Installation Manual Installation Manual

Floor
mounted
Installation
Manual
•
•
•
•
Installation
Startup
Maintenance
Parts
Wall
mounted
Models
EL-80 N/LP EL-220 N/LP
EL-110 N/LP EL-299 N/LP
EL-150 N/LP EL-399 N/LP
n WARNING
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
severe personal injury, death or substantial property damage.
NOTICE
Heat Transfer Products, Inc., reserves the right to make product changes or updates without
notice and will not be held liable for typographical errors in literature.
Boiler Manual
WARNING
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.
•
•
•
1
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
gas supplier's instructions.
Do not touch any electrical switch:
• If you cannot reach your gas
do not use any phone in your
supplier, call the fire department.
building.
Installation and service must be
performed by a qualified installer,
Immediately call your gas supplier
service agency or the gas supplier.
from a neighbor's phone. Follow the
Boiler Manual
CONTENTS
Part 1 – Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Part 2 – Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
A. What’s In The Box
B. How The Boiler Operates
C. Optional Equipment
Part 3 – Prepare Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
A.
B.
C.
D.
E.
F.
G.
H.
Boiler Location / Dimensions
Installations Must Comply With:
Before Locating Boiler
Clearances for Service Access
Residential Garage Installation
Exhaust Vent and Intake Air Vent
Prevent Combustion Air Contamination
When Removing a Boiler from an Existing Common Vent System
Part 4 – Prepare Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Part 5 – Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
Relief Valve
General Piping Information
Backflow Preventer
System Water Piping Methods
Circulators
Hydronic Piping with Circulators, Zone Valves and Multiple Boilers
Boiler Piping Details
Circulator Sizing
Fill and Purge Heating System
Zoning with Zone Valves
Zoning with Circulators
Multiple Boilers
Part 6 – Venting, Combustion Air & Condensate Removal . . . . . . . . . . . . . . . . . . . . . 24-35
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
J.
Installing Exhaust Vent and Intake Air Vent
General
Approved Materials for Exhaust Vent and Intake Air Vent
Exhaust Vent and Intake Air Vent Pipe Location
Exhaust Vent and Intake Air Vent Sizing
Longer Vent Runs
Exhaust Vent and Intake Air Pipe Installation
Heater Removal from a Common Vent System
Diagrams for Sidewall Venting
Diagram for Vertical Venting
Diagram for Horizontal Venting
Diagram for Unbalanced Flue Venting
Part 7 – Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-37
A.
B.
C.
D.
Gas Connection
Gas Piping
Check Inlet Gas Pressure
Elite Gas Valve
2
Boiler Manual
CONTENTS (CONT’D)
Part 8 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-46
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Installation Must Comply With
Field Wiring
Line Voltage Wiring for Standard Boiler
Low Voltage Connections for Standard Boiler
Thermostat
Outdoor Sensor
Indirect Sensor
Optional 0-10 Volt Building Control Signal
Optional UL353 Low Water Cutoff Switch
Wiring of Cascade System Communication Bus
Part 9 – Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-50
A.
B.
C.
D.
E.
F.
G.
H.
I.
Check/Control Water Chemistry
Freeze Protection (when used)
Fill and Test Water System
Purge Air from Water System
Check for Gas Leaks
Check Thermostat Circuit(s)
Condensate Removal
Final Checks Before Starting Boiler
Cascade System
Part 10 – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
A.
B.
C.
D.
E.
F.
Control Overview
Navigation of the Display
Operating Instructions
Programming Boiler Settings
Programming the System Setting
System Setting Program Navigation
Part 11 – Start-Up Procedures for the Installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-61
A. Elite Control Status Menu
B. Elite Control Test Mode
C. Test Mode Access
Part 12 – Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-69
A.
B.
C.
D.
Elite Heating Boilers® Error Code
Boiler Error
Boiler Fault
User Interface Display
Part 13 – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-77
A. Maintenance Procedures
B. Combustion Chamber Coil Cleaning Instructions for Elite Heating Boilers®
Inspection and Maintenance Start-Up Charts
3
Boiler Manual
PART 1: PRODUCT AND SAFETY INFORMATION
SPECIAL ATTENTION BOXES
The following defined terms are used throughout this manual to bring attention to the presence of
hazards of various risk levels or to important information concerning the product.
DEFINITIONS
n DANGER
n CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
n WARNING
CAUTION
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
This appliance must be installed by qualified and licensed personnel in accordance with
local codes, or in the absence of local codes, by the national fuel gas code, ANSI Z223.12002. This appliance is for indoor installations only. Clearance to combustible materials: 0”
top, bottom, sides and back. Front must have room for service, 24” recommended. (A
combustible door or removable panel is acceptable front clearance.) This appliance has
been approved for closet installation. Do not install this appliance directly on carpeting. For
installation on combustible flooring directly. Category IV vent systems only.
4
Boiler Manual
PART 1: PRODUCT AND SAFETY INFORMATION (CONT’D)
n WARNING
CAUTION
User — This manual is for use only by a
qualified heating installer/service technician.
Refer to User’s Information Manual for your
reference.
Due to the low water content of the boiler, missizing of the boiler with regard to the heating
system load will result in excessive boiler
cycling and accelerated component failure. Heat
Transfer Products DOES NOT warrant failures
caused by mis-sized boiler applications. DO
NOT oversize the boiler to the system. Modular
boiler installations greatly reduce the likelihood
of boiler oversizing.
User — Have this boiler serviced/inspected by
a qualified service technician annually.
BEFORE INSTALLING
Installer — Read all instructions in this manual,
and Elite Heating Boilers® Venting section,
before installing. Perform steps in the order
given.
Failure to comply with the above could result in
severe personal injury, death or substantial
property damage.
n WARNING
Failure to adhere to the guidelines on this page
can result in severe personal injury, death or
substantial property damage.
n WARNING
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• 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.
5
WHEN SERVICING BOILER
•
To avoid electric shock, disconnect electrical
supply before performing maintenance.
•
To avoid severe burns, allow boiler to cool
before performing maintenance.
BOILER OPERATION
•
Do not block flow of combustion or
ventilation air to boiler.
