or death.
1. MOUNTING TO A WOOD STUDDED WALL
a. The building frame (studs) must be 2 X 4 minimum and
16” on center (24” on the EFT-399). If not, you must use ½” minimum plywood 24” x 48” with at least fourteen (14) #12 x 3” (3/16” x 3”) round head tapping screws to the frame of the building to provide proper support for the boiler. No alternate methods of mounting or fastening (ex. Toggle bolts, hollow wall anchors, or any other fastener) may be used.
LP-387 REV. 3.4.15
19 b. The provided mounting bracket must be mounted directly to the center of at least 2 studs using standard steel or stainless steel
¼” x
2 ½
” lag bolts for all models. Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location.
Ensure the marked holes are located in the center of the building frame (studs). c. For all EFT models,
2 ½” is the minimum lag bolt length if the bracket is directly on stud. Increase lag bolt length for any materials covering the studs. d. Predrill pilot holes on the marked stud locations. The pilot holes for bare studs should be
2” deep for all EFT models. See table below for pilot hole diameter by wood type. Increase length for any material covering the stud. Ensure that the predrilled holes are straight and square to the wall. Failure to do so could lead to insufficient support or out of level boiler. See Figure 6.
NOTE:
Bolt must embed into the wood structure a minimum of 2”. d. Using the predrilled holes, mount the hanger bracket to the building frame (studs) using the appropriately sized standard steel (or stainless) lag bolt. Hang boiler on the wall mounted bracket. Be sure that the bracket is engaged before letting the boiler hang free.
Slowly release the weight of the boiler while ensuring that the bracket is properly secured. Verify that the boiler is securely mounted before leaving the boiler unsupervised.
REQUIRED AMOUNT OF BOLTS FOR WALL MOUNTING THE EFT BOILER
MODEL
EFT-55
– EFT-110
EFT-155
– EFT-285
EFT-399
AMOUNT OF BOLTS
2
4
6
PILOT HOLE SIZE BY WOOD TYPE
TYPE
SOFT
HARD
DRILL BIT SIZE
3/32
”
3/16”
If the boiler is not installed vertically plumb, improper and unsatisfactory operation may occur, causing excessive condensation build-up, nuisance fault codes, and unnecessary maintenance.
2. MOUNTING TO A METAL FRAME
a. The provided mounting bracket must be mounted to the center of at least 2 studs using standard steel or stainless steel toggle bolts
3/16” diameter or larger, and at least 2” long for direct mounting on stud for EFT-55 – 110 models, and 3/8” diameter or larger, and at least 2” long for EFT-155 – 399 models for direct mounting on at least 18 gauge studs. Be sure the bracket is level and mark the hole location of the top bracket height and horizontal stud location. Ensure the marked holes are located in the center of the building frame
(studs). b. 2” is the minimum toggle bolt length if the bracket is directly on stud. Increase length for any materials covering the studs. c. Predrill holes on the marked stud locations. The predrilled holes should be ½” in diameter for 3/16” bolts, and ¾” in diameter for 3/8” bolts, to allow for the collapsed wings of the toggle to slide through. Ensure that the predrilled holes are straight and square to the wall.
Failure to do so could lead to insufficient support of out of level boiler. See Figure 6. d. Using the predrilled holes, mount the hanger bracket to the building frame (studs) with the toggle bolts. Ensure that the bolt toggles are through the stud and expanded catching the inside of the stud. Tighten the toggle bolt until the mounting bracket is secure. Hang boiler on the now wall mounted bracket. Be certain that the bracket is engaged before letting the boiler hang free. Slowly release the weight of the boiler while ensuring the bracket is properly secure. Verify that the boiler is securely mounted before leaving it unsupervised.
If the boiler is not installed upright and level, improper and unsatisfactory operation may occur, causing excessive condensation buildup, nuisance fault codes, and unnecessary maintenance.
PART 5 – BOILER PIPING
Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death.
LP-387 REV. 3.4.15
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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.
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 a storage tank to supply domestic hot water. HTP offers 60/80/119/175 gallon size storage tanks in either stainless steel or glass-lined construction. These storage tanks can be directly connected to the boiler supply and return connection.
The National Standard Plumbing Code, the National Plumbing Code of Canada, and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. The heat transfer th fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5
Edition.
A. GENERAL PIPING INFORMATION
The building piping system must meet or exceed the piping requirements in this manual.
Use two wrenches when tightening water piping at the boiler. Use one wrench to prevent the boiler return or supply line from turning.
Failure to prevent piping connections from turning could cause damage to boiler components.
The control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module may also provide low water protection (through the addition of an optional kit) by sensing the water level in the heat exchanger.
An optional flow switch may be installed on the supply of the system to activate the boiler when there is enough flow. Some codes/jurisdictions may require additional external controls.
NOTE:
The addition of a high temperature limiting device is important if the boiler is to be connected to a domestic hot water system.
B. RELIEF VALVE
To avoid water damage or scalding due to relief valve operation:
Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge.
Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.
D ischarge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly visible.
Discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375 o
F or greater.
Do not pipe discharge to any location where freezing could occur.
No shutoff valve may be installed between the relief valve and boiler or in the discharge line. Do not plug or place any obstruction in the discharge line.
Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.
Test relief valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the boiler
“off”
and call a plumber immediately.
Take care whenever operating relief valve to avoid scalding injury or property damage.
For boilers installed with only a pressure relief valve, the separate storage vessel must have a temperature and pressure relief valve installed. This relief valve shall comply with
Relief Valves for Hot Water Supply Systems, ANSI Z21.22 CSA4.4.
FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION,
RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
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C. BACKFLOW PREVENTER
Use a backflow preventer specifically designed for hydronic installations. This valve should be installed on the cold water fill supply line per local codes (see Piping Details, Part 5, Section G).
D. SYSTEM WATER PIPING METHODS
EXPANSION TANK AND MAKE-UP WATER
1. Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature. For sizing information, refer to expansion tank manufacturer’s sizing guidelines or the latest ASHRAE expansion tank sizing standards.
Expansion tanks must be sized according to total system volume. This includes all length of pipe, all fixtures, boilers, etc. Failure to properly size system expansion could result in wasted time, money, and possible property damage, personal injury, or death.
MODEL
EFT-55 / EFT-80
EFT-110
EFT-155
EFT-199
EFT-285
EFT-399
ADDED VOLUME TO SYSTEM BY ELITE FT BOILER
GALLONS
2.2
2.6
6.2
6.1
6.1
7.9
Table 3
Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual boiler failure can result due to excessive make-up water addition.
SUCH FAILURE IS NOT COVERED BY WARRANTY.
2. The expansion tank must be located as shown in Part 5, Boiler Piping, or following recognized design methods. See expansion tank manufacturer’s instructions for details.
3. Connect the expansion tank to the air separator only if the air separator is on the side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system.
DO NOT
install automatic air vents on closed type expansion tank systems. Air must remain in the system and return to the tank to provide an air cushion. An automatic air vent would cause air to leave the system, resulting in improper operation of the expansion tank.
DIAPHRAGM (OR BLADDER) EXPANSION TANK
Always install an automatic air vent on top of the air separator to remove residual air from the system.
E. CIRCULATORS
DO NOT
use the boiler circulator in any location other than the ones shown in this manual. The boiler circulator location is selected to ensure adequate flow through the boiler. Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insufficient flow.
Sizing Space Heat System Piping
1. See Piping Details, Part 5, Section G. In most diagrams, the space heating system is isolated from the boiler loop by the primary/secondary connection.
2. Size the piping and components in the space heating system using recognized design methods.
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F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS
This boiler is designed to function in a closed loop hydronic system. It is recommended to install a temperature and pressure gauge (not included with the boiler) to allow the user to monitor system pressure and outlet temperature from the boiler. It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators. Unless the system has a closed type expansion tank, each boiler installation must have an air elimination device that will remove air from the system.
Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) Allow clearance for basic service of boiler circulator, valves and other components.
Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials.
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 # 7600P-104 for EFT-55
– 110 models, 7600P-990 for EFT-155 – 399 models). 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.
Chilled water medium must be piped in parallel with, and isolated from, the boiler. Freeze protection for new or existing systems must use glycol that is specifically formulated for this purpose. Antifreeze must include inhibitors that will prevent the glycol from attacking the metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping. Example: 50% by volume glycol solution expands 4.8% in volume for a temperature increase from 32 o
F to 180 o
F, while water expands 3% with the same temperature rise.
G. PIPING DETAILS
Mixing valves are required for the protection of low temperature loops.
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Figure 7
– Near Boiler Piping* –
NOTE: This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. *Top / Bottom Supply / Return Connections available on EFT-155, EFT-199, EFT-285, and
EFT-399 Models ONLY
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 boiler to prevent gravity circulation.
LP-387 REV. 3.4.15
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Figure 8
– Piping Symbol Legend
LP-387 REV. 3.4.15
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Figure 9
– Standard Piping with Zone Valves and DHW Priority -
NOTES:
1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.
2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.
4. The
minimum
pipe size for connecting a SuperStor indirect water heater is 1”
5. The
minimum
pipe size for connecting an EFT-55 or 80 - 1
”.
6. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.
7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 o
F.
8. Piping shown is Standard.
VERY IMPORTANT:
Minimum flow rates outlined in the manual must be maintained to minimize short cycling
.
9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
LP-387 REV. 3.4.15
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Figure 10 - Standard Piping with Pumps and DHW Priority - NOTES:
1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.
2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.
4. The
minimum
pipe size for connecting a SuperStor indirect water heater is 1”
5. The
minimum
pipe size for connecting an EFT-55 or 80 - 1
”.
6. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.
7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 o
F.
8. Piping shown is Standard.
9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
10.
VERY IMPORTANT
– Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.
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Figure 11
– Primary/Secondary Boiler Piping – Zone Valves and DHW Priority – Outdoor Reset - NOTES:
1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.
2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.
4. The
minimum
pipe size for connecting a SuperStor indirect water heater is 1”
5. The
minimum
pipe size for connecting an EFT-55/80/110 - 1
”, EFT-155/199/285 – 1.25”, EFT-399 – 1.5”.
6. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.
7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 o
F.
8. Piping shown is Primary/S econdary. System flow (secondary loop) must be greater than the boiler’s primary loop flow.
9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
10.
VERY IMPORTANT
– Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.
LP-387 REV. 3.4.15
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Figure 12
– Primary/Secondary Boiler Piping – Pumps and DHW Priority – Outdoor Reset - NOTES:
1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.
2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.
4. The
minimum
pipe size for connecting a SuperStor indirect water heater is 1”
5. The
minimum
pipe size for connecting an EFT-55/80/110 - 1
”, EFT-155/199/285 – 1.25”, EFT-399 – 1.5”.
6. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.
7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 o
F.
8. Piping shown is Primary/Se condary. System flow (secondary loop) must be greater than the boiler’s primary loop flow.
9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
10.
VERY IMPORTANT
– Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.
LP-387 REV. 3.4.15
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Figure 13
– Multiple Boilers – Primary/Secondary Piping – Circulators - NOTES:
1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.
2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.
4. The
minimum
pipe size for connecting a SuperStor indirect water heater is 1”
5. The
minimum
pipe size for connecting an EFT-55/80/110 - 1
”, EFT-155/199/285 – 1.25”, EFT-399 – 1.5”.
6. Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with circulator flanges as an alternative.
7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 o
F.
8. Piping shown is Primary/Secondary. System flow (secondary loop) must be greater than the boiler’s primary loop flow.
9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
10.
VERY IMPORTANT
– Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.
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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. Connect the system return marked “Boiler Return”.
2. Connect the system supply marked “Boiler Supply”.
3. Install a purge and balance valve or shut off valve and drain on the system return to purge air out of each zone.
4. Install a back flow preventer on the cold feed make-up water line.
5. Install a pressure reducing valve on the cold feed make-up water line (15 psi nominal on the system return). This boiler has a maximum working pressure of 160 psi. You may order a higher pressure relief valve kit from the factory. Check temperature and pressure gauge when operating. It should read a minimum pressure of 12 psi.
6. Install a circulator as shown in piping details (this section). Make sure the circulator is properly sized for the system and friction loss.
7. Install an expansion tank on the system supply (see Part 5, Section D for water volume). Consult the expansion tank manufa cturer’s instructions for specific information relating to expansion tank installation. Size the expansion tank for the required system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. NOTE: The boiler cannot be drained completely of water without purging the boiler with an air pressure of 15 psi.
10. The relief valve and temperature and pressure gauge are included in the boiler accessory kit. A pipe discharge line should be installed 6” above the drain in the event of pressure relief. The pipe size must be the same size as the relief valve outlet.
NEVER
BLOCK THE OUTLET OF THE SAFETY RELIEF VALVE.
I. CIRCULATOR SIZING
heat exchanger.
Table 4
– Boiler Pressure Drop
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The chart below represents the various system design temperature rise through the boiler along with their respective flows and friction loss, which will aid in circulator selection.
Table 5
– Boiler Flow Rates
In addition, the boiler heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator.
Minimum boiler flow rates are listed in the table below.
MINIMUM BOILER FLOW RATES
MODEL
EFT-55
MINIMUM FLOW RATE (GPM)
3.5
EFT-80
EFT-110
EFT-155
EFT-199
EFT-285
EFT-399
Table 6
– Minimum Boiler Flow Rates
5.4
7
9.7
12.5
17.9
25
The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit. To size, simply add up the number of boilers and the required flow rates for the system design temperature.
Example: (5) EFT-55 boilers with a design of 20°
Δt degree temperature rise with each boiler having an individual flow rate of 5.3 GPM.
To correctly size the manifold feeding these (5) boilers you would need a pipe size of 2
”.
MULTIPLE BOILER MANIFOLD PIPING
Maximum Flow Rate
(GPM at 3 feet per second)
Schedule 40 Pipe Diameter (Inches)
8
1
14
1¼
19
1½
31.5
2
45
2½
69
3
93
3½
120
4
150
4½
188
5
271
6
Table 7
J. CHECK/CONTROL WATER CHEMISTRY
NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY.
Sodium less than 20 mGL
Water pH between 6 and 8
1. Maintain boiler water pH between 6 and 8. Check with litmus paper or have chemically analyzed by water treatment company.
2. If pH differs from above, consult local water treatment company for treatment needed.
Hardness less than 7 grains
Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).
Chlorine concentration less than 100 ppm
1. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm.
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.
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ACIDITY
CONDUCTIVITY
CHLORIDE
IRON
COPPER
SODIUM
HARDNESS
Table 8
– Water Quality Requirements
6 to 8 pH
Less than 400 uS/cm at 25 o
C
Less than 100 ppm
Less than 0.5 mg/L
Less than 0.1 mg/L
Less than 20 mg/L
Less than 7 Grains
Clean system to remove sediment*
1. You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.
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. Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section (Part 14 of this manual).
Test/replace freeze protection fluid
1. For sy stems using freeze protection fluids, follow fluid manufacturer’s instructions to verify inhibitor level and that other fluid characteristics are satisfactory.
2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions.
Piping components
Heating system piping:
Water boiler system piping MUST be sized per technical pipe requirements listed in Tables 4 through 7.
Reducing pipe size can restrict flow rate through the water boiler, causing inadvertent short cycling and poor system performance.
Check valves:
Field supplied. Check valves are recommended for installation as shown in Piping Details.
Water boiler isolation valves:
Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the water boiler.
Mixing valve:
Field supplied. A mixing valve is recommended when storing domestic hot water above 115°F.
Unions:
Field supplied: Recommended for boiler serviceability.
DO NOT USE DIELECTRIC UNIONS! ONLY BRASS, COPPER, OR
STAINLESS STEEL.
Pressure relief valve:
Factory supplied on Boiler. The pressure relief valve is sized to ASME specifications. Storage tank may require additional relief valves depending on local codes.
MINIMUM PIPE SIZES
EFT-55, EFT-80, EFT-110
EFT-155, EFT-199, EFT-285
EFT-399
1” NPT or Copper
1 ¼” NPT or Copper
1 ½” NPT or Copper
Table 9
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. Close the other side of the balance and purge valve or shut off valve after the drain.
3. Open the first zone balance and purge or drain valve to let water flow out of the hose. If zone valves are used, open the valves one at a time manually. NOTE: You should check zone valve manufacturer’s instructions prior to opening valves manually, so as not to damage the zone valve.
4. Manually operate fill valve regulator. When water runs out of the hose, you will see a steady stream without bubbles. Close the balance and purge valve or drain to stop the water from flowing. Disconnect the hose and connect it to next zone to be purged.
5. Repeat this procedure for additional zones (one at a time).
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For installations that incorporate standing iron radiation and systems with manual vents at the high points, follow the previous section and, starting with the nearest manual air vent, open the vent until water flows out. Then close the vent. Repeat the procedure, working your way toward the furthest air vent. It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary.
Upon completion, make sure that the fill valve and zone valves are in automatic positions. You must also assure the purge and shut off valves are in open positions.
L. GLYCOL ANTIFREEZE SOLUTIONS
Glycol in hydronic applications should include inhibitors that prevent the glycol from attacking metallic system components.
Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level.
The glycol solution should be tested at least once a year or as recommended by the glycol manufacturer.
Anti-freeze solutions expand more than water. For example: A 50% by volume solution expands 4.8% in volume for a temperature increase from 32 o
F to 180 o
F, while water expands 3% over the same temperature rise. Allowances must be made in system design for expansion.
A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.
A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator.
Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Glycol mixtures should not exceed 50%.
It is highly recommended to 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.
M. ZONING WITH ZONE VALVES
1. When zoning with zone valves, connect the boiler to the system as shown in Piping Details, Part 5, Section G. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. It also avoids applying the high head of the boiler circulator to the zone valves.
2. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Piping Details.
N. ZONING WITH CIRCULATORS
1. When using circulator zoning, connect the boiler to the system as shown in Piping Details, Part 5, Section G.
NOTE:
The boiler circulator cannot be used for a zone. It must only supply the boiler loop.
2. Install a separate circulator for each zone.
3. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Piping Details.
O. MULTIPLE BOILERS
1. Connect multiple boilers as shown in Piping Details, Part 5, Section G.
2. All piping shown is reverse return to assure balanced flow throughout the connected boilers.
3. Each connected boiler must have its own circulator pump to assure adequate flow.
4. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Piping Details.
5. The system flow (secondary loop) must be greater than the boiler
’s primary loop flow.
LP-387 REV. 3.4.15
34
PART 6 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL
The boiler must be vented as detailed in this Venting 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 with the instructions provided in this manual. Failure to properly install the vent system will result in property damage, severe personal injury, or death.
A. GENERAL
This boiler is certified as a “Category IV” appliance, and requires a special venting system. The vent system will operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions.
Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting instructions below carefully. Failure to do so will result in substantial property damage, severe personal injury, or death.
1. Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.
2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
CAN/CGA B149, and/or applicable provisions of local building codes.
3. This boiler must be vented with materials, components, and systems listed and approved for Category IV boilers.
Exhaust vent and intake pipes are to be piped separately. This boiler cannot share a common exhaust or intake with multiple appliances. Failure to follow this instruction will result in substantial property damage, severe personal injury, or death.
NOTE:
To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors.
NOTE:
If exhaust vent pipe system passes through an unheated space, such as an alcove or attic, the space must be heated or the pipe must be insulated. The insulation must have an R value sufficient to prevent freezing of the condensate.
Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent is properly beveled and seated before insertion into the flue adapter. Failure to do so could result in property damage, severe personal injury, or death.
Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’ responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.
LP-387 REV. 3.4.15
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B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE
Item
Exhaust vent or Intake pipe and fittings
Pipe cement/primer
APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL
Standards for Installation in:
Material
United States Canada
PVC schedule 40/80
PVC-DWV*
CPVC schedule 40/80
Polypropylene
ANSI/ASTM D1785
ANSI/ASTM D2665*
ANSI/ASTM F441
UL-1738
PP, CPVC, and PVC venting must be
ULC-S636 Certified. IPEX is an approved manufacturer in Canada, supplying vent material listed to ULC-
S636.
Stainless Steel AL29-4C
PVC
CPVC
Certified for Category IV and direct vent appliance venting
ANSI/ASTM D2564
ANSI/ASTM F493
Certified for Category IV and direct vent appliance venting
IPEX System 636 Cements & Primers
The exhaust and intake components installed with this boiler must be used for near boiler piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID boiler warranty.
PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.
Do NOT use Foam Core Pipe in any portion of the exhaust piping from this boiler.
DO NOT connect PVC/CPVC to PP without an approved vent connector.
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.
*PVC-DWV for air intake applications ONLY.
Failure to follow these directions will result in substantial property damage, severe personal injury, or death.
Table 10
– Approved Materials for Exhaust Vent and Intake Pipe
DO NOT mix components from different venting systems without proper adapters. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, primer and cement, and adapters specifically designed for the material used, as listed in Table 10. Failure to do so could result in property damage, severe personal injury, or death.
Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. 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. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.
For closet and alcove installations: CPVC, polypropylene, or stainless steel venting material MUST BE USED. Failure to follow this statement could result in product damage, severe personal injury, or death.
NOTE:
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.
High heat sources (sources generating heat 100 o
F / 37 o
C or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this boiler and related components near high heat sources.
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. The first three (3) feet of vent pipe from the boiler flue outlet must be readily accessible for visual inspection.
3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings.
LP-387 REV. 3.4.15
36
Cellular foam core piping may be used on air inlet piping
only
.
You must not use “B” vent in an exhaust application. “B” vent is for intake applications
ONLY
. Using “B” vent in an exhaust application will result in serious injury or death.
D. EXHAUST VENT AND INTAKE PIPE LOCATION
Figure 14
– ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems
DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION
– FIGURE 14 NOTES:
A.
Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation level. Snow removal may be necessary to maintain clearance.
B.
Provide a minimum of 1 foot distance from exhaust vent termination to any door, operable window, or gravity intake into any building.
C.
Provide a minimum of 1 foot distance from exhaust vent termination to any permanently closed door or window.
D.
Provide a minimum of 4 feet vertical clearance from the exhaust vent to all roof overhangs.
E.
Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather, and could result in blockage of the exhaust vent. To prevent icicles from forming, maintain 4 feet vertical clearance from the exhaust vent to all roof overhangs.
F.
Provide 4 feet clearance from the outside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs.
G.
Provide 6 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs.
H.
Provide 4 feet clearance from center line within a height of 15 feet above electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets.
I.
Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained.
J.
This boiler vent system shall terminate at least 3 feet (0.9 m) above any forced air intake located within 10 ft (3 m).
NOTE:
This does not apply to the combustion air intake of a direct-vent appliance.
K.
When venting with a two pipe system, maximum distance between exhaust vent and intake pipe is 6 feet (1.8 m). Minimum distance between exhaust vent and intake pipe on single direct vented appliance is 10” (0.255 m) center-to-center. Minimum distance between exhaust vents and intake pipes on multiple boiler s is 10” (0.255 m) center-to-center.
L.
When adjacent to a public walkway, locate exit terminal at least 7 feet above grade.
In addition:
Total length of vent piping shall not exceed the limits specified in this manual.
The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.
The flue products coming from the exhaust vent will create a large plume when the boiler is in operation. Avoid venting in areas that will affect neighboring buildings or be considered objectionable.
DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.
DO NOT locate the exhaust vent or intake pipe terminals under a porch, balcony, or veranda.
Avoid terminating exhaust vents near shrubs, air conditioners, or other objects that will obstruct the exhaust stream.
DO NOT vent over a public walkway. Condensate could drip or freeze and create a nuisance or hazard.
LP-387 REV. 3.4.15
37
NOTE:
Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting installation and location to save time and cost.
You must insert the provided exhaust and intake screens at your vent termination to prevent blockage caused by debris or birds.
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the boiler could result in property damage, severe personal injury, or death.
For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the boiler. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with requirements for detectors and alarms could result in property damage, severe personal injury, or death.
DETERMINE LOCATION OF CONDENSATE PIPING
This is a high efficiency boiler, and therefore produces condensate: a by-product of the combustion process. A condensate collection system with an internal float switch monitors condensate level to prevent it from backing up into the combustion system. There is a flexible line that must be piped as shown in Figure 16 to a suitable drain.
NOTE:
Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of
Massachusetts, condensate must be neutralized before entering a drain.
Figure 15-1 - Condensate Detail, 15-2
– Condensate Trap Installation
LP-387 REV. 3.4.15
38
CONDENSATE TRAP INSTALLATION INSTRUCTIONS
The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the boiler.
Operating the boiler without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death.
1. Ensure all parts shown in Figure 15-1, Condensate Detail, are included with the condensate trap. If any parts are missing, DO NOT install the trap. Replace the entire condensate assembly.
NOTE:
Before installation, clean out the condensate collector with water to remove any foreign matter that may block the condensate line.
Do not install the condensate assembly if a component is lost or missing. Replace the entire assembly. Failure to follow this warning could result in property damage, serious personal injury, or death.
2.
NOTE:
The installer should fill the condensate trap with tap water prior to assembly on the boiler.
3. Slide the condensate trap adapter onto the drain tube until the holes line up with the groove.
4. Insert stainless steel lock pin to lock condensate adapter to the drain tube.
5. Connect the clear hose from the pressure switch to the hose barb.
Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch. Failure to follow this warning could result in property damage, serious personal injury, or death.
NOTE:
The use of ¾” PVC or CPVC pipe are acceptable materials for condensate piping. However, use materials approved by the authority having jurisdiction.
In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with
ASME D2564 or F493. For Canada, use CSA or ULC certified PVC or CPVC pipe, fittings, and cement. If pipe is used, deburr and chamfer pipe to allow proper mating to the drainage assembly.
5. Run condensate drain hose to 1
” PVC or CPVC drain pipe. See Figure 16.
NOTE:
DO NOT cement drain hose to the PVC drainage pipe!
NOTE:
To allow for proper drainage on long horizontal runs, a second line vent may be required and tubing size may need to increase to 1”. Failure to add a second vacuum break could result in condensate backup, improper boiler operation, and nuisance shutdowns.
NOTE:
See Part 14, this manual, for instructions on how to maintain the condensate trap.
CONDENSATE NEUTRALIZATION
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). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the water vapor. The neutralizer kit should be checked annually and the limestone chips replenished if necessary. When replacing the limestone chips, take care to ensure chips are no smaller than ½” to avoid blockage in condensate piping (for piping details, refer to condensate neutralizer installation instruction.)
LP-387 REV. 3.4.15
39
Figure 16 - Condensate Piping Suggestions
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.
2. Plastic pipe should be the only material used for the condensate line. Steel, brass, copper, or other materials will be subject to corrosion or deterioration.
3. NEVER install condensate lines outside. It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.
4. Support of the condensate line may be necessary to avoid blockage of the condensate flow.
If using a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage.
It is very important that the conden sate piping be no smaller than ¾”. To prevent sagging and maintain pitch, condensate piping should be supported with pipe supports
, and pitched ¼” per foot to allow for proper drainage.
The condensate line must remain unobstructed, allowing free flow of condensate. If condensate freezes in the line, or if line is obstructed in any other manner, condensate can exit from the tee, resulting in potential water damage to property.
LP-387 REV. 3.4.15
40
Figure 17
– Piping Exhaust around Obstructions – Suggested Condensate Removal
E. EXHAUST VENT AND INTAKE PIPE SIZING
1. The exhaust vent and intake pipes are 3” for EFT-55/80/110/155/199/285 models, and 4” for the EFT-399.
2. The total equivalent length of exhaust vent and intake pipe should not exceed 200 feet for all models EXCEPT the EFT-285. Total equivalent length for the EFT-285 should not exceed 150 feet.
Coupling
FRICTION LOSS EQUIVALENT FOR STAINLESS OR PLASTIC PIPING AND FITTINGS
FITTING DESCRIPTION
90 o
elbow short radius
90 o
elbow long radius
45 o
elbow
3”
5’
4’
3’
0’
Tee (intake only)
V Series Vent Kit
AL20 4C Vent Terminal
0’
1’
1’
4”
5’
4’
3’
0’
Pipe (All Materials)
1’ 1’
Table 11 -
*Friction loss for long radius elbow is 1’ less. NOTE: Consult Polypropylene venting instructions for friction loss and pressure drop equivalents.