•
Should overheating occur or gas supply fail to
shut off, do not turn off or disconnect electrical
supply to circulator. Instead, shut off the gas
supply at a location external to the appliance.
•
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 under water.
BOILER WATER
•
If you have an old system with cast iron radiators,
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 this type of system.
•
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals
in the system may be damaged. This can result
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.
Boiler Manual
PART 1: PRODUCT AND SAFETY INFORMATION (CONT’D)
•
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 carried in by make-up water
can cause internal corrosion in system
components. Leaks in boiler or piping must be
repaired at once to prevent make-up water.
FREEZE PROTECTION FLUIDS
n CAUTION
NEVER use automotive or standard glycol
antifreeze, ethylene glycol made for hydronic
systems. 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.
CAUTION
Consider piping and installation when
determining boiler location.
PART 2: BEFORE YOU START
A. WHAT’S IN THE BOX
Also included with the Elite Heating Boilers® are:
• Pressure and Temperature Gauge
• Indirect Sensor
• Installation Manual
• Outdoor Sensor
• Warranty
• Pressure Relief Valve
• CSD-1 Form
• Brass Tee
• H-3 Data Sheet
• Brass Nipple
• Intake PVC Tee with Screens
• Exhaust PVC Coupling with Screens
B. HOW BOILER OPERATES
Elite Heating Boiler® Condensing Technology is
an intelligent system that delivers highly efficient hydronic heating, while maximizing efficiency by measuring the data parameters of
your heating system. Outlined below are the
features of the system and how they operate:
1. Stainless Steel Heat Exchanger – The highly
efficient Elite Heating Boiler® Stainless Steel
Heat exchanger is designed to use the cold
return water from the system and extract the
last bit of heat before it is exhausted.
2. 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.
3. Control – The integrated control system
monitors the system and regulates the fan
speed to control the boilers output. This
allows the boiler to deliver only the amount
of heated energy required and nothing more.
This control can be set up to monitor outdoor
temperature through an outdoor sensor to
regulate the set point of the boiler. The
system can be further enhanced by
connecting up to 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 will have a cascade system sensor and
a cascade pump connected to it in addition to
its own boiler pump. The follower boilers will
have their own individual pump connected to
6
Boiler Manual
PART 2: BEFORE YOU START (CONT’D)
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
7
each follower boiler.
Text Display and Operational Led light
Indicators – The display allows the user to
change the system parameters and monitor
the system outputs.
Gas Valve – The gas valve senses suction
from the blower allowing gas to flow only if
the gas valve is powered and combustion air
is flowing.
All Metal Integrated Venturi – Controls the air
and gas flow into the burner.
Burner – Constructed of high grade stainless
steel, the burner uses premixed air gas and
provides a wide range of firing rates.
Spark Ignition – The burner is ignited by
applying a high voltage through the system
spark electrode. This causes the spark from
the electrode to ignite the mixed gas off of
the burner.
Supply Water Temperature Sensor – This
sensor monitors the boiler outlet water
temperature (System Supply). The control
adjusts the boiler firing rate so the supply
temperature will match the 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 the 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 appliance, therefore the
boiler will produce condensate. The collection
system has a float switch to monitor the
condensation level to prevent condensation
from backing up into the combustion system.
Inside the collection system there is a built in
trap to seal the combustion system to the
connected drain. This condensate should be
neutralized to avoid damage to the drainage
system or piping.
Outdoor Sensor – The outdoor sensor will
16.
19.
20.
21.
monitor the outdoor temperature and adjust
the unit’s set point to provide greater efficiency.
0-10 Volt Input – Allows Installer to connect
to a BMS (Building Management System) to
control the boiler.
Condensate Flue Check System – Check
system keeps exhaust from Heat Exchanger
backing up into cabinet.
Pump Service Mode – Allows manual
operation of pumps to commission system
and check pump operation.
The Vision II system allows the user to supply
mixed temperatures to up to eight zones
when connected to the Elite Boiler. Vision II
controls three way mixing valves to control
the temperature to each zone. The Vision II
also controls the output temperature of the
Elite Boiler to assure accurate temperature
delivery to all the connected zones.
C. OPTIONAL EQUIPMENT
Below is the list of optional equipment available
for Elite Heating Boiler®.
• Wall Mount Bracket (Part # 7450P-211)
• System Sensor (Part # 7250P-324)
• Indirect Sensor (Part # 7250P-325)
• 3" Stainless Steel Outside Termination Vent
Kit (V1000)
• 4” Stainless Steel Outside Termination Vent
Kit (V2000)
• 6” Stainless Steel Outside Termination Vent
Kit (V3000)
• 3 " P V C C o n c e n t r i c Ve n t K i t ( Pa r t
#KGAVT0601CVT)
• U.L. 353 Compliant Low Water Cut-Off
Interface Kit with Manual Reset (Part # 7350P601)
• Alarm System (Part # 7350P-602) (to monitor
any failure)
• PC Connection Kit (Part # 7250P-320)
• Elite Heating Boiler® Condensate Neutralizer
(Part # 7450P-212 for EL-80, EL-299, Part #
7350P-611 for EL-399), EL-80/110/150/220/299
• Flow Switch Kit (Part # 7450P-213 for
EL-80/110/150/220, EL-220, Part # 7450P-214
for EL-299, Part # 7450P-215 for EL-399)
• Vision II (Part # 7250P-322)
These additional options may be purchased
through your HTP Distributor.
Boiler Manual
PART 3: PREPARE BOILER LOCATION
A. BOILER LOCATION / DIMENSIONS
Before considering the Boiler location, there are
many factors that have to be addressed that are
covered in detail in this installation manual.
Please read the entire manual as it could save
time and money. Piping, Venting, Condensation
Removal are just a few issues that need to be
addressed prior to the installation of the boiler.
n CAUTION
When preparing the boiler location, make sure the area where you are placing the boiler is level. In order
for the condensate to properly flow out of the collection system, the boiler must be level to assure proper
flow direction. The Elite Heating Boiler® comes equipped with leveling feet. Should you find the floor
beneath the boiler is uneven, adjust the leveling feet with a wrench.