0’
1’
1’
LP-387 REV. 3.4.15
41 b. For example: If the
3” exhaust vent has two short 90 o
elbows and
10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length
= (2x5) + 10 = 20 feet.
Further, if the
3” intake pipe has two short 90 o
elbows, one 45 o
elbow, and 10 feet of PVC pipe, the following calculation applies: Intake Pipe
Equivalent Length = (2x5) + 3 + 10 = 23 feet.
The Exhaust Vent Equivalent Length + the Intake Pipe Equivalent
Length equal the Total Equivalent Length. In this example, the Total
Equivalent Length is 43 feet. c. The minimum Total Equivalent Length is 15 feet.
Figure 18
F. LONGER VENT RUNS
The maximum total equivalent length can be extended by equally increasing the diameter of both the exhaust vent and intake pipes.
However, the transitions should begin a minimum of 16 total equivalent feet from the boiler.
On all units EXCEPT the EFT-285, maximum equivalent length for increased diameter vent pipes is 275 ft, which includes the 16 ft from the boiler with a transition total of 259 ft upsize piping for longer vent runs (234 ft for the EFT-285). On the EFT-285, the maximum equivalent length for increased diameter vent pipes is 250 ft., which includes the 16 ft from the boiler with a transition total of 234 ft upsize piping for longer vent runs.
VENT TRANSITION FITTING
SIZE
3” Venting
4” Venting
REDUCING COUPLING
4” x 3”
6” x 4”
FINAL VENT SIZE
4”
6”
Table 12
Do not exceed the maximum lengths for increased diameter vent pipes. Excessive length could result in appliance shutdown and property damage.
G. EXHAUST VENT AND INTAKE PIPE INSTALLATION
All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.
1. Use only solid PVC or CPVC pipe, AL29-4C Stainless Steel, or a Polypropylene vent system, approved for use with Category IV boilers.
FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST APPLICATIONS. Foam core piping may be used on air inlet piping
only
.
2. Remove all burrs and debris from joints and fittings.
3. When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe.
NOTE: DO NOT
CEMENT POLYPROPYLENE PIPE.
4. Ensure the vent is located where it will not be exposed to prevailing winds.
5. In all roof venting applications, exhaust discharge must point away from the pitch of the roof.
6. If the exhaust vent is to be terminated in a walled off area (such as a roof with a parapet wall), ensure the exhaust vent terminates a minimum of 10' from nearest wall and extends level with or above the top of the wall. This will ensure flue gas does not get trapped and possibly recirculated into the intake air pipe, which could contaminate the combustion air.
7. To prevent water leakage, install adequate roof flashing where the pipe enters the roof.
8. Do not locate vent over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.
9. Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully consider venting installation and location.
LP-387 REV. 3.4.15
10. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼" per foot to allow condensate to drain from the vent pipe.
11. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.
12. In vacant chimney applications, install and seal a rain cap over existing chimney openings.
13. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.
14. Do not use the boiler to support any piping.
15. A screened straight coupling is provided with the boiler for use as an outside exhaust termination.
16. A screened inlet air tee is provided with the boiler to be used as an outside intake termination.
The following information on Table 13 lists optional exhaust/intake terminations available from HTP:
DESCRIPTION
3” PVC CONCENTRIC VENT TERMINATION KIT
3” POLYPRO VENT KIT
3” STAINLESS STEEL TERMINATION KIT
4” STAINLESS STEEL TERMINATION KIT
STOCK CODE
KGAVT0601CVT
8400P-001
V1000
V2000
Table 13
42
H. VENTING DRAWINGS
1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE
If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.
Unbalanced Venting.
Be sure to locate the appliance such that the exhaust vent and intake piping can be routed through the building and properly terminated. Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional
Equipment in Venting Section). The exhaust vent and intake piping lengths, routing and termination methods must all comply with the methods and limits given in the Venting section of this manual.
When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air.
NOTE: To prevent combustion air contamination, see Table 2.
Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated vent piping could result in property damage, serious personal injury, or death due to flue gas leakage.
LP-387 REV. 3.4.15
Figure 19
– Two Pipe Roof and Sidewall Venting with Tee (Intake) and Coupling (Exhaust) NOTE: Drawing is meant to demonstrate system venting ONLY. The installer is responsible for all equipment and detailing required by local codes.
43
Figure 20
– Venting with Optional Kits (NOT INCLUDED WITH THE BOILER)
NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
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. When placing support brackets on vent piping, the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
LP-387 REV. 3.4.15
44
Figure 21
– 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. When placing support brackets on vent piping, the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
An unbalanced vent system can be installed ONLY when the exhaust is installed in a vertical position.
LP-387 REV. 3.4.15
45
Figure 22
– 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]).
B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake.
C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater).
D. Minimum 12” between vents when installing multiple vents.
E. 12” minimum beyond air intake.
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. When placing support brackets on vent piping, the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
2. VENTING THROUGH AN EXISTING SYSTEM
This boiler may be vented through an existing unused vent system. The inner diameter of the existing vent system is utilized for the combustion air source. Two methods have been approved for such venting: Concentric Venting Through an Existing System and
Venting as a Chase.
VENT / AIR INLET SIZE
2”
3”
4”
Table 14
– Minimum Existing Vent / Chase Sizing
MINIMUM EXISTING VENT / CHASE SIZE
4”
5”
7”
LP-387 REV. 3.4.15
46
Do not install the boiler into a common existing vent with any other appliance. This will cause flue gas spillage or boiler malfunction, resulting in substantial property damage, severe personal injury, or death.
Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions. Failure to check state and local codes before installing through an existing opening could result in property damage and add significantly to installation costs.
If an existing venting system is converted for use with this boiler, the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the boiler. Failure to do so could result in property damage and boiler failure.
Such failure IS NOT covered under warranty.
CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM
NOTE:
The following instructions refer only to venting through an existing vent system, and n ot to venting with HTP’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.
Concentric venting through an existing system must run vertically through the roof. See Table 14 for proper minimum vent sizing. Use only the approved venting materials specified in Table 10 for piping the system. All instructions listed in the Venting section apply. See
Figures 23-1 and 23-2 for venting demonstrations.
The upper and lower vent terminations as well as all joints in the venting system must be properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system. Failure to properly seal the venting system will result in property damage, severe personal injury, or death.
CHASE VENTING THROUGH AN EXISTING SYSTEM
When venting as a chase, follow all instructions included in Venting section of this manual, as well as the previous Concentric Venting section. See Figure 23-3 for chase venting demonstration.
Figures 23
– 1, 23 – 2 Concentric Venting Through an Existing System, 23 – 3 Chase Venting Through an Existing System NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
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47
3. INDOOR COMBUSTION AIR INSTALLATION 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 2.
Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the boiler input.
Never obstruct the supply of combustion air to the boiler.
If the boiler is
combustion air is taken directly from the outdoors into the boiler intake connection.
Unconfined space
is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.
Confined space
is space with volume less than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.
When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening
2 should have a free area of one square inch per 1,000 Btu/hr (22cm than 100 square inches (645cm
2
).
/kW) of the total input of all appliances in the space, but not less
If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual. See Figure 25.
Figure 24
– LP-325-X
LP-387 REV. 3.4.15
48
Figure 25
– 1, 25 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
LP-387 REV. 3.4.15
49
PART 7 – 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). The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" (.12 kPa) as stated in the National Fuel
Gas Code. This information is listed on the rating label.
NOTE:
Maximum inlet gas pressure must not exceed 14” w.c. (3.5 kPa).
*
NOTE:
Installer must supply trap to meet local code requirements.
It is very important that you are connected to the type of gas noted on the rating plate.
“LP” for liquefied petroleum, propane gas, or “NAT” for natural or city gas. You must not do a gas conversion without an approved gas conversion kit. Prior to turning the gas on, all gas connections must be approved by the local gas supplier or utility, in addition to the governing authority.
A gas conversion kit comes with the boiler. Follow the included instructions VERY carefully. Failure to follow gas conversion instructions could result in property damage, serious injury, or death.
Figure 26
– Gas Line
Do not attempt to support the weight of gas piping with the boiler or its accessories. The gas valve and blower will not support the weight of the piping. Failure to follow this warning could result in substantial property damage, severe personal injury, or death.
The gas connection on the boiler is 3/4”. It is mandatory that this fitting is used for connection to a field fabricated drip leg as shown in Figure 26 per the National Fuel Gas Code. You must ensure that the entire gas line to the connection at the boiler is no smaller than the boiler supplied connection.
Once all inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum inlet pressure, you must isolate the boiler from the gas line. In order to do this, shut the gas off using factory and field-installed gas cocks. This will prevent high pressure. Failure to do so may damage the gas valve.
In the event the gas valve is exposed to a pressure greater than ½ PSI, 14" w.c., or 3.5 kPa, the gas valve must be replaced. Never use an open flame (match, lighter, etc.) to check gas connections.
Table 15
– Gas Pipe Sizing / BTU’s per Hour
B. GAS PIPING
1. Run the gas supply line in accordance with all applicable codes.
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.
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4. It is important to support gas piping as the boiler is not designed to structurally support a large amount of weight.
5. Purge all gas lines thoroughly to avoid start up issues with air in the lines.
6. Sealing compound (pipe dope) must be used and approved for gas connections. Apply sparingly, and only to the male threads. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the boiler.
Failure to apply pipe sealing compound as detailed above could result in substantial property damage, severe personal injury, or death.
CSA / UL listed flexible gas connections can be used when installing the boiler. Flexible gas connections have different capacities and must be sized correctly for the connected boiler firing rates. Consult with the flex line supplier to assure the line size is adequate for the job. Follow local codes for proper installation and service requirements.
Never use an open flame (match or lighter) to check for gas leaks. Use a soapy solution to test connection. Failure to use a soapy solution test or check gas connection for leaks could result in substantial property damage, severe personal injury, or death.
Use a two-wrench method when tightening gas piping near the boiler and its piping connection: One wrench to prevent the boiler gas line connection from turning; the second to tighten the adjacent piping. Failure to support the boiler gas piping connection could damage the boiler beyond repair. Such damage IS NOT covered by warranty.
C. CHECK INLET GAS PRESSURE
The gas valve is equipped with an inlet gas pressure tap that can be used to measure the gas pressure to the boiler. To check gas pressure, perform the steps listed below:
1.
IMPORTANT!
Before you connect to the inlet pressure, shut off the gas and electrical power to boiler.
2. Loosen the pressure tap with a small screwdriver. Refer to Figure 27 for location.
3. Each boiler is equipped with a needle valve that will accept a 5/16 ID hose to connect to a digital manometer or liquid gauge designed to measure incoming pressure from 0-
35” w.c. See 7.
4. Turn on the gas and power up the boiler.
5. Put the boiler into manual test mode (details on test mode are in Part 11
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 boiler. If Gas Pressure is within normal range proceed to Step 6.
6. Exit test mode, then turn power off and shut off gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device. Tighten screw on the pressure tap and turn gas on. Check for leaks with soapy solution. Bubbles will appear on the pipe to indicate a leak is present.
Ensure the pressure tap screw is properly tightened to prevent gas leaks. Failure to do so could cause substantial property damage, severe personal injury, or death.
The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop. The gas meter and regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1" w.c. (.87 kPa), the meter, regulator or gas line
LP-387 REV. 3.4.15
51 may be undersized or in need of service. You can attach a manometer to the incoming gas drip leg after removing the cap. The gas pressure must remain between 3.5" (.87 kPa) and 14" (3.5 kPa) during stand-by (static) mode and while in operating (dynamic) mode.
If an in-line high gas pressure regulator is used, it must be installed a minimum of 10 feet from the boiler. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines, or improper line sizing, will result in ignition failure.
This problem is especially noticeable in NEW LP installations and empty tank situations. This situation can also occur when a utility company shuts off service to an area to provide maintenance to their lines. This gas valve must not be replaced with a conventional gas valve under any circumstances.
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve and cause substantial property damage, severe personal injury, or death.
D. BOILER GAS VALVE
Figure 27
– Gas Valve Detail
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.
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Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.
Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO
2
and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death.
PART 8 – FIELD WIRING
To avoid electrical shock, turn off all power to the boiler 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. Such product failure IS NOT covered by warranty.
ELECTRICAL SHOCK HAZARD -
Turn off electrical power supply at service entrance panel before making any electrical connections.
Failure to do so can result in severe personal injury or death.
Wiring must be N.E.C. Class 1. If original wiring supplied with the boiler must be replaced, use only UL Listed TEW 105 o
C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70
– Latest Edition.
In order to ease future servicing and maintenance, it is advised to label all wires. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions could result in property damage or personal injury.
A. INSTALLATION MUST COMPLY WITH:
1. National Electrical Code and any other national, state, provincial or local codes or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.
B. FIELD WIRING TERMINATIONS
All connections made to the boiler in the field are done inside the electrical junction box located on the left side of the boiler. Multiple knockout locations are available to route field wires into and out of the electrical junction box. See Figure 28.
C. FIELD WIRING
The control used in the boiler is capable of directly controlling 1 pump in standard mode and 2 pumps when configured as a cascade master boiler. As a standard boiler, each pump can provide a maximum of 4 amps at 120 volts. If a pump requires more than this amount of power, an external contactor or motor starter is needed. If the boiler is configured as a cascade master, the system pump output is a dry contact output capable of switching 5 amps at 120 volts, in addition to the boiler pump output sourcing 4 amps each.
The electrical junction box has separate, clearly marked terminal strips for line voltage and low voltage wiring. Special jacks are provided for trouble-free cascade system wiring using standard CAT3 or CAT5 patch cables.
NOTE:
If local electrical codes or conditions require an additional service switch, the installer must provide and install a fused disconnect or 15 amp (minimum) service switch.