INCORRECT
CORRECT
INCORRECT
CORRECT
8
Boiler Manual
DIMENSIONS
H
J
1
5
SYSTEM SUPPLY
6
RELIEF VALVE
3
7
CONDENSATE CONNECTION
4
8
GAS LINE CONNECTION
9
DISPLAY/CONTROL PANEL
EXHAUST VENT CONNECTION
1
COMBUSTION AIR INLET CONNECTION
2
ELECTRICAL CONNECTIONS
SYSTEM RETURN
K
2
L
A
B
C
D
M
9
F
3
4
5
E
G
6
7
LEFT SIDE
VIEW
MODEL*
A
B
8
RIGHT SIDE
VIEW
FRONT VIEW
C
D
E
F
G
H
J
K
L
M
UNIT
WEIGHTS
EL-80
17.00
7.50
5.50
2.50
27.25
14.50
20.00
11.75
7.38
4.25
8.50
2.18
104
EL-110
17.00
7.50
5.50
2.50
27.25
14.50
20.00
11.75
7.38
4.25
8.50
2.18
109
EL-150
19.50
10.50
8.25
2.50
27.25
14.50
20.00
11.75
7.38
4.25
8.50
2.18
122
EL-220
26.50
17.50
15.25
6.00
27.25
14.50
20.00
11.75
7.38
4.25
8.50
2.18
164
EL-299
23.75
13.50
6.38
2.25
36.50
14.50
21.00
11.00
7.88
3.63
8.50
3.00
200
EL-399
30.75
20.50
9.75
2.75
36.50
14.50
21.00
11.00
7.88
3.63
8.50
3.00
240
MODEL
BTU/INPUT
LOW FIRE
SUPPLY/
RETURN
EXHAUST/
AIR INLET
GAS
CONNECTION
EL-80
EL-110
EL-150
14,000-80,000
18,000-110,000
25,000-150,000
1"
1"
1"
3"
3"
3"
3/4"
3/4"
3/4"
1"
EL-220
37,000-220,000
1"
3"
EL-299
50,000-299,000
1-1/4"
4"
1"
EL-399
67,000-399,000
1-1-2"
4"
1"
*
*"N""N"
DENOTES
NATURAL
DENOTESPROPANE
PROPANE
DENOTES
NATURALGAS,
GAS "LP" DENOTES
ALL DIMENSIONS
ARE APPROXIMATE
AND ARE SUBJECT TO CHANGE
ALL DIMENSIONS
ARE APPROXIMATE
AND ARE SUBJECT TO CHANGE
Figure 3-1
9
LP-285-A Rev. 9/14/09
Boiler Manual
PART 3: PREPARE BOILER LOCATION (CONTINUED)
•
•
B. INSTALLATIONS MUST COMPLY WITH:
•
Local, state, provincial, and national codes,
laws, regulations and ordinances.
•
National Fuel Gas Code, ANSI Z223.1 – latest
edition.
•
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME
CSD-1, when required.
•
National Electrical Code.
•
For Canada only: B149.1 or B149.2
Installation Code, CSA C22.1 Canadian
Electrical Code Part 1 and any local codes.
•
•
Incorrectly-sized expansion tank.
Lack of freeze protection in boiler water
causing system and boiler to freeze and leak.
Excessive glycol which will affect the
boiler system operation.
Clean and flush system when re-installing
a boiler.
D. CLEARANCES FOR SERVICE ACCESS
1. See Figure 3-1 for recommended service
clearances. If you do not provide minimum
clearances shown, it might not be possible to
service the boiler without removing it from
the space.
NOTICE
SERVICE CLEARANCES
The Elite Heating Boiler® gas manifold and
controls met safe lighting and other
performance criteria when the boiler underwent
tests specified in ANSI Z21.13 — latest edition.
16 "
C. BEFORE LOCATING THE BOILER
1. Check for nearby connections to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
• Condensate drain
2. Check area around boiler. Remove any
combustible materials, gasoline and other
flammable liquids.
n WARNING
Failure to keep boiler area clear and free of
combustible materials, gasoline and other
flammable liquids and vapors can result in
severe personal injury, death or substantial
property damage.
3. The Elite Heating Boiler® Gas Control System
components must be protected from dripping
water during operation or service.
4. If the Elite Heating Boiler® is to replace an
existing boiler, check for and correct any
existing system problems such as:
• System leaks.
0"
0"
24"
24"
Figure 3-2
LP-293-K Rev. 9/22/09
n WARNING
The space must be provided with combustion/ventilation air openings correctly sized for
all other appliances located in the same space as
the Elite Heating Boiler®. The boiler cover must
be securely fastened to the boiler to prevent the
boiler from drawing air from inside the boiler
room. This is particularly important if the boiler
is located in the same room as other appliances.
Failure to comply with the above warnings could
result in severe personal injury, death or substantial property damage.
E. RESIDENTIAL GARAGE INSTALLATION
Precautions
Take the following special precautions when
installing the boiler in a residential garage. If the
10
Boiler Manual
PART 3: PREPARE BOILER LOCATION (CONTINUED)
boiler is located in a residential garage, per ANSI
Z223.1, paragraph 5.1.9:
•
Mount the boiler with a minimum of 18
inches above the floor of the garage to the
bottom of the boiler to ensure the burner and
ignition devices will be no less than 18 inches
above the floor.
•
Locate or protect the boiler so it cannot be
damaged by a moving vehicle.
F. EXHAUST VENT AND INTAKE AIR VENT
n WARNING
Vents must be properly supported. The Elite
H e a t i n g B o i l e r ’ s ® I n t a ke a n d E x h a u s t
Connections are not designed to carry heavy
weight. Vent support brackets must be within 1
foot of the boiler and the balance at 4 foot
intervals. The Elite Heating Boiler® venting
must be readily accessible for visual inspection
for the first three feet from the boiler.
The Elite Heating Boiler® requires a special vent
system, designed for pressurized venting. Elite
Heating Boilers® are rated ANSI Z21.13 Category
IV (pressurized vent, likely to form condensate in
the vent).
Boiler® as described in the Venting section. Do
not terminate exhaust in locations that can allow
contamination of intake air.
n WARNING
You must pipe outside air to the boiler air
intake. Ensure that the intake air will not
contain any of the contaminants below.
Contaminated air will damage the boiler,
resulting in possible severe personal injury,
death or substantial property damage. For
example, do not pipe intake air vent near a
swimming pool. Also avoid areas subject to
exhaust fumes from laundry facilities. These
areas will always contain contaminants.
Table 3-3: Corrosive contaminants and sources
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
You must also install air intake piping from outdoors to the boiler flue adaptor. The resultant
installation is categorized as direct vent (sealed
combustion). Note: To prevent combustion
air contamination see Table 3-3 in this
section when considering exhaust vent
and intake air vent termination.
Hydrochloric acid/muriatic acid
Intake and exhaust must terminate near each
other and may be vented vertically through the
roof or out a side wall. The intake and exhaust
venting methods are detailed in the Venting
Section. Do not attempt to install the Elite
Heating Boiler® using any other means. Be sure
to locate the boiler such that the air intake and
exhaust vent piping can be routed through the
building and properly terminated. The air intake
and exhaust vent piping lengths, routing and termination method must all comply with the methods and limits given in the venting section.
Areas likely to have contaminants
G. PREVENT COMBUSTION AIR
CONTAMINATION
Install intake air piping for the Elite Heating
11
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
Adhesives used to fasten building products and
other similar products
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
Boiler Manual
PART 3: PREPARE BOILER LOCATION (CONTINUED)
determine that there is no blockage or
restriction, leakage, corrosion or other
deficiencies which could cause an unsafe
condition.
H. WHEN REMOVING A BOILER FROM AN
EXISTING COMMON VENT SYSTEM
n DANGER
Do not install the Elite Heating Boiler® into a
common vent with any other appliance. This will
cause flue gas spillage or appliance malfunction,
resulting in possible severe personal injury,
death or substantial property damage.
c. Insofar as is practical, close all building doors
and windows and all doors between the
space in which the appliances remaining
connected to the common venting system
are located and other spaces of the building.
Turn on clothes dryers and any appliance not
connected to the common venting system.
Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate
a summer exhaust fan. Close fireplace
dampers.
d. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
e. Test for spillage at draft hood opening after 5
minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar, pipe or artificial smoke.
f.
At the time of removal of an existing boiler, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to the
common venting system are not in operation.
a. Seal any unused openings in the common
venting system.
b. Visually inspect the venting system for
proper size and horizontal pitch and
After it has been determined that each
appliance remaining connected to the
common venting system properly vents
when tested as outlined herein, return doors,
windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their
previous conditions of use.
g. Any improper operation of common venting
system should be corrected so the
installation conforms with the National Fuel
Gas Code, ANSI Z223.1 — latest edition.
Correct by resizing to approach the minimum
size as determined using the appropriate
tables in Table 13 of NFPA54 ANSI Z223.1
2006 of that code. Canadian installations
must comply with B149.1 or B149.2
Installation Code.
12
Boiler Manual
PART 4: PREPARE BOILER
n WARNING
Uncrating Boiler – Any Claims for damage or
shortage in shipment must be filed immediately
against the transportation company by the
consignee.
CAUTION
Cold weather handling — If boiler has been
stored in a very cold location (below 0°F) before
installation, handle with care until the plastic
components come to room temperature.
Remove all sides of the Elite Heating Boiler®
shipping crate in order to allow the boiler to be
lifted into its installation location. The Elite
Heating Boiler® is also equipped with leveling
feet that can be used to level the boiler properly
if the surface location is not level. If surface
flooring is rough, care should be taken when
sliding boiler into position, you could catch the
leveling feet and damage the boiler if it is slid to
its location.
n WARNING
Never use dielectric unions for galvanized steel
fittings when connecting to a stainless steel
storage tank or boiler.
PART 5: BOILER PIPING
A. RELIEF VALVE
Connect discharge piping to a safe disposal location, follow the guidelines in the WARNING below.
n WARNING
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 valve discharge.
• Discharge line must be as short as possible and be the same size as the valve discharge connection
throughout its entire length.
• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain
where any discharge will be clearly visible.
• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of
375 °F or greater.
• Do not pipe the discharge to any place where freezing could occur.
• No shutoff valve shall 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 valve after filling and pressurizing 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.
• Failure to comply with the above guidelines could result in failure of the relief valve to operate,
resulting in possibility of severe personal injury, death or substantial property damage.
13
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
B. GENERAL PIPING INFORMATION
NOTICE
The Elite Heating Boiler® control module uses
temperature sensors to provide both high limit
protection and modulating temperature control.
The control module also provides low water
protection by sensing the water level in the heat
exchanger. Some codes/jurisdictions may
require additional external controls.
C. BACKFLOW PREVENTER
Use a backflow preventer specifically designed
for hydronic boiler installations. This valve
should be installed on the cold water fill supply
line per local codes. (See Boiler Piping Details)
CAUTION
All piping methods shown in this manual use
primary/secondary connection to the boiler loop.
This is to avoid the possibility of inadequate flow
through the boiler. For other piping methods,
consult your local Heat Transfer Products
representative or refer to separate Elite Heating
Boiler® piping details in this manual (Part 5).
CAUTION
Undersized expansion tanks cause system
water to be lost from relief valve and makeup
water to be added through a fill valve. Eventual
boiler failure can result due to excessive makeup water addition. This type of failure is NOT
covered by warranty.
2. The expansion tank must be located as
shown in Boiler Piping Part 5 or following
recognized design methods. See tank
manufacturer’s instructions for details.
3. Connect the expansion tank to the air
separator only if the separator is on the
suction side of the circulator. Always install
the system fill connection at the same point
as the expansion tank connection to the
system.
4. Most chilled water systems are piped using a
closed type expansion tank.
Diaphragm (or bladder) expansion tank
1. Always install an automatic air vent on top of
the air separator to remove residual air from
the system.
E. CIRCULATORS
D. SYSTEM WATER PIPING METHODS
Expansion tank and make-up water
1. Ensure that the expansion tank size will
handle boiler and system water volume and
temperature. Allow for boiler and its piping:
n CAUTION
DO NOT install automatic air vents on closedtype expansion tank systems. Air must remain
in the system and return to the tank to provide
its air cushion. An automatic air vent would
cause air to leave system, resulting in waterlogging the expansion tank.