Figure 28
– Knockout Locations
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D. LINE VOLTAGE WIRING FOR STANDARD BOILER
NOTE:
A termination plug is included in the CAT 3 / CAT 5 Bus Connection Point, labeled J3 in Figure 29. DO NOT REMOVE THIS
PLUG! Doing so will affect boiler operation and void warranty.
1. Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V, Neutral, Ground
(shown in Figure 29).
2. A line voltage fused disconnect switch may be required, externally mounted and connected according to local codes that may apply.
3. Connect the boiler pump as shown in Figure 29 to the terminals marked 1
– (HOT), 2 – (NEUT), and 3 – (GND). The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If the pump requires more current or voltage than the
120 volts supplied, an external motor starter or contactor will be required.
E. ALARM CONNECTIONS
The control includes a dry contact alarm output. This is an
SPDT circuit, rated at 5 amps at 120 volts. This contact can be used to activate an alarm light or bell or notify a building management system if the boiler goes into a lockout condition. The circuit between the ALARM COM and NC terminals is closed during normal operation and the circuit between ALARM COM and NO is open during normal operation. The connections depicted in Figure 29 show two 120 volt lights connected to the alarm terminals.
One light will be on when the boiler is in normal mode and the other light will be on when the boiler is in lockout mode.
NOTE:
Isolate 120V wiring from 24V wiring to prevent any electrical “noise”.
F. LOW VOLTAGE CONNECTIONS FOR
STANDARD BOILER
1. All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 28.
2. Connect all low voltage field devices to the low voltage terminal strip located in the electrical junction box.
NOTE:
When making low voltage connections, ensure no external voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to prevent damage to the control.
G. THERMOSTAT
1. Connect the room thermostat to the terminals marked
THERMOSTAT in the electrical junction box (see Figure
29). Alternately, any dry contact closure across these terminals will cause the boiler to run. Take caution to ensure neither of the terminals becomes connected to ground.
2. Mount the thermostat on an inside wall as central as possible to the area being heated, but away from drafts or heat producing devices such as television sets that could influence the ability of the thermostat to measure room temperature.
3. If the thermostat is equipped with an anticipator and it is connected directly to the boiler, the anticipator should be set at 0.1 amps. If the thermostat is connected to other device(s), the anticipator should be set to match the power requirements of the device(s). See the instruction manual of the connected device(s) for further information.
Figure 29
– Boiler Control
LP-387 REV. 3.4.15
H. OUTDOOR SENSOR
NOTE:
If the system requires a fixed operating temperature, the outdoor sensor is not required and should not be installed.
There is no connection required if an outdoor sensor is not used in the installation.
1. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet.
2. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions.
NOTE:
For correct mounting procedures, follow instructions provided with the sensor.
NOTE:
If sensor wires are located in an area with sources of potential electromagnetic interference (EMI), the sensor wires should be shielded, or the wires routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the boiler.
54
I. INDIRECT SENSOR
There is no connection required if an indirect water heater is not used in the installation.
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. The demand will continue until the sensor measures that the indirect water heater temperature is above the set point.
2. Connect the indirect sensor (7250P-325) to the terminals marked DHW SENSOR (shown in Figure 30) in the electrical junction box.
Caution should be used to ensure neither of these terminals becomes connected to ground.
NOTE:
If sensor wires are located in an area with sources of potential electromagnetic interference (EMI), the sensor wires should be shielded, or the wires routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the boiler.
Failure to use the correct sensor may result in tank temperature being either above or below set point, and could result in decreased performance, substantial property damage, or heightened risk of injuries due to scalds.
J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL
1. A signal from a building management system may be connected to the boiler to enable remote control. This signal should be a 0-10 volt positive-going DC signal. When this input is enabled using the installer menu, a building control system can be used to control the set point temperature of the boiler. The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the boiler will be in standby mode, not firing. When the signal rises above 1.5 volts, the boiler will ignite. As the signal continues to rise towards its maximum of 10 volts, the boiler will increase in set point temperature. See Part 11 for details on the setting of function 16.
2. Connect a building management system or other auxiliary control signal to the terminals marked 16, 0-10 VOLT + and 17, 0-10
VOLT
– in the electrical junction box (shown in Figure 30). Caution should be used to ensure that the 0-10 VOLT + connection does not become connected to ground.
3. Move jumper on connection board (shown in Figure 30) from A to B.
4. See Part 10, Section D, Function 17 to program the 0-10 volt signal.
LP-387 REV. 3.4.15
NOTE:
When a 0-10 volt building management system is installed, the return sensor temperature cannot be monitored through the boiler display.
NOTE:
Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct. Reversed polarity could lead to erratic and/or no response from the boiler controller.
55
K. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT
If an optional UL 353 Low Water Cut-Off (LWCO) Interface Kit is used, the control box of the kit should be mounted to the left side of the boiler cabinet near the low water cut-off probe, which is located on the outlet nipple of the boiler.
Follow the complete instructions included in the kit for proper installation.
NOTE:
The control system senses system water temperatures entering and exiting the heat exchanger to provide protection against low water conditions. Where local codes or jurisdictions do not accept a pressure device for low water protection, the jurisdictions may accept these control functions as a means of providing low water protection.
L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS
1. A Cascade Bus Termination Plug has been installed on the customer connection board of this boiler. The purpose of this plug is to stabilize communication between multiple boilers and reduce electrical “noise”. See Figure 32 for Cascade Bus Termination Plug installation detail.
2. Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers. These cables are readily available at any office supply, computer, electronic, department or discount home supply store in varying lengths. If you possess the skills you can also construct custom length cables.
3. It is recommended to use the shortest length cable that will reach between the boilers and create a neat installation. 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.
4. Route the communication cables through one of the knockouts in the cabinet.
5. Connect the boilers in a daisy chain configuration as shown below.
It is best to wire the boilers using the shortest wire runs rather than trying to wire them in the order that they are addressed. The communication bus jacks on the customer connection panel are interchangeable so you can use either one or both in any order to connect the cable.
Figure 30
– LP-387-W
If you have connected the boilers to each other properly, there will be no open communication connection ports.
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56
Figure 31
– Cascade Resistor Plug Installation Detail
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. Connect a jumper wire from the 120 VOLT terminal to the 9 terminal.
4. Connect the boiler pump to the terminals marked 1 (HOT), 2 (NEUT) and 3 (GND).
5. Connect the system pipe sensor to the terminals marked 10 and 11.
NOTE:
See Figure 32 for Cascade Master and Follower Wiring detail.
N. CASCADE FOLLOWER PUMP AND SENSOR WIRING
1. Connect the boiler pump to the terminals labeled 1 (HOT), 2 (NEUT), and 3 (GND).
2. An alarm bell or light can be connected to the alarm contacts of the follower boiler. The normally closed alarm contact may be used to turn a device off if the boiler goes into lockout mode. The alarm contacts are rated 5 amps at 120 VAC.
To connect an alarm device, connect the power for the device to the ALARM COM terminal. Connect the alarm device hot wire to the
ALARM NO terminal. Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device.
To connect a device that should be powered off during a boiler lockout condition, follow the same instructions as above except use the
ALARM NC terminal rather than the ALARM NC terminal.
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.
NOTE:
See Figure 32 for Cascade Master and Follower Wiring detail.
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Figure 32
– Cascade Master and Follower Wiring
LP-387 REV. 3.4.15
58
Figure 33
– Internal Connection Diagram – LP-293-J
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59
PART 9 – 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.
You may have to have your water quality professionally analyzed to determine whether you need to install a water softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the boiler, as water quality will affect the reliability of the system. Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years.
Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH or other imbalance IS NOT covered by the warranty.
To assure good extended service life, it is recommended that you test your water quality prior to installation. Listed below are some guidelines.
Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.
Sodium less than 20 mGL
Water pH between 6 and 8
1. Maintain boiler water pH between 6 and 8. Check with litmus paper or have chemically analyzed by water treatment company.
2. If pH differs from above, consult local water treatment company for treatment needed.
Hardness less than 7 grains
Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).
Chlorine concentration less than 100 ppm
1. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm.
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.
ACIDITY
CONDUCTIVITY
CHLORIDE
IRON
COPPER
SODIUM
HARDNESS
Table 16
6 to 8 pH
Less than 400 uS/cm at 25 o
C
Less than 100 ppm
Less than 0.5 mg/L
Less than 0.1 mg/L
Less than 20 mg/L
Less than 7 Grains
Clean system to remove sediment*
1. You must thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.
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. Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section (Part 14 of this manual).
Test/replace freeze protection fluid
1. For systems using freeze pro tection fluids, follow fluid manufacturer’s instructions to verify inhibitor level and that other fluid characteristics are satisfactory.
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2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions.
NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY.
B. CHECK FOR GAS LEAKS
Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor.
Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak.
Repair any leaks at once.
PROPANE BOILERS ONLY
– Propane suppliers mix an odorant with the gas to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup and periodically thereafter, have the propane supplier verify the correct odorant level in the gas.
C. FREEZE PROTECTION (WHEN USED)
NEVER use automotive or standard glycol antifreeze. Do not use ethylene glycol made for hydronic systems. System water, including additives, must be non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products. Use only freeze-protection fluids certified by fluid manufacturer as suitable for use with stainless steel boilers, verified in the fluid manufacturer’s literature. Thoroughly clean and flush any system that has used glycol before installing the new boiler. Provide the boiler owner with a material safety data sheet (MSDS) on the fluid used.
1. Determine the freeze protection fluid quantity using total system water content following the fluid manufacturer’s instructions.
Remember to include expansion tank water content. DO NOT exceed a 50/50 ratio of antifreeze to water.
2.
NOTE:
Local codes may require back flow preventer or actual disconnect from city water supply.
3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.
D. FILL AND TEST WATER SYSTEM
Ensure the boiler is full of water before firing the burner. Failure to do so will damage the boiler. Such damage IS NOT covered by warranty, and could result in property damage, severe personal injury, or death.
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. Typical cold water fill pressure for a residential system is 12 psi. b. Pressure will rise when boiler is turned on and system water temperature increases. Operating pressure of the system should never exceed 25 psi, and must never exceed the relief valve pressure setting.
4. At initial fill and during boiler startup and testing, check system thoroughly for leaks. Repair all leaks before proceeding further.
Eliminate all system leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, causing heat exchanger failure and possibly resulting in property damage, severe personal injury, or death.
5. The system may have residual substances that could affect water chemistry. After the system has been filled and leak tested, verify that water pH and chlorine concentrations are acceptable by sample testing.
It is important to purge the system of air to avoid damage to the boiler.
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E. PURGE AIR FROM WATER SYSTEM
IMPORTANT!
While commissioning the system, the air vent on top of the boiler must remain fully open to allow the boiler to properly fill. Failure to keep the air vent open could lead to improper boiler and system operation.
To purge air from the system: a. Connect a hose to the purge valve and route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c. Close zone isolation valves. d. Open quick-fill valve on cold water make-up line. e. Open purge valve. f. Open the isolation valves one zone at a time. Allow water to run through the zone, pushing out the air. Run water until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged. g. Close the quick-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch the system pressure rise to correct cold-fill pressure. It is recommended that you put the pumps into manual operation to assist in purging the circuits. h. Disconnect the wires that are connected to the THERMOSTAT terminals of the customer connection board. Apply power to the boiler. The display will show the temperature of the water in the boiler. Press the
▼ and
ENTER keys simultaneously and hold for 1 second. The display will read:
The central heating pump will come on. If you then press the
▲ key, the central heating pump will shut off. The display will read:
The DHW pump will come on. If the boiler is set up as the cascade master and you press the
▲ key again, the DHW pump will shut off. The display will read:
The system pump will come on. Use the ▲ and ▼ keys to toggle between running each pump in the system as required to help bleed out all entrapped air. Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet. Pressing ▲ and ▼ together at any time will return the boiler to normal operation. i. After the system has operated for some time, eliminate any residual air by using the manual air vents located throughout the system. j. If purge valves are not installed in the system, open manual air vents in the system one at a time, beginning with the lowest floor. Close vent when water squirts out. Repeat with remaining vents. k. Refill to correct pressure.
F. CHECK THERMOSTAT CIRCUIT(S)
1. Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip).
2. Connect a voltmeter across these two incoming wires with power supplied to the thermostat circuits. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage reading does occur under any condition, check and correct the external wiring. (This is a common problem when using 3wire zone valves.)
5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler low voltage terminal strip. Allow the boiler to cycle.
G. CONDENSATE REMOVAL
1. The boiler is a high efficiency condensing boiler. Therefore, the boiler has a condensate drain. Condensate fluid is nothing more than water derived from combustion products, similar to that produced by an automobile when it is initially started.
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Condensate is slightly acidic (typically with a pH of 3 to 5) and must be piped with the correct materials. Never pipe the condensate using steel, copper, brass or other materials that will be subject to corrosion. Plastic PVC or CPVC pipe are the only approved materials.
A condensate neutralizer, if required by local authorities, may be purchased from HTP (7450P-212).
2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain. It is very important that the condensate line is sloped downward away from the boiler to a suitable inside drain. If the condensate outlet on the boiler is lower than the drain, you must use a condensate removal pump, available from 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.
3. If a long horizontal run is used, it may be necessary to create a vent in the horizontal run to prevent a vacuum lock in the condensate line.
4. Do not expose the condensate to freezing temperatures.
5. It is very important you support the condensation line to assure proper drainage.
H. FINAL CHECKS BEFORE STARTING BOILER
1. Read Start-Up Procedure, Part 10 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. Fill the condensate trap with water.
4. Verify electrical connections are correct and securely attached.
5. Inspect exhaust vent and intake piping for signs of deterioration from corrosion, physical damage, or sagging. Verify exhaust vent and intake piping are intact and correctly installed per Venting Section (Part 6) and local codes.
I. CASCADE SYSTEM
1. If a single boiler is installed, skip this section.
2. Programming the Master Boiler: a. Make sure there is no demand for heat being supplied to the boiler. b. Apply power to the boiler. c. Enter the system setting program navigation following instructions in Part 11 of this manual. d. Verify that the cascade address function 15 is set to 0. This sets the Master Boiler
’s address as 0.
NOTE:
The Master Boiler MUST be addressed as 0. e. Change cascade mode function 23 to 926 Boiler. This makes it a Master Boiler. f. Exit the installer menu.
NOTE:
In order for the system to operate properly, the temperature set point of the master must match the follower boiler set point.
NOTE: READ THE NOTES BELOW BEFORE PROGRAMMING FOLLOWER BOILERS:
The boiler addressed as 1 will share its alarm output with the master boiler.
If one of the follower boilers has an indirect fired water heater connected to it, the address of this boiler must be 2 or greater.
It is recommended but not necessary to address boilers in the order that they are wired.
No two boilers can have the same address.
It is not required to use all consecutive address numbers. Example: In a 2 boiler system with an indirect connected to the follower, the follower address would be 2 (address 1 is not used).
3. Programming Follower Boilers: a. Make sure there is no demand for heat being supplied to the master boiler. b. Apply power to the follower boiler you are working on. c. Enter the system settings following instructions in Part 11 of this manual. d. Set the Cascade Address parameter 15 to 1 for the first follower, 2 for the second follower, etc., depending on which boiler you are programming. e. Change “CASCADE MODE” parameter to “926 BOILER”. This makes the boiler a follower and enables all data to be transferred between boilers as needed for the system to function to full capability. f. Exit the system menu.
NOTE:
For the system to operate properly, the temperature set point of the follower must match that of the master boiler.
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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.
So, if any individual boiler control senses an unsafe condition, it will extinguish the burner and, if necessary, go to a lockout condition. In this way, every boiler in the system has its individual safety controls intact and operational, even if the firing of the boiler is under control of the master boiler.
PART 10 – START-UP PROCEDURE
FOR YOUR OWN SAFETY READ BEFORE OPERATING
1. This boiler does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
2. BEFORE OPERATING: smell all around the boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any boiler.
Do not touch any electric switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers' instructions.
If you cannot reach your gas supplier, call the fire department.
Turn off gas shutoff valve (located outside of the boiler) so that the handle is crosswise to the gas pipe. If the handle will not turn by hand, don't try to force or repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
4. Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been damaged.
5. The boiler shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.)
Failure to follow these instructions could result in property damage, serious personal injury, or death.
If you discover any evidence of a gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately.
Do not start the boiler again until the leak is repaired. Failure to comply could result in substantial property damage, severe personal injury, or death.
A. CONTROL OVERVIEW
The control is one of the primary safety devices of the boiler. It monitors the safety sensors of the boiler to assure safe and efficient operation.
The control has many features associated with system design. This section addresses programming features, including Boiler Settings /
System Settings / Maintenance Settings and System Diagnostics, to help in customizing your control. It is important to fully understand control capabilities before customization, as its factory defaults may already fit your system design and not require any adjustment at all.
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 function of each button is described below.
RESET
– The RESET button has two functions.
– Resets any lockout error code
– Returns the user to the default display screen.
ENTER MENU CODE
000
ENTER
– The ENTER key is used to enter the parameter programming mode. To enter this mode, hold down the ENTER key for more than 4 seconds. The readout will change to:
One of the zeroes will be blinking. Use the
▲▼ arrow keys to change the blinking digit to the correct value. Use the
arrow keys to select the next digit to change and again use the
▼▲ keys to change the value. Repeat until the correct code is entered. Press the
LP-387 REV. 3.4.15
64
ENTER
key to accept the code entered. If the code is correct, the readout will change to the appropriate screen. If the programming code is not accepted, the readout will continue to display as shown above.
The
ENTER
key is also used to enable a function for editing. After the user navigates to the desired function, the user would hold down the
ENTER
key for one second. When the
ENTER
key is released, the function value will begin to blink. The function can now be changed using the
▼▲
ARROW
keys. After the new value is displayed, the user then presses the
ENTER
key for 1 second to lock the new value of the function in. The value will then stop blinking.
LEFT AND RIGHT ARROW KEYS
– are used to navigate between the default display, status display, analog and cascade displays if they are enabled. The
keys are also used in programming modes to change between the programmable functions. It is recommended you use the Menu Maps in the back of this manual and the detailed menu instructions printed in this section to help in menu navigation.
UP AND DOWN ARROW KEYS
– ▼▲ are used to navigate between the various functions displayed in the menu. After the function is enabled for editing by pushing the
ENTER
key, the
▼▲ keys are used to adjust the function upward or downward to the desired value.
C. OPERATING INSTRUCTIONS
Before operating the boiler, it is important to remove the cover and verify that the gas line and water lines are connected to boiler and fully purged. If you smell gas, STOP; Follow the safety instructions listed in the first part of this section. If you do not smell gas, follow the next steps.
1. Turn down the thermostats before applying power to the boiler. If 0
–10 volt or other inputs are used, make sure that they are set so there is no call for heat while programming.
2. Turn on the power to the boiler or boilers if a cascade system used.
3. Next, check the boiler settings. Adjustment and factory defaults are outlined within this section. If a cascade system is used, it is important that all the boilers have the same boiler settings.
4. Next, check the system settings. Adjustments and factory defaults are outlined within this section. If a cascade system is used, it is important that the Master Boiler is programmed with the correct system settings.
5. Create a demand on the boiler or boilers if a cascade system is used. The user can monitor system functions when the boilers are operational.
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.
SCREEN
ENTER MENU CODE
000
DESCRIPTION
To access the boiler setting program, press and hold the
ENTER
Key for 4 seconds, until the display shows the screen at left.
ENTER MENU CODE
600
Using the arrow keys, log in the
Boiler
Menu Access Code “600”
. To confirm the code, press
ENTER
to access
Boiler Setting Program
Table 17
– Programming Screens
navigation menu.
Boiler Setting Program Navigation
Once the code is confirmed, the user can now start to set
the Boiler Settings
. Use the arrow keys on the display to navigate through the
Boiler Setting Program
. A blinking setting indicates it can be changed. To change a setting, press the
ENTER
Key. Boiler settings can be increased by pressing the
UP ARROW
▲ and decreased by pressing the
DOWN ARROW
▼ on the display. When done, press
ENTER
. Setting will stop blinking and you can move on to next setting. Press
RESET
to exit programming and store settings. Listed below are the boiler settings that can be programmed into the control.
CENTRAL HEAT
180 o
F
SCREEN DESCRIPTION
Function:
Adjusts the boiler set point. Default: 180 o
F (Range: 50 o
F to 190 o
F).
CENTRAL DIFF SET
30 o
F
Function:
Adjusts the boiler differential set point. Default: 30 o
F (Range: 5 o
F to 30 o
F).
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65
DHW SET POINT
119 o
F
Function:
Adjusts the indirect tank set point. Default: 119 o
F (Range: 70 o
F to 185 o
F).
DHW DIFF SET POINT
7 o
F
Function:
Adjusts the indirect tank differential set point. Default: 7 o
F (Range: 1 o
F to 30 o
F).
TEMP DISPLAY C OR F o
F
Function:
Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit).
Table 18
– Boiler Setting Screen Descriptions
Clock Settings
(NOTE: The clock will reset if the boiler is powered off for more than a week.)
SCREEN
CLOCK MODE (12/24)
08/28/2009 Fr 9:42A
DESCRIPTION
Function:
Changes the clock from 12 hour mode (8:45 PM) to 24 hour mode (20:45). To change to 24 hour mode, press the
ENTER
key. The letter (A or P) after the time will blink. Press the up or down arrow key once and the letter will disappear. Press the
ENTER
key to save the new setting.
CLOCK HOUR
08/28/2009 Fr 10:01A
Function:
Allows the user to adjust the hour setting.
CLOCK MINUTE
Adjusts the minute setting.
08/28/2009 Fr 10:01A
CLOCK DAY OF WEEK
Adjusts the day of week.
08/28/2009 Fr 10:01A
CLOCK DATE MODE
Allows the user to switch to European date format (2009/08/28) from US format (08/28/2009).
08/28/2009 Fr 10:01A
CLOCK YEAR
08/28/2009 Fr 10:01A
Function:
Adjusts the year setting.
CLOCK MONTH
Function:
Adjusts the month setting.
08/28/2009 Fr 10:01A
CLOCK DATE The clock is set.
08/28/2009 Fr 10:01A
Table 19
– Clock Setting Screens
NOTE:
The clock does not automatically adjust for Daylight Savings Time, and requires manual adjustment.
E. PROGRAMMING THE SYSTEM SETTING
System 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.
SCREEN
ENTER MENU CODE
000
DESCRIPTION
To access the boiler setting program, press and hold the
ENTER
Key for 4 seconds, until the display shows the screen at left.
ENTER MENU CODE
Using the arrow keys on the display, log in your
System Menu Access Code “925”
. To confirm code, press
ENTER
925 to access system setting program navigation menu.
Table 20
– System Setting Access
F. SYSTEM SETTING PROGRAM NAVIGATION
Once the
System Menu Access Code
is confirmed, the user can begin to set the system setting menu. Use the
arrow keys on the display to navigate through the system setting program. To change a setting, press
ENTER
. System settings can be
increased
by pressing the
UP ARROW
and
decreased
by pressing the
DOWN ARROW
on the display. When done, press
ENTER
. Setting will stop blinking and you can move on to next setting. Press
RESET
to exit programming and store settings. Listed below are the boiler settings that can be programmed into the control.
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66
SCREEN DESCRIPTION
Function 1
MODE
Factory Program Mode
This screen indicates that the control is configured correctly. Do not change this setting.
INDIRECT 1
Function 3 DHW Tank Max Temp
DHW TANK MAX TEMP
180 o
F 3
This is the maximum temperature that can be selected for the DHW indirect tank set point in the boiler menu. Default:
180 o
F (Range: 95 o
F to 180 o
F).
Function 6 DHW Post Pump Time
0 MINUTES 6 achieved. Please note that running the pump for a time greater than 5 minutes may cause tank energy to be released back to the boiler heat exchanger. Default: 0 Minutes (Range: 0
– 10 minutes).
Warm Weather Shutoff Function 7
WARM WEATHER OFF
68 o
F 7
When used with an outdoor sensor, warm weather shut down will disable the boiler if the programmed outdoor temperature is exceeded. Default: 68 o
F (Range: 41 o
F to 122 o
F).
Function 8 Min Outdoor Temp
MIN OUTDOOR TEMP
5 o
F 8
Sets the minimum outdoor design temperature for the system. Default: 5 o
F (Range: -49 o
F to 32 o
F).
Function 9 Max Supply Temp
MAX SUPPLY TEMP
190 o
F 9
(Range: 77 o
F to 190 o
F).
o
F
Function 10 Max Outdoor Temp
MAX OUTDOOR TEMP
68 o
F 10
Sets the maximum outdoor design temperature for the system design. Default: 68 o
F (Range 32 o
F to 190 o
F).
Function 11 Min Supply Temp
MIN SUPPLY TEMP
95 o
F 11
Sets the design supply water temperature based on the maximum outdoor design temperature. Default: 95 o
32 o
F to 190 o
F).
F (Range:
Function 12 Min Boiler Temp
MIN BOILER TEMP
68 o
F 12
Sets the design minimum heat curve temperature for central heat. Default: 68 o
F (Range: 32 o
F to 190 o
F).
Function 13 CH Post Pump Time
CH POST PUMP TIME
–
0 MINUTES 13
10 minutes).
Function 14 DHW Priority
DHW PRIORITY
30 MINUTES 14
Function 15
Allows the user to set the maximum run time for the indirect fired water heater and the minimum run time for central heating. Default: 30 minutes (Range: 0
– 60 minutes).
Cascade Address
CASCADE ADDRESS
0 15
Boilers are addressed 1 thru 7. Default: 0 (Range: 0
– 8). NOTE: DO NOT USE ADDRESS 8.
Function 16 Optional Inputs
OPTIONAL INPUT
RETURN SEN 16
Board / 0-10 Volt / DHW Sensor / Return Sen).
Function 17 0-10 Volt Function
0-10 VOLT FUNCTION
TEMPERATURE 17 or Fan Speed).
Function 18 Step Modulation Mode
STEP MODULATE MODE
ON 18
Allows the user to turn ON the step modulation, which regulates burner output in six steps at one minute intervals. Step modulation will start at the last modulation rate of the boiler and work up one minute at a time. Default: OFF (Selection:
OFF or ON).
Function 19 Boiler DHW Temp
BOILER SUPPLY DHW
180 o
F 19 Default: 180 o
F (Range: 119 o
F to 190 o
F).
Function 20 Water Safety Input
WATER SAFETY INPUT
WATER PRESSURE
20
Function 21
The user can select various water safety inputs used in the boiler system. Default: Flow Switch (Range: None / Low
Water Cut off / Flow Switch / Water Pressure).
Error Outdoor Sensor
ON 21
Function 22
does not stop the boiler from running. Factory Default: ON (Range: ON / OFF / PHOEN ON).
Adjust Boiler Output %
Allows the user to adjust the boiler output down from 100% to 50%. Factory Default: 100%. (Range: 100%
– 50%)
100% 22
Function 23 Cascade Mode
CASCADE MODE
VISION 3 23
LP-387 REV. 3.4.15
Function 24 Cascade Rotation
CASCADE ROTATION
48 HOURS 24 set to 0, the firing order of the boilers will not rotate. Default: 48 hours (Range: 0
– 240 hours).
Function 25
NOT USED
NOT USED 25
Cascade DHW Mode
Not used on this product.
Function 26 System Freeze Protect
SYS FREEZE PROT
This parameter is only present if the boiler is a cascade master. Allows the user to set the freeze protection when a system pump is used. Factory Default: OFF. Selection of temperature activates freeze protection. (Range:
PROTECT OFF 26
OFF, -40 o
F
– 104 o
F).
Function 27 Error System Sensor
ERROR SYSTEM SENS
ON 27 error does not stop the boiler (or boilers) from running. Factory Default: ON (Range: ON / OFF).