Elite Heating Boiler® EL-80
1.4 Gallons
Elite Heating Boiler® EL-110
1.7 Gallons
n CAUTION
Elite Heating Boiler® EL-150
2.0 Gallons
Elite Heating Boiler® EL-220
2.6 Gallons
Elite Heating Boiler® EL-299
3.1 Gallons
DO NOT use the boiler circulator in any location
other than the ones shown in this manual. The
boiler circulator is selected to ensure adequate
flow through the Elite Heating Boiler®. Failure to
comply could result in unreliable performance
and nuisance shut downs from insufficient flow.
Elite Heating Boiler® EL-399
3.7 Gallons
Sizing space heat system piping
1. See Piping Details in this manual Part 5. In all
diagrams, the space heating system is
14
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
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.
F. HYDRONIC PIPING WITH CIRCULATORS,
ZONE VALVES AND MULTIPLE BOILERS
The Elite Heating Boiler® is designed to function in
a closed loop Hydronic System. We have also included a Temperature and Pressure gauge that allows the user to monitor the system pressure and
outlet temperature from the Elite Heating Boiler®.
It is important to note that the Elite Heating Boiler®
has a minimal amount of pressure drop and must
be calculated when sizing the circulators. Each Elite
Heating Boiler® installation must have an Air
Elimination device that will remove air from the
system. Install the Elite Heating Boiler® so the gas
ignition system components are protected from
water (dripping, spraying, etc.) allowing clearance
for basic service of boiler circulator, valves and
other components. Observe minimum 1” clearance around all un-insulated hot water pipes when
openings around pipes are not protected by non-
15
combustible materials. On a Elite Heating Boiler®
installed above radiation level, some states and
local codes require a low water cut off device
which is standard on the Elite Heating Boiler®.
Check with local codes for additional requirements.
If the Elite Heating 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 the boiler. Freeze protection for new
or existing systems must use glycol that is specifically formulated for this purpose. It will 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 recommend 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 the temperature increase from 32 F to
180 F, while water expands 3% with the same temperature rise.
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
G. BOILER PIPING DETAILS
Single Elite Heating Boiler® Space Heating with Indirect Priority
BALL VALVE
(TYPICAL)
4 PIPE DIAMETER
SPACING MAXIMUM
AIR ELIMINATOR
FROM SYSTEM
SUPPLY SENSOR
(OPTIONAL)
SYSTEM
CIRCULATOR
BOILER
CIRCULATOR
DRAIN
VALVE
SWING CHECK VALVE
EXPANSION
TANK
DRAIN VALVE
(PURGE POINT)
TO SYSTEM
MAKE-UP
WATER
INDIRECT
HOT WATER
TANK
BACKFLOW
PREVENTER
PRESSURE
REDUCING
VALVE
ANTI-SCALD
MIXING VALVE
PRESSURE RELIEF
VALVE (TYPICAL)
PRESSURE
GAUGE
HOT WATER
OUTLET
COLD WATER
INLET
HOT WATER
CIRCULATOR
ELITE BOILER
SWING CHECK VALVE
TEMP/PRESSURE
GAUGE (TYPICAL)
UNION
(TYPICAL)
BALL VALVE
DRAIN VALVE
NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. Piping shown is Primary/Secondary
5. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
6. Installations must comply with all local codes.
7. In Massachusetts, a vacuum relief must be installed in the cold water line per 248 CMR.
LP-293-L Rev. 9/23/09
16
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
Cascade Multiple Elite Heating Boilers® with
Indirect Priority on One Boiler
BALL VALVE
(TYPICAL)
4 PIPE DIAMETER
SPACING MAXIMUM
AIR ELIMINATOR
SUPPLY SENSOR
PRESSURE GAUGE
SYSTEM
CIRCULATOR
FROM SYSTEM
DRAIN
VALVE
EXPANSION
TANK
DRAIN VALVE
(PURGE POINT)
TO SYSTEM
MAKE-UP WATER
BACKFLOW
PREVENTER
PRESSURE
REDUCING VALVE
INDIRECT
HOT WATER
TANK
BOILER CIRCULATOR
(TYPICAL)
RELIEF VALVE
(TYPICAL)
ANTI-SCALD
MIXING
VALVE
HOT
WATER
OUTLET
COLD
WATER
INLET
ELITE BOILER
MASTER
DOMESTIC
HOT WATER
CIRCULATOR
SWING CHECK VALVE
(TYPICAL)
ELITE BOILER
FOLLOWER
TEMP/PRESSURE
GAUGE
UNION
(TYPICAL)
BALL VALVE
(TYP)
DRAIN VALVE
(TYPICAL)
NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. Piping shown is Primary/Secondary
5. Reference Figure 5-2 to determine manifold pipe sizing.
6. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
7. Installations must comply with all local codes.
8. In Massachusetts, a vacuum relief must be installed in the cold water line per 248 CMR.
LP-293-Q Rev. 9/23/09
17
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
Single Elite Heating Boiler®
Space Heating
%$//9$/9(
7<3,&$/
3,3(',$0(7(5
63$&,1*0$;,080
$,5(/,0,1$725
)5206<67(0
6833/<6(1625
237,21$/
'5$,19$/9(
6<67(0
&,5&8/$725
%2,/(5
&,5&8/$725
6:,1*&+(&.
9$/9(
(;3$16,21
7$1.
'5$,19$/9(
385*(32,17
726<67(0
0$.(83
:$7(5
%$&.)/2:
35(9(17(5
35(6685(
5('8&,1*
9$/9(
35(6685(5(/,()
9$/9(7<3,&$/
35(6685(
*$8*(
7(0335(6685(
*$8*(
7<3,&$/
81,21
7<3,&$/
(/,7(%2,/(5
'5$,19$/9(
NOTES:
1.
2.
3.
4.