Function 28 Freeze Protection
FREEZE PROTECTION
ON 28
Function 29 DHW Modulation Mode
This parameter controls how the boiler modulates for a DHW demand. In NORMAL MOD mode, the boiler will
67
NORMAL MOD 29
Function 30
EXTRA BOILER MODE
OFF 30
Function 31
SYSTEM SENSOR MODE
OFF 31
Function 32
fire when there is a DHW demand. This mode is useful to minimize short cycling when a large boiler and small indirect tank are used together. Factory Default: NORMAL MOD (Range: NORMAL MOD / LOW MOD).
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%).
System Sensor Mode
Suppresses the ‘NO FOLLOWER’ message on the display if the boiler is used as a cascade master boiler with no follower boilers connected. Factory Default: OFF (Range: ON / OFF).
Service Schedule
SERVICE SCHEDULE schedule. Factory Default: OFF (Range: Date or Run Hours). NOTE: Without setting this function, Functions
OFF 32
33/34/35/36 will not display.
Function 37 Modbus Mode
Enables Modbus Mode on the appliance. Factory Default: OFF (Range: OFF, ON, AUTO).
NOTE:
Turning Modbus
MODBUS MODE OFF
372) for details.
NOTE:
Turning this Mode
“ON” without a connected and powered Modbus communication adapter
37
(p/n 7350P-629) will result in improper appliance operation. Service calls associated with this ARE NOT covered by warranty.
Table 21
– System Setting Menu Screens
NOTE:
For the following functions, you must have your maintenance function turned on.
To change, press
ENTER
. The left most digit will begin to blink. Use the up
▲ or down ▼ arrows to change the digit. Use the
arrow keys to switch between digits. When you’ve made your selection, press
ENTER
again.
SCREEN DESCRIPTION
Function 33 Year
SERVICE SCHEDULE
YEAR 00/00/2000 33
Hours
SERVICE SCHEDULE
10000’s
00 0000h 33
Allows the user to set the left two digits of the amount of run hours before next service reminder.
Function 34 Month
SERVICE SCHEDULE
MONTH 00/00/2000 34 function, you will need to program 10,000 hours, if required.
Hours
SERVICE SCHEDULE
10000’s 00
00 00 34
Function 35 Day
SERVICE SCHEDULE
DAY 00/00/2000 35
Function 36
TELEPHONE #
Hours
SERVICE SCHEDULE
10000’s 0000
00 35
Telephone
Allows the user to input a telephone number that will be displayed when maintenance is required.
000 000 0000 36
Table 22
– Maintenance Reminder Function Screens
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68
G. RESETTING THE MAINTENANCE SCHEDULE
When the system control flashes MAINTENANCE REQUIRED, it is advisable that you call for service. After the service is performed, reset the schedule for the next required service by using the following steps.
Press
ENTER
on the display for 3 seconds. The Menu code will appear as 000. This does not change. Press
ENTER
again. SERVICE
SCHEDULE RESET will be displayed. Using the right arrow key
scroll to the selection of year or hours. Select enter to reset the mode you are in. Use the up
▲ or down ▼ arrow key for each adjustment then select
ENTER
when reset is complete.
PART 11 – START-UP PROCEDURES FOR INSTALLER
Table 23
– 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
.
Once the first value is displayed, press the up arrow
▲ or down arrow ▼ to access additional information. At any point you may press the RESET button to exit the status screen. Listed below are the status screens.
SCREEN
SUPPLY SEN 180 o
F
RETURN SEN 150 o
F
DESCRIPTION
This screen is displayed after pressing the
key as described above. This shows the actual temperature that the supply and return sensors are measuring. NOTE: If the boiler is configured to use a 0
– 10 volt input, the return sensor is disabled and the second line of the display will be blank.
Press the
▼ key once.
CH SET 180 o
SUPPLY 122 o
F
F
The screen displays the current central heating temperature set point on the top line. NOTE: This temperature set point may vary from what was set in the boiler settings if an outdoor sensor is used. The actual temperature measured by the supply sensor is displayed on the bottom line.
Press the
▼ key once.
CH DEMAND OFF
BOILER
Press the
▼ key once.
0-10 SIGNL ON
*
Press the
▼ key once.
This screen displays the central heat demand set for the cascade system.
Shows if 0
– 10 volt is enabled.
CAS SET 190 o
F
SYSTEM 112 o
F
NOTE:
This screen will appear only when set in Master Boiler mode.
This screen displays the cascade set point (maximum 190 o
F) on the top line. The system sensor value reading is on the second line. The control will cascade the boilers up to this set point depending on demand.
LP-387 REV. 3.4.15
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Press the
▼ key once.
DHW SET 119 o
DHW 117 o
F
F
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 line. If a mechanical aquastat is used in place of the recommended sensor, the second li ne will display ‘OFF’ in place of the temperature if the aquastat measures close to its set temperature, or ‘ON’ in place of the temperature if the aquastat temperature is too low.
Press the
▼ key once.
OUTDOOR 11 o
F
FLUE 95 o
F
Press the
▼ key once.
FLAME 0.0uA
FAN SPEED 3497 RPM
Press the
▼ key once.
0-10 V 0.0 V
BOILER
Press the
▼ key once.
The current outdoor temperature is displayed on the top line. If there is no outdoor sensor connected to the boiler
, this line will display ‘OFF’ in place of the temperature. If the outdoor sensor is shorted, this line will display
‘ON’ in place of the temperature. The second line displays the current flue temperature of the boiler.
This screen displays the boiler flame current on the top line. The second line displays the fan speed in the boiler.
The top line displays the voltage on the optional input. This voltage is only relevant if an external 0-10 volt signal is being used to control the boiler.
BUS COMM NO CONN
This display shows the status of the communication bus between multiple boilers. If the boiler is in a single boiler configuration, the display will show ‘NO CONN’. If the boiler is used in a multiple coiler configuration, is the
Master Boiler, and other boilers are connected to the communication bus and powered, this screen will show the address of each boiler connected to the bus.
Press the
▼ key once.
POWER ON 0H
CH ON 0H
Press the
▼ key once.
The top line of this display indicates the amount of hours the boiler has had power applied to it over its life. The second line indicates how many hours the burner has been on for central heat demand over its life.
DHW ON
GOOD IGNIT 1X
0H in the life of the boiler. The second line indicates how many times the burner has successfully ignited in the life of the boiler.
Press the
▼ key once.
SYS CH ON 0h
This screen displays how many hours the boiler has run to meet central heat and DWH demand.
SYS DWH ON 0h
Table 24
– Boiler Control Status Menu Screens
The following 10 screens display the last ten boiler lockout faults. The faults are displayed from most recent to oldest by pressing the
▼ key.
SCREEN
Press the
▼ key once.
DESCRIPTION
FAULT HISTORY 1
07/27/2009 Mo 5:19A
This screen displays the last lockout fault the boiler controller had. The top line will alternate between the words
‘FAULT HISTORY’ and the actual fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 2
08/28/2009 Fr 5:19A
This screen displays the second oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.
Press the
▼ key once.
FAULT HISTORY 3
08/28/2009 Fr 5:19A
This screen displays the third oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered if one has occurred. The bottom line displays the date and time a fault occurred.
Press the
▼ key once.
FAULT HISTORY 4
08/28/2009 Fr 5:19A
This screen displays the fourth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 5
08/28/2009 Fr 5:19A
This screen displays the fifth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 6
08/28/2009 Fr 5:19A
This screen displays the sixth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 7
08/28/2009 Fr 5:19A
This screen displays the seventh oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 8
08/28/2009 Fr 5:19A
This screen displays the eighth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
LP-387 REV. 3.4.15
70
Press the
▼ key once.
FAULT HISTORY 9
08/28/2009 Fr 5:19A
This screen displays the ninth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the fault occurred.
Press the
▼ key once.
FAULT HISTORY 10
This screen displays the tenth oldest lockout fault that occurred in the boiler controller. The top line will alternate between the words ‘FAULT HISTORY’ and the fault encountered. The bottom line displays the date and time the
08/28/2009 Fr 5:19A
Table 25
– Fault History Screens
fault occurred.
B. CASCADE MENU
This menu is accessed by pressing the
key from the default menu or the
key from the status menu.
SCREEN
CASCADE MASTER READY
SYS PUMP OFF
DESCRIPTION
This screen tells the user that the boiler is configured as a Cascade Master Boiler and that the cascade system is ready to accept a demand for heat. The second line indicates the status of the system pump output of the cascade system. This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the
key from the default screen.
CASCADE NO FOLLOWER
SYS PUMP OFF
This screen is displayed when the boiler is configured as a Master Boiler and there are no connected follower boilers, or the follower boilers are not powered. The second line indicates status of the cascade system pump output. This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the
key from the default screen.
CASCADE NO SENSOR
SYS PUMP OFF
This screen is displayed when the boiler is configured as a Master Boiler and there is no system temperature sensor connected or the system sensor is defective. The cascade system will still function in this situation with reduced efficiency. All boilers will run simultaneously rather than in a staged fashion. The second line indicates the status of the system pump output of the cascade system. This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the
key from the default screen.
CASCADE TT 0123 567
SYS PUMP ON 12:47P
Shows information about cascade status. The TT in the center of the top line shows that the cascade demand is coming from the TT contact being closed. You may also see DHW if the demand is from a DHW sensor, or 0-10 if the demand is from a 0-10 volt input. The following numbers show which boiler addresses are currently communicating to the master. If a boiler address is not used or communicating, the number will not show on the display. In the example above, boiler address #4 is not communicating. When a boiler in the system is firing, its address number will alternate with a ‘.’ to signify it is firing. The bottom line shows the status of system pump output contacts.
Press the
▼ key once.
CASCADE PWR 100%
PRESENT 01234567
This screen shows the overall cascade power output. The range of this value is the number of boilers communicating with the Master x 100. For example, if 8 boilers are connected and communicating, the maximum cascade power is 800%. The second line shows which boiler addresses are communicating with the
Master.
Press the
▼ key once.
CASCADE SYST 118 o
F
CASCADE SET 190 o
F
Press the
▼ key once.
This screen shows the current system temperature sensor reading on the top line and the cascade system temperature setting on the bottom.
BOILER 0 100%
BOILER 1 56%
This screen shows the current cascade power demand output on a per connected boiler basis for boilers addressed as 0 and 1. In the screen above, boiler 0 is being commanded to fire at 100% and boiler 1 at 56%. If this were a 2 boiler system, the ‘CASCADE PWR’ screen above would read 156%.
Press the
▼ key once.
BOILER 2 0%
BOILER 3 0%
Press the
▼ key once.
This screen shows the current cascade power demand output on a per connected boiler basis for boilers addressed as 2 and 3.
BOILER 4 0%
BOILER 5 0%
Press the
▼ key once.
This screen shows the current cascade power demand output on a per connected boiler basis for boilers addressed as 4 and 5.
BOILER 6 0%
This screen shows the current cascade power demand output on a per connected boiler basis for boilers
BOILER 7 0% addressed as 6 and 7.
Table 26
– Cascade Menu Screens
C. BOILER TEST MODE
selected to run the boilers. Automatic modulation does not take place when the controller is in test mode. However, the boilers will modulate down if the program set point is reached while running in test mode. It is recommended you have the largest load possible to create a heat demand so the test mode operation will not be interrupted. To enter test mode, press the
▲ and
ENTER
keys simultaneously. To exit, press
▲ and ▼ simultaneously.
LP-387 REV. 3.4.15
NOTE:
The boiler will automatically exit test mode after 20 minutes of operation.
Fan Speed
Carbon Monoxide PPM
Carbon Dioxide (CO
2
)
Table 27
Low
5
– 50
8 - 10%
COMBUSTION SETTINGS ON ALL MODELS
Natural Gas
Ignition
60 - 100
High
< 150
8 ½ - 10 ½%
SERVICE RUN
PUMP ON
Low
5
– 50
8 ½ - 10 ½%
Propane LP
Ignition
60 - 100
9 - 10 ½%
Table 28
MODEL
EFT-55
EFT-80
EFT-110
EFT-155
EFT-199
EFT-285
EFT-399
IGNITION
3800
3800
3800
4100
3800
4600
4200
ELITE FT FAN SPEEDS
MIN
1650
1850
1850
1850
1750
1800
1900
MAX
4050
5000
6050
5400
6050
6050
6950
High
< 150
9 ½ - 11%
71
3400 RPM
4:49P
PART 12 – SHUTDOWN
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 o
F and wait for the burner to shut off. Continue to wait for the combustion blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 40 to 90 seconds.
B. VACATION PROCEDURE
If there is danger of freezing, change the set point to 70 o
F. DO NOT turn off electrical power. If there is no danger of freezing, follow
“Shutdown Procedure”.
C. FAILURE TO OPERATE
Should the burner fail to light, the control will perform two more ignition trials prior to entering a lockout state. Note that each subsequent ignition trial will not occur immediately. After a failed ignition trial, the blower must run for approximately 10 seconds to purge the system. Therefore, a time period of approximately 40 to 90 seconds will expire between each ignition trial.
If the burner lights during any one of these three ignition trails, normal operation will resume. If the burner lights, but goes off in about 4 seconds, check the polarity of the wiring. See electrical connection section.
If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout state indicates that a problem exists with the boiler, the controls, or the gas supply. Under such circumstances, a qualified service technician should be contacted immediately to properly service the boiler and correct the problem. If a technician is not available, depressing and holding the RESET button for more than 1 second will remove the lockout state so additional trials for ignition can be performed. The unit will try to re-light once every 6 minutes.
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PART 13 – TROUBLESHOOTING
A. BOILER ERROR CODE
If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the boiler, the display may show an error message and error code. This message and code may be the result of a temporary condition, in which case the display will revert to its normal readout when the condition is corrected, or it may be a condition that the controller has evaluated as not safe to restart the boiler. In this case, the boiler control will be locked out, the red FAULT light will be lit, and the mes sage “LOCKOUT” will be displayed on the readout on the lower line.
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 mes sage “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.
IMPORTANT NOTE: If you see error messages on your display readout, call a technician immediately, since the message may indicate a more serious problem will occur soon.
B. BOILER ERROR
When an error condition occurs, the controller will display a description and code on the display readout. These error messages and their recommended corrective actions are described in Section D.
C. BOILER FAULT
1.
When a fault condition occurs, the controller will illuminate the red “FAULT” indication light and display a fault message in the screen.
The alarm output will also activate. Most fault conditions cause the CH pump to run in an attempt to cool the boiler.
2. Note the fault message displayed and refer to Part D in this section for an explanation of the message along with several suggestions for corrective actions.
3. Press the reset key to clear the fault and resume operation. Be sure to observe the operation of the boiler for a period of time to assure correct operation and no reoccurrence of fault message.
When servicing or replacing any components of this boiler, be certain that:
The gas is off.
All electrical power is disconnected.
When servicing or replacing components that are in direct contact with boiler water, be certain that:
There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure gauge reading.
The boiler water is not hot.
The electrical power is disconnected.
DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER.
Immediately call a qualified service technician. The boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged boiler could result in property damage, severe personal injury, or death.
NOTE:
Boiler damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.
Observe the position of each wire and label before removing. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.
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.
NOTE:
If system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler cabinet and cause some internal sheet metal components to rust.
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D. USER INTERFACE DISPLAY
Cascade Control FAULT Codes
SCREEN
Fault Code EO3
System Sensor Failure
DESCRIPTION
SYS SUPPLY SENSOR
PUMP OFF E03
This screen shows that there is a problem with the system sensor circuit. The circuit could be open or shorted. Possible reasons for this error are:
There is no system sensor connected to the
Master Boiler.
The system sensor is faulty.
There is a short circuit in the system sensor wiring; possibly from a staple placed through the wire, or damage to the wire causing both conductors to touch.
The system sensor wiring is open due to defect or damage.
Fault Code TT
Temperature Blocking TT Demand
POSSIBLE REMEDY
Disconnect the system sensor from the wiring and measure the resistance of it. Compare the measured resistance to the table in this manual to see if it corresponds to the temperature of the sensor. If the resistance does not agree with the sensor, replace the sensor. If the sensor is OK, disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter. Repair or replace as necessary.
If this error is present, all boilers in the cascaded group will run and ignite simultaneously when there is a heat demand. Each boiler will modulate to maintain set point temperature on its own supply sensor. This code will reset automatically when repair is complete. This code will not display if system setting function ERROR SYSTEM SENS is set to OFF.
This screen indicates a temporary hold on the burner. There is a demand on the boiler, the pump is powered on, but the
PUMP ON TT ture measured by the supply sensor is higher than the boiler temperature
– ignition diff setting. This error will clear itself when the water temperature measured by the supply sensor is less than the boiler temperature
– ignition diff setting.
Fault Code DHW
Temperature Blocking DHW Demand
TEMPER BLOCKING
PUMP ON DHW
This display indicates a temporary hold on the burner. There is a demand on the boiler from the DHW circuit for heat, the pump is powered on, but the boiler supply sensor indicates that the water temperature is too high to ignite. This is a temporary hold on the burner only and all other functions will remain functioning properly. This error will clear itself when either the boiler supply temperature drops below the BOILER SUPPLY minus boiler supply differential (5 o
F) or DHW
SETPOINT is satisfied and no longer calls for heat.
Fault Code PRO
LOW WATER PRESS
PUMP OFF PRO
This display indicates that there is low water pressure in the boiler. This code will reset automatically after the water pressure is high enough for the boiler to run safely. The second line indicates the status of the pump. Note that while the water pressure is low, the pump will be off.
1. Assure that the system pressure is above 10 psig.
2. Check for leaks in the system piping.
Fault Code FLU
HIGH FLUE PRESS FLU
PUMP ON
This display indicates that there is excessive flue pressure. This code resets automatically after the high pressure condition is resolved. The second line indicates the status of the pump.
1. Assure that the flue is not blocked.
2. Check the switch wiring by applying a jumper in place of the switch. If the code clears with the jumper in place, REPLACE the flue switch and connect the wires to the new switch BEFORE running boiler.
WARNING:
Do not use jumper to remedy an FLU error. Faulty switch MUST be replaced. Failure to do so could result in serious injury or death.
Fault Code LOU
24 VOLT LOW LOU
PUMP ON
This display indicates that the 24 volt power supply on the control is damaged or overloaded. This code resets automatically if it is the result of an overload and that overload condition is removed. The second line indicates the status of the pump. Note that while 24 volt power is low, the pump output will be on.
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. Use this as a troubleshooting guide as you follow the steps below.
3. Remove the 10 pin Molex connector from customer connection board. If the message clears, then the problem is with the external sensor wiring. Examine the external sensor wiring for shorts to the ground, repairing as necessary. If the message is still present and the boiler is so equipped, disconnect the UL 353 low water cut-off to see if the message clears. Replace the faulty part. Check the low voltage wire harness in boiler for shorts to ground.
4. If a message only occurs when the burner tries to light, check the gas valve for excessive current draw.
5. If a message is present with the low voltage harness disconnected from the 926 control board, replace the 926 control board.
Fault Code F00
WATER HIGH TEMP F00
PUMP ON
This display indicates if the water in the boiler has overheated. This code indicates a serious safety issue and the boiler will not restart until it cools sufficiently and a technician repairs the cause of overheating and pushes the RESET button on the display. This is a serious situation and is indicated by the red light on the display illuminating and the word LOCKOUT flashing on the display. During this lockout fault, the pump will be on as indicated on the second line in an effort to cool the boiler down.
1. Check circulator pump operation
2. If the circulator pump is running, be sure that there is water in the system and that the water is moving through the system as intended. Be sure that all correct ball valves and or zone valves are open or closed as intended.
3. Observe the temperature/pressure gauge. If the water is not too hot and this message is displayed, check the wiring to the water
ECO sensor and repair if necessary. If the wiring is ok and this code is still present and the water is not excessively hot, replace the ECO sensor.
LP-387 REV. 3.4.15
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SCREEN
Fault Code F01
FLUE SENSOR F04
PUMP ON
DESCRIPTION
This display indicates that the flue temperature sensor of the boiler has failed. This is a serious safety issue. The boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display. This situation is indicated by the red light and the flashing word LOCKOUT on the display. During this lockout fault, the pump will be on as indicated on the second line of the display.
POSSIBLE REMEDY
FLUE TEMP/WAT LV F01
PUMP ON
RETURN SENSOR F03
PUMP ON
This display indicates that the flue temperature limit switch of the boiler has tripped or that the water level in the boiler is low (this will only occur if the optional UL353 LWCO is installed). This code indicates a serious safety issue. The boiler will not restart until the flue cools down sufficiently or the water level is restored. A technician must repair the cause of the problem and push the RESET button first on the low water cut-off control box, then on the display. This situation is indicated by the red light on the display and the word LOCKOUT flashing on the display. During this lockout fault, the pump will be on as indicated on the second line of the display.
1. If the boiler has a UL353 LWCO, check if the red LED on the
LWCO control box is illuminated. If so, correct the low water condition and press the reset button on the LWCO control box to reset the LWCO. The LED should change to green. Press the reset button on the front panel of the boiler to reset the boiler control.
2. Check the flue for obstructions or any sign of damage, especially signs of excessive heat. Repair as necessary. Push the red reset button on the flue temperature switch located on the flue inside the rear access door of the boiler. NOTE: The switch temperature must be less than 90°F to reset. Press the reset button on the display.
Run the boiler and check the flue temperature by using both an external thermometer in the flue pipe and the flue temperature display in the status screens. If the flue temperature is within specs and the switch trips, replace the switch. If the flue temperature is excessive, check and adjust combustion controls on the boiler. If the problem persists, inspect the target wall in the combustion chamber and replace it if cracked or damaged.
Fault Code F02
SUPPLY SENSOR F02
PUMP ON
Indicates that the supply temperature sensor of the boiler has failed. This is a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display. This situation is indicated by the red light on the display and the flashing word LOCKOUT. During this lockout fault, the pump will be on as indicated on the second line of the display.
Fault Code F03
This display indicates that the return temperature sensor of the boiler has failed. This code indicates a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display. This situation is indicated by the red light on the display and the word LOCKOUT flashing on the display.
During this lockout fault, the pump will be on as indicated on the second line of the display.
1. Check the electrical connection to the thermistor on the outlet manifold. Verify 5 VDC by checking in Molex connector. If there is no 5 VDC, check the harness. If harness is OK, replace control. NOTE: The boiler will reset automatically. Verify thermistor values by referencing chart in this manual.
2. Replace thermistor if necessary.
1. Check circulator pump operation.
2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the return thermistor to the supply thermistor.
3. Troubleshoot thermistor by following steps in F02 .
Fault Code F04
Inspect the flue sensor for physical damage or corrosion and replace it if necessary. Check the electrical connection to the flue sensor and repair as necessary. Measure the resistance of the sensor and refer to the Supply Temperature Sensor chart in Table
30 of this manual. The temperature on the chart should be close to the same as the temperature in the flue. If not, replace the flue sensor.
Fault Code F05
SUPPLY TEMP HIGH F05
PUMP ON
This display indicates that the supply temperature of the boiler is excessive. If accompanied by the red FAULT light and
LOCKOUT flashing on the display, this code indicates that the temperature on the supply sensor has exceeded 199 o
F and a serious safety issue exists. The boiler will not restart until the cause of the excessive temperature is repaired by a technician and the RESET button is pushed on the display.
If the FAULT light is not illuminated and this message is displayed, then the supply temperature of the boiler is at or above 199 o
F. The message will clear automatically when the temperature drops below 194 o
F. During the time that this message or lockout fault is displayed, the pump will be on as indicated on the second line.
1.
Check circulator pump operation.
2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the return thermistor to the supply thermistor.
3. Check the direction of flow off the boiler circulator.
(See Piping Details in this manual.)
4. Troubleshoot the thermistor by following steps in
F02 .
Fault Code F06
RETURN TEMP HIGH F06
PUMP ON
This display indicates that the return temperature of the boiler is excessive. If accompanied by the red FAULT light and LOCKOUT flashing on the display, the return sensor temperature has exceeded 199 o
F and a serious safety issue exists. The boiler will not restart until the cause of excessive temperature is repaired by a technician and the boiler is
RESET.
If the red FAULT light is not illuminated, then the return temperature of the boiler is at or above 199 o
F. The message will clear automatically when the temperature drops below 194 o
F. During the time that this message or lockout fault is displayed, the pump will be on as indicated on the second line.
1. Check circulator pump operation.
2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the return thermistor to the supply thermistor.
3. Check the direction of flow on boiler circulator. (See
Piping Details in this manual.)
4. Troubleshoot thermistor by following steps in F02 .
LP-387 REV. 3.4.15
Fault Code F09
NO FLAME ON IGN F09
PUMP ON
The boiler tried to ignite four times during one heat call and failed. The red FAULT light and
LOCKOUT will flash on the display. This code indicates a serious safety issue. The boiler will not restart until the cause of ignition failure is repaired by a technician and he pushes the
RESET button on the display.
During this lockout fault, the pump will remain on as indicated on the second line of the display.
1. Watch the igniter through the observation window provided.
2. If there is no spark, check the spark electr ode for the proper .156” (3.96 mm) gap (See Figure 34).
3. Remove any corrosion from the spark electrode and flame rectifier probe.
4. If there is a spark but no flame, check the gas supply to the boiler.
5. If there is a flame, check the flame sensor.
6. Check any flue blockage or condensate blocks.
75
Fault Code F10
Fault Code F11
FALSE FLAME SIG F11
PUMP ON
Fault Code F13
FAN SPEED ERROR
F13
PUMP ON
FLAME LOSS F10
Figure 34
– Proper Electrode Spacing
The flame was lost while the boiler was firing 3 times during 1 demand call. The red light will display and the word LOCKOUT will flash. This code indicates a serious safety issue. The boiler will not restart until the cause of flame loss is determined by a technician and he pushes the
RESET button on the display.
During this lockout fault, the pump will be on as indicated on the second line of the display.
1. Monitor the gas pressure to the boiler while in operation.
2. Assure that the flame is stable when lit.
3. Check to see if the dis play readout changes from “GAS VALVE ON” to “RUN” within a few seconds after the boiler ignites.
4. Check the FLAME signal on the status display. It should be above 1.0 when the boiler is firing.
5. If the signal reads less than 1 microampere, clean the flame rectifier and spark probe.
6. If the problem persists and the ‘FLAME” signal is still less than 1.0, replace the flame probe and spark igniter probe.
7. The flame signal should be steady after the boiler has been firing for 1 minute and is normally at 5.0 to 9.0. If the flame signal is not steady, disassemble the burner door and check the burner and its sealing gaskets.
There is flame when the control is not telling the boiler to run. The red light will display and the word
LOCKOUT will flash. This code indicates a serious safety issue.
The boiler will not restart until the cause is determined by a technician and he pushes the
RESET button on the display.
During this lockout fault, the pump will be on as indicated on the second line of the display.
1. Look into window. If there is flame, turn the gas off to the boiler at the service valve and replace the gas valve.
2. If the flame signal on the status menu is greater than 1.0 when the burner is not lit, replace the spark igniter and the flame rectification probe.
3. If the flame return sensor is not present after turning off the gas supply, check the gas valve electrical connection.
4. Repair condensate system as necessary. If condensate has backed up and partially filled the combustion chamber, the refractory wall may be damaged and should be replaced.
5. Turn the gas on at the service valve after corrective action is taken.
6. If the refractory wall falls against the rectifier probe, it may conduct the signal to ground, giving a false reading.
The fan is not running at the speed that the control has commanded it to run at. The fan speed had been more than 30% faster or slower than the commanded speed for more than 10 seconds. The red light will display and the word
LOCKOUT will flash. This code indicates a serious safety issue and the boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display.
During this lockout fault, the pump will be on as indicated on the second line.
1. Check the combustion air fan wiring.
2. Measure the DC voltage from the red fan wire to ground while it is connected to the fan. It should be between 24 to 40 volts. If it is lower than 24 volts, check for excessive external loads connected to the boiler sensor terminals. Disconnect the 5 pin plug from the fan and check the voltage on the red wire again. If it is now between 24-
40 volts, replace the fan. If it is still below 24 volts replace the boiler control board.