This drawing is meant to show system piping concept only.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
Piping shown is Primary/Secondary
Installations must comply with all local codes
LP-293-O Rev. 9/24/09
18
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
Cascade Elite Heating Boilers®
Space Heating Only
DRAIN VALVE
(PURGE POINT)
AIR ELIMINATOR
4 PIPE DIAMETER
SPACING MAXIMUM
FROM SYSTEM
SUPPLY SENSOR
(OPTIONAL)
SYSTEM CIRCULATOR
BALL VALVE
(TYPICAL)
DRAIN VALVE
EXPANSION
TANK
TO SYSTEM
MAKE-UP
WATER
BACKFLOW
PREVENTER
PRESSURE
REDUCING
VALVE
SWING CHECK
VALVE
(TYPICAL)
PRESSURE GAUGE
BOILER CIRCULATOR
(TYPICAL)
PRESSURE RELIEF
VALVE (TYPICAL)
TEMP/PRESSURE
GAUGE
(TYPICAL)
UNION
(TYPICAL)
ELITE BOILER 1
(MASTER)
ELITE BOILER 2
(FOLLOWER)
BALL VALVE
(TYPICAL)
DRAIN VALVE
(TYPICAL)
NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
5. Installations must comply with all local codes
LP-293-P Rev. 9/24/09
19
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
n CAUTION
The Elite Heating 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, with Illustration,
that will guide you through the installation of the
Elite Heating Boiler®.
1. Connect the system return marked “Boiler
Return”.
2. Connect the system supply marked “Boiler
Supply”.
3. Install Purge and Balance Valve or shut off
valve and drain on 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). Check Temperature and
Pressure Gauge when operating. It should
read 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. Consult the tank manufacturer’s
instruction 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 Elite Heating Boiler® can
not be drained completely of water without
purging the unit with an air pressure 15 PSI.
10. The relief valve is installed at the factory. A
pipe discharge line should be installed 6”
above the drain in the event of a pressure
relief. The pipe size must be the same size as
the relief valve outlet. NEVER BLOCK THE
OUTLET OF THE SAFETY RELIEF VALVE.
H. CIRCULATOR SIZING
The Elite Heating Boiler® Heat Exchanger does
have pressure drop which must be considered
in your system design. Refer to the graph in Fig.
5-1 for pressure drop through the Elite Heating
Boiler® Heat Exchanger.
20
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
HEAT EXCHANGER PRESSURE DROP CHART
Model
Flow
Rate
EL-80
EL-110
EL-150
EL-220
EL-299
EL-399
Flow
Rate
EL-80
EL-110
EL-150
EL-220
EL-299
EL-399
Flow
Module Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
Flow
Rate
Δ P’
2
GPM
2.5’
3
GPM
3’
3’
4
GPM
4’
4’
3’
5
GPM
7’
7’
4’
6
GPM
10’
9’
5’
10
GPM
26’
22’
12’
4’
4’
13
GPM
14
GPM
15
GPM
16
GPM
17
GPM
18
GPM
19
GPM
20
GPM
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
9
GPM
21’
17’
10’
3’
3.5’
12
GPM
*
*
*
8
GPM
17’
15’
9’
2’
3’
11
GPM
*
*
*
7
GPM
14’
12’
6’
2’
3+1
4+1
5+2
8+4
10+6
15+8
3+1
4+1
5+2
8+4
10+6
15+8
*
*
*
*
*
*
*
*
*
*
*
*
25’
15’
5’
4.5’
33’
17’
5.5’
5’
19’
6’
6’
3.8’
22’
7’
7’
4’
27’
8’
8’
5’
10’
8.75’
6’
11.5’
9.25’
6.6’
13’
10.25
7’
15’
11’
7.8’
16.5’
13’
8.3’
*
*
*
*
*
21
GPM
22
GPM
23
GPM
24
GPM
25
GPM
26
GPM
27
GPM
28
GPM
29
GPM
30
GPM
31
GPM
32
GPM
33
GPM
34
GPM
35
GPM
36
GPM
37
GPM
38
GPM
39
GPM
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
17’
14’
9.2’
19’
15’
9.7’
21’
16.5’
10.3’
23’
18’
11.1’
24’
20’
12’
22’
12.9’
24’
13.6’
26’
14’
29’
15.7’
33’
17’
36’
18’
19.4’
21’
22.5’
26’
28’
31’
34’
39’
Figure 5-1
*Do not operate boiler at these flow settings as it will damage the heat exchanger or related components caused by excessive flow rates or minimum flow rates.
The chart below represents the various system design temperature rise through the Mod Con along
with their respective flows and friction loss which will aid in circulator selection.
SYSTEM TEMPERATURE RISE CHART
20°Δt
Model Module
25°Δt
30°Δt
35°Δt
40°Δt
Ft / Friction Flow Rate Ft / Friction Flow Rate Ft / Friction Flow Rate Ft / Friction Flow Rate Ft / Friction Flow Rate
EL-80
3+1
17’
8 GPM
10’
EL-110
4+1
25’
11 GPM
17’
EL-150
5+2
27’
15 GPM
17’
EL-220
6.6 GPM
7’
5.3 GPM
7’
4.6 GPM
4’
4 GPM
9.1 GPM
12’
7.3 GPM
9’
6.4 GPM
8.2’
5.5 GPM
12.5 GPM
12’
10 GPM
10’
8.8 GPM
8.8’
7.5 GPM
8+4
19’
22 GPM
13’
18.3 GPM
12’
14.6 GPM
6’
12.8 GPM
5’
11 GPM
EL-299 10+6
29’
29 GPM
18’
24.5 GPM
13’
20 GPM
9.5’
17.3 GPM
8’
14.5 GPM
EL-399 15+8
39’
39 GPM
19’
32.5 GPM
13’
26 GPM
10’
22.8 GPM
8’
19.5 GPM
Figure 5-1a
21
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
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.
Flow Rate (GPM)
Pipe Dia. (Inches)
16
2
22
2
24
2
30
2
Example: (5) EL-220 Elite Heating Boilers® with a
design of 20°Δt degree temperature rise with
each boiler having an individual flow rate of 22
GPM. To correctly size the manifold feeding
these (5) Elite Heating Boilers you would need a
pipe size of 4”.
MULTIPLE BOILER MANIFOLD PIPING
32 33 40 44 45 48 55 60 66 75 80
2 2½ 2½ 2½ 2½ 2½ 2½ 2½ 2½ 3
3
88
3
90 110 120 132 150 160 179 200 239
3
4
4
4
4
4
4
4
5
MulƟple Boiler Manifold Piping
6
Pipe Diameter Size (Inches)
5
4
3
2
1
0
0
50
100
150
200
250
Combined Boiler Water Flow (GPM)
Figure 5-2
LP-293-JJ Rev. 7/31/09
MULTIPLE BOILER MANIFOLD PIPING
Flow rate 30
Pipe Dia.
50
60
85
2” 2½” 2½” 3”
90 100 120 150 170 180 200 210 240 250 255 300 340 350 400 425 510 595 680
3”
3”
4”
4”
4”
4”
4”
4”
I. FILL AND PURGE HEATING SYSTEM
•
•
•
Attach the hose to balance and purge hose
connector or drain valve and run hose to
nearest drain.
Close the other side of the balance and purge
valve or the shut off valve after the drain.
Open first zone balance and purge or drain
valve to let water flow out the hose. If zone
valves are used, open the valves one at a
time manually. (Note: You should check valve
manufacturer’s instruction prior to opening
•
•
5”
5”
5”
5”
5”
5”
5”
5”
6”
6”
6”
valves manually, so as not to damage the
valve.)
Manually operate fill valve regulator. When
water runs out of the hose, while it’s
connected to the balance and purge valve or
drain you will see a steady stream of water
(without bubbles). Close balance and purge
valve or drain to stop the water from flowing.
Disconnect the hose and connect it to next
zone to be purged.
Repeat this procedure for additional zones
(one at time).
22
Boiler Manual
PART 5: BOILER PIPING (CONTINUED)
n CAUTION
n CAUTION
For installation that incorporates standing iron
radiation and systems with manual vents at the
high points. Follow previous section and
starting with the nearest manual air vent, open
vent until water flows out, then close vent.
Repeat procedure, working your way toward
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.
It is highly recommended that you carefully
follow the glycol manufacturer’s recommended
concentrations, expansion requirements and
maintenance recommendations (pH additive
breakdown, inhibitor reduction, etc.). You must
carefully figure the additional friction loss in the
system as well as the reduction in heat transfer
co-efficients.
J. ZONING WITH ZONE VALVES
Upon completion, make sure that the fill valve is
in the automatic position and each zone balance
and purge or shut off is in an open position and
zone valves are positioned for automatic operation.
1. Connect the boiler to the system as shown in
Piping Details when zoning with zone valves.
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.
n WARNING
2. Connect DHW (domestic hot water) piping to
indirect storage water heater as shown.
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%.
1. Glycol in hydronic applications which is
specially formulated for this purpose includes
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.
2. The glycol solution should be tested at least
once a year and as recommended by the
glycol manufacturer.
3. 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° F to 180° F, while water
expands 3% with the same temperature rise.
Allowances must be made for this expansion
in the system design.
K. ZONING WITH CIRCULATORS
1. Connect the boiler to the system when using
circulator zoning as shown in Piping Details
when zoning with circulators. NOTE: The
boiler circulator cannot be used for a zone. It
must supply only 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.
L. MULTIPLE BOILERS
1. Connect multiple boilers as shown in Piping
Details.
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. A 30% mixture of glycol will result in a BTU
output loss of 15% with a 5% increase in
head against the system circulator.
4. Connect DHW (domestic hot water) piping to
indirect storage water heater as shown in
Piping Details.
5. A 50% mixture of glycol will result in a BTU
output loss of 30% with a 50% increase in
head against the system circulator.
5. The system flow (secondary loop) must be
greater than the boiler’s primary loop flow.
23
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL
A. INSTALLING EXHAUST VENT AND
INTAKE AIR VENT
n DANGER
n WARNING
Use only the materials listed in Tables 6-1
through 6-6 for the venting systems. Failure to
do so could result in severe personal injury,
death or substantial property damage.
The Elite Heating Boiler® must be vented as
detailed in this section. Ensure the exhaust and
intake piping comply with these instructions
regarding the venting system.
Inspect finished combustion air intake and
exhaust piping thoroughly to ensure all joints
are secure and airtight and comply with all
applicable code requirements, as well as with
the instructions provided in this manual.
Failure to provide a properly installed vent
system will cause severe personal injury or
death.
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 AL294C stainless
steel venting to comply with Canadian
requirements.
n WARNING
2. The first three (3) feet of vent pipe from the
appliance flue outlet must be readily
accessible for visual inspection.
This vent system will operate with a positive
pressure in the pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft
systems operating under positive pressure.
Follow these venting instructions carefully.
Failure to do so may result in severe personal
injury, death, or substantial property damage.
REQUIREMENTS FOR INSTALLATION
IN CANADA
3. The components of the certified vent system
must not be interchanged with other vent
systems or unlisted pipe / fittings.
n WARNING
Do not use Cellular Foam Core Pipe in any portion
of the exhaust piping from this boiler. Use of
Foam Core Pipe may result in severe personal
injury, death, or substantial property damage.
B. GENERAL
1. Install the boiler venting system in
accordance with these instructions and with
t h e N a t i o n a l Fu e l G a s C o d e , A N S I
Z223.1/NFPA 54, CAN/CGA B149, and/or
applicable provisions of local building codes.
Cellular foam core piping may be used on air
inlet piping only.
2. This boiler is a direct vent appliance and is
listed as a Category IV appliance with
Underwriters Laboratories, Inc.
C. APPROVED MATERIALS FOR EXHAUST
VENT AND INTAKE AIR VENT
1. Use only Non Foam Core venting material or
AL294C. The following materials are
approved for use as vent pipe for this boiler.
See Tables 6-1 through 6-6 for all approved
venting.