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SCREEN DESCRIPTION POSSIBLE REMEDY
Fault Code F20
CONDENSATE FULL F20
PUMP ON
The condensate trap is full. The red light will display and the word LOCKOUT will flash. This code indicates a serious safety issue. The boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display. During this lockout fault, the pump will be off as indicated on the second line of the display.
1. Check condensate lines for obstructions.
2. Check wiring from condensate reservoir to 926 control. Verify the leads are green and red. Repair as necessary.
Fault Code F31
PROGRAM ERROR
F31
There was an error while programming the control and the memory is corrupt. The boiler control will not function in this state and the pump will be off as indicated on the bottom line. This error only occurs if a technician is programming the control and the programming function fails. The only way to recover from this error is to reprogram the control. If this error occurs at any time other than when a technician is servicing the boiler, the control has failed and must be replaced by a qualified technician
The control must be re-programmed. If programming does not solve problem, the control must be replaced.
Fault Code PP
CONTROL PROGRAMED
PP
The control has been programmed by a technician or the factory. After programming, the control is left in a locked out mode. Press the
RESET key for at least 1 second to begin use of the control.
Fault Code FOU
OUTDOOR SENSOR FOU
PUMP ON 1:45P
There is an issue with the outdoor sensor. It is shorted, damaged, or disconnected from the boiler.
1. Check outdoor sensor connections and wiring. Ensure the sensor and wiring are intact and that the sensor is connected to the boiler.
2. Check the outdoor sensor resistance with an ohmmeter. See
Table 30 for correct outdoor sensor resistance.
3. Replace the outdoor sensor.
NOTE:
If an outdoor sensor IS NOT used in the installation, enter the System Setting Program Navigation, go to Function 21, and turn the setting from
ON to OFF.
The following blocking codes will block operation until the control determines the situation safe for boiler operation.
Blocking Code E07
FLUE TEMP HIGH E07
PUMP OFF TIME
This display indicates that the flue sensor temperature is excessive and above 199 o
F. When this code is displayed, the boiler will not respond to a demand for heat. When the flue temperature o decreases below 194 F, the display will return to normal and allow the boiler to respond to a heat demand. The bottom line indicates the status of the pump. The pump will remain off when this error is displayed.
Check the flue for obstructions or any sign of damage, especially signs of excessive heat. Repair as necessary. Run the boiler and check the flue temperature with an external thermometer. If the flue temperature on the thermometer does not agree with the flue temperature displayed in the status menu, inspect the wiring to the flue temperature sensor in the boiler and repair as necessary. If the wiring is intact, replace the flue sensor. If the flue temperature is excessive on the status menu and the test thermometer reads the same, check and adjust combustion controls on the boiler. If the problem persists, inspect the target wall in the combustion chamber and replace it if cracked or damaged.
Blocking Code E19
This display indicates that the line voltage fre-
LINE VOLTAGE quency is out of range. This could happen if the boiler is being powered from a small gasoline
PUMP OFF E19 powered generator that is not functioning correctly or overloaded.
Table 29
– Fault and Blocking Code Screens
Inspect power wiring to boiler and repair as necessary. If connected to line voltage, notify the power company. If connected to an alternate power source such as generator or inverter, make sure the line voltage frequency supplied by the device is 60 Hz.
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Table 30
PART 14 – 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. The installer must also inform the owner that a lack of proper care and maintenance of the boiler may result in a hazardous condition.
BEFORE EACH HEATING SEASON a trained and qualified service technician should perform the inspections as per the boiler inspection and maintenance schedule in the back of the manual. Failure to do so could result in death or serious injury.
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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).”
Avoid breathing dust and contact with skin and eyes.
Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on job site conditions.
Current NIOSH recommendations can be found on the NIOSH website: http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.
Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent dust.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER
*Before beginning this procedure, you must have on hand the following items:
a nylon brush
NOTE:
Do not use a metal brush on the heat exchanger. Doing so could scratch the heat exchanger, and lead to early boiler failure. Such failure IS NOT covered by warranty.
an FDA approved liquid lime scale remover for use with stainless steel, or water, in a spray bottle
gloves and eye protection
1. Shut down the Boiler by using the following steps: a. Turn off power to the boiler. Turn thermostats down to ensure there is no call for heat, or disconnect thermostat connections from terminals. Close the gas valve inside the boiler cabinet. Wait for the boiler to be cool to the touch. b. Disconnect the wires plugged into the fan, spark electrode, flame rod, and gas valve. c. Disconnect the flexible gas lines from the venture attached to the fan. d. Loosen the nuts that hold the burner plate to the heat exchanger. e. Remove the combustion assembly. f. Spray water or solution into the combustion assembly and monitor the flow through the combustion system. g. Liquid should flow freely through each tube. If there is an obstruction, increase the flow on the tube to force blockage out. h. Once complete, reinstall combustion assembly with gaskets and secure nuts. Tighten properly. i. Reconnect all wire and piping connections. Once connected, apply power and disconnect the wire harness with the whiteblue-red-black wires to run fan and dry combustion assembly. Let fan run for five minutes. When finished, reconnect harness to the fan. j. Connect the thermostat wires to the field connection board, or turn up thermostat to fire the combustion system. Check for leaks in the combustion system. Observe operation for 5 to 10 minutes.
If boiler is operating properly, condensate is flowing normally, and no gas leaks are detected, combustion coil cleaning is complete.
Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation. Failure to do so could result in death or serious injury.
C. CLEANING WATER SIDE OF HEAT EXCHANGER
1. Make sure power is turned off to the boiler. Run water through the hot water system to assure it is below room temperature.
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2. Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams within this manual. Slowly open the ball valves and release pressure into a bucket. Once pressure is released, connect a hose to the water line to flush the boiler.
Scale removing solution may be used, but must be approved for use with stainless steel and FDA approved for use in a potable water system.
3. Thoroughly flush the heat exchanger before commissioning the boiler back in service.
D. MAINTAINING THE CONDENSATE SYSTEM
The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the boiler.
Operating the boiler without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death.
When servicing is complete, make sure the condensate collector cap is replaced securely. Failure to do so will cause venting issues that will result in serious injury or death.
1. Ensure the boiler is powered off.
2. Remove the stainless steel lock pin to release the condensate trap. Remove the clear plastic hose from the hose barb. Remove the trap from the drain tube.
3. Remove the bottom cap from the condensate trap.
4. Flush trap with fresh water to remove debris from the trap.
NOTE:
Ensure the float moves freely within the trap. If the float does not move, DO NOT reinstall the trap.
5. When the condensate trap is sufficiently clean, reinstall the bottom cap on the trap.
NOTE:
Ensure all parts shown in Figure 35-1, Condensate Detail, are installed with the condensate trap. If any parts are missing, DO
NOT reinstall the trap. Replace the entire assembly.
Figure 35-1 - Condensate Detail, 35-2
– Condensate Trap Installation
LP-387 REV. 3.4.15
80
Do not install the condensate assembly if a component is lost or missing. Replace the entire assembly. Failure to follow this warning could result in property damage, serious personal injury, or death.
6. Fill the condensate trap with fresh water prior to reassembly on the boiler.
7. Slide the condensate trap adapter onto the drain tube until the holes line up with the groove.
8. Insert stainless steel hitch pin to lock condensate adapter to the drain tube.
9. Reattach the clear plastic hose to the hose barb.
Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch. Failure to follow this warning could result in property damage, serious personal injury, or death.
10. If a condensate neutralizer kit is installed with the boiler, check the assembly when cleaning the condensate trap, and replenish the limestone chips if necessary. When replacing the limestone chips, take care to ensure chips are no smaller than ½” to avoid blockage in condensate piping (for piping details, refer to condensate neutralizer installation instruction.)
11. Check condensate piping for sagging and/or leakage. Repair any sags or leaks before restoring power to the boiler.
It is very important that the condensate piping be no smaller than ½”. To prevent sagging and maintain pitch, condensate piping should be supported with pipe supports, and pitched ¼” per foot to allow for proper drainage.
The condensate line must remain unobstructed, allowing free flow of condensate. If condensate freezes in the line, or if line is obstructed in any other manner, condensate can exit from the tee, resulting in potential water damage to property.
12. If the boiler has a condensate pump, ensure the pump operates properly before considering maintenance complete.
LP-387 REV. 3.4.15
EFT-55 / 80 / 110 PARTS BREAKDOWN
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Figure 36 - Replacement Parts - LP-387-J
LP-387 REV. 3.4.15
EFT-55 / 80 / 110 PARTS BREAKDOWN
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Figure 37
– Replacement Parts - *#20 – Switch on the Left is the Blocked Flue Pressure Switch, Switch on the Right is the
Blocked Condensate Pressure Switch
– Both share same Part Number
LP-387 REV. 3.4.15
EFT-155 / 199 / 285 / 399 PARTS BREAKDOWN
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Figure 38 - Replacement Parts - LP-387-KK
LP-387 REV. 3.4.15
EFT-155 / 199 / 285 / 399 MODEL PARTS BREAKDOWN
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Figure 39 - Replacement Parts - LP-387-JJ
– EFT-155 - 399 Models - *#15 – Switch on the Left is the Blocked Flue Pressure
Switch, Switch on the Right is the Blocked Condensate Pressure Switch
– Both share same Part Number
LP-387 REV. 3.4.15
BOILER START-UP REPORT
LIGHT OFF ACTIVITIES
1) Fill the heating
Check all piping and gas connections, verify all are tight system
Pressurize system (12
– 15 psi)
Add water to prime condensate cup
Percentage of glycol in system (0
– 50%)
Verify near boiler piping is properly supported
2) Check gas pipe
Leak test using locally approved methods (consult jurisdictional code book)
Check incoming gas pressure (3.5” to 14” W.C.)
What is the “drop” on light off (No more than 1”
W.C.)?
3) Check combustion
Check and adjust (if necessary) carbon dioxide content
Check and adjust (if necessary) carbon monoxide content
4) Verify system operation
Turn up thermostat to verify wiring connections
5) Record ionization current
6) Indirect water heater
7) Convert the boiler
Check uA reading at d7 on the status menu (see start-up section)
Verify safety and operation of the indirect water heater, record settings
If necessary, convert the boiler to the proper gas type
Locate the stickers in the appropriate locations on the boiler
Verify combustion settings after gas conversion,
Carbon Dioxide
Verify combustion settings after gas conversion,
Carbon Monoxide
Mail in the conversion registration
Record heating curve, record steps 8) Record system settings
Notes:
Table 31
DATE COMPLETED ________________
____ PSI
____ %
____ in w.c.
____ in w.c.
Static
Dynamic
____% CO2 High Fire
____ppm CO High Fire
____ uA
____de
____*8
High Fire
____dh
____% CO2 High Fire
____ppm CO High Fire
____*9
____ % CO2
____ ppm CO
____ uA
____% CO2
____ppm CO
____*10
Low Fire
Low Fire
Low Fire
____*11
Low Fire
Low Fire
85
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. Such product failures ARE NOT covered under warranty.
The boiler requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended.
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. Installer must also inform the owner that the lack of proper care and maintenance of the boiler may result in a hazardous condition.
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INSPECTION ACTIVITIES
PIPING
Near boiler piping
Vent
Gas
Check boiler and system piping for any sign of leakage.
Continual fresh make-up water will reduce boiler life.
Leaking pipes could cause property damage. Make sure all piping is properly supported.
Check condition of all vent pipes and joints. Ensure all vent piping is properly supported. Check for obstructions at exhaust and intake termination points.
Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.
SYSTEM
Visual
Functional
Temperatures
Temperatures
ELECTRICAL
Connections
Smoke and CO detector
Circuit Breakers
Switch and Plug
CHAMBER/BURNER
Combustion Chamber Check burner tube and combustion chamber coils. Clean
Spark Electrode according to maintenance section of manual. Vacuum combustion chamber. Replace any gaskets that show signs of damage.
C lean. Set gap at .156”. See Figure 34.
Flame Probe Clean. Check ionization in uA (d7 on status menu in Start-up
Procedures). Record high fire and low fire.
CONDENSATE
Neutralizer
Condensate trap and hose
Check condensate neutralizer. Replace if necessary.
Ensure the condensate trap is filled with water. Disconnect condensate hose. Clean out dirt. Fill with water to level of outlet and re-install. (NOTE: Verify the flow of condensate, making sure that the hose is properly connected during final inspection.)
GAS
Pressure
Pressure Drop
Measure incoming gas pressure (
3.5” to 14” W.C.)
Measure drop in pressure on light off (no more than 1” W.C.)
Check piping for leaks. Verify that all are properly supported. Check gas pipe for leaks
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
Out)
Thermistors
FINAL INSPECTION
Check list
Homeowner
TECH SIGN OFF
Do a full visual inspection of all system components.
Test all functions of the system (Heat, Safeties)
Verify safe settings on boiler or Anti-Scald Valve
Verify programmed temperature settings
Check wire connections. Make sure they are tight.
Verify devices are installed and working properly. Change batteries if necessary.
Check to see that the circuit breaker is clearly labeled.
Exercise circuit breaker.
Verify ON/OFF switch and convenience plug are both functional
Check continuity on Flue and Water ECO. Replace if corroded.
Check wiring. Verify through ohms reading.
Verify that you have completed entire check list. WARNING:
FAILURE TO DO SO COULD RESULT IN SERIOUS
INJURY OR DEATH.
Review what you have done with the homeowner.
1 st
YEAR
Table 32 *Continue annual maintenance beyond the 4 th
year as required.
DATE LAST COMPLETED
2 nd
YEAR 3 rd
YEAR 4 th
YEAR*
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LP-387 REV. 3.4.15
MAINTENANCE NOTES
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90
HTP CUSTOMER INSTALLATION RECORD FORM
The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
Customer’s Name:
Installation Address:
Date of Installation:
Installer’s Code/Name:
Product Serial Number(s):
Combustion Setting at Time of Installation:
Comments:
Installer’s Phone Number:
Signed by Installer:
Signed by Customer:
IMPORTANT NOTES:
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.
LP-387 REV. 3.4.15
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