24
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
Table 6-1
APPROVED PLASTIC EXHAUST VENTING MATERIAL
STANDARDS FOR INSTALLATION IN:
UNITED STATES
CANADA
PVC SCHEDULE 40 / 80
ANSI /ASTM D1785
ULC S636**
PVC -DWV
ANSI /ASTM D2665
ULC-S636**
CPVC SCHEDULE 40 / 80
ANSI /ASTM F441
ULC- S636**
**Note: IPEX is an approved
*Note: Cellular Foam Core Pipe must only
Manufacturer in Canada
be used on INTAKE piping.
supplying vent material listed to
ULC-S636
MATERIAL
Table 6-2
APPROVED PLASTIC INTAKE VENTING MATERIAL
STANDARDS FOR INSTALLATION IN:
UNITED STATES
CANADA
PVC SCHEDULE 40 / 80
ANSI /ASTM D1785
ULC S636**
CPVC SCHEDULE 40 / 80
ANSI /ASTM F441
ULC- S636**
N/A
PVC DWV
ANSI /ASTM D2665
PVC-CELLULAR FOAM CORE*
U.L. LISTED
N/A
**Note: IPEX is an approved
*Note: Cellular Foam Core Pipe must only
Manufacturer in Canada
be used on INTAKE piping.
supplying vent material listed to
ULC-S636
MATERIAL
Table 6-3
APPROVED PLASTIC CONDENSATE PIPING MATERIAL
MATERIAL
STANDARDS FOR INSTALLATION IN:
UNITED STATES
CANADA
ANSI /ASTM D1785
ULC S636**
PVC SCHEDULE 40 / 80
**Note: IPEX is an approved
Manufacturer in Canada
supplying vent material listed to
ULC-S636
Table 6-4
APPROVED PIPE CEMENT AND PRIMER FOR PLASTIC PIPE
STANDARDS FOR INSTALLATION IN:
MATERIAL
UNITED STATES
CANADA
CEMENT AND PRIMER
ANSI/ASTM F493
IPEX System 636
CPVC
ANSI/ASTM D2564
Cements and Primers
PVC
Table 6-5
APPROVED METALLIC EXHAUST VENTING MATERIAL
MATERIAL
STANDARDS FOR INSTALLATION IN:
UNITED STATES
CANADA
AL294C
U.L.LISTED
U.L.LISTED
Table 6-6
APPROVED METALLIC INTAKE VENTING MATERIAL
STANDARDS FOR INSTALLATION IN:
UNITED STATES
CANADA
"B" GAS VENT
U.L. LISTED
U.L. LISTED
GALVANIZED
U.L. LISTED
U.L. LISTED
MATERIAL
25
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
n WARNING
You must not use “B” Vent in an exhaust
application. ‘B’ vent is for intake applications
only. Failure to do so will result in serious injury
or death.
intake located within 10 ft (3 m). Note:
this does not apply to the combustion air
intake of a direct-vent appliance.
•
Provide a minimum of 1 foot distance
from any door, operable window, or
gravity intake into any building.
•
Provide a minimum of 1 foot clearance
from the bottom of the exhaust above the
expected snow accumulation level. Snow
removal may be necessary to maintain
clearance.
•
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.
You must insert the provided intake and exhaust
screen at your vent terminations to prevent
blockage caused by birds or debris.
•
Please refer to chart below for U.L.-approved
stainless steel adapters and terminations.
Do not locate the exhaust over public
walkways where condensate could drip
and/or freeze and create a nuisance or
hazard.
•
When adjacent to a public walkway,
locate exit terminal at least 7 feet above
grade.
•
Do not locate the exhaust directly under
roof overhangs to prevent icicles from
forming.
•
Provide 6 feet clearance from the inside
corner of vertical walls, chimneys, etc., as
well as horizontal corners created by roof
overhangs.
n WARNING
Both exhaust and intake air vents must exit
from the same side of the building to assure
correct appliance operation.
D. EXHAUST VENT AND INTAKE AIR VENT
PIPE LOCATION
n WARNING
See additional requirements for Massachusetts
in the back of this manual.
1. Determine exhaust vent location:
• Total length of vent may not exceed the
limits specified in the venting Sizing
Section.
•
The vent piping for this boiler is approved
for zero clearance to combustible
construction.
•
See illustration within this section of
clearances for location of exit terminals of
direct-vent venting systems.
• Avoid terminating exhaust vent near
shrubs, air conditioners or other objects
that will obstruct the exhaust stream.
• The flue products coming from the
exhaust vent will creat a large plume
when the boiler is in operation. Avoid
venting in areas that will affect
neighboring buildings or be considered
objectionable.
•
The boiler vent system shall terminate at
least 3 feet (0.9 m) above any forced air
2. Determine air intake vent location.
•
Provide 1 foot clearance from the bottom
of the intake air vent and the level of
maximum snow accumulation. Snow
removal may be necessary to maintain
clearances.
•
Do not locate intake air vent in a parking area
where machinery may damage the pipe.
•
Follow required minimum clearances
located in Fig. 6-3, 6-4, 6-5.
3. Determine location of Condensate Piping
This boiler is a high efficiency appliance,
therefore the boiler produces condensate.
Condensate is a by-product of the boiler
26
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
combustion process. A condensate
collection system with an internal float switch
monitors the condensate level to prevent it
from backing up into the combustion system.
There is a ¾” sweat connection provided to
connect the outlet of the collection system to
a drain or condensate pump. (See Table 6-3
for approved condensate piping material)
CAUTION
It is very important that the condensate piping
be no smaller than ¾” and you must use a tee
at the condensate connection with the branch
vertically up and open to the atmosphere so it
will not cause a vacuum that could obstruct the
flow of condensate from the boiler. The
condensate piping should also be properly
supported with pipe supports to prevent
sagging and to maintain the pitch of the piping.
27
4. Condensate Neutralization
The condensate from the boiler is slightly
acidic with a pH of 3.2 – 4.5 Heat Transfer
Products recommends neutralizing the
condensate with a Condensate Neutralizer Kit
p/n 7450P-212 (EL-80/110/150/220) p/n 7350P611 (EL-299/399) that can be added to your
system to avoid long term damage to the
drainage system and to meet local code
requirements. The neutralizer kit is connected
to the drain system and contains marble
chips that will neutralize the pH level of the
water vapor. The neutralizer should be
checked at least once a year and the marble
chips should be replenished if necessary.
When replacing the marble chips, they
should be no smaller than ½” to avoid
blockage in condensate piping. (Refer to Fig.
6-1 and 6-2 for piping of the Condensate
neutralizer.)
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
NOTE: To clean out condensate collector,
blow water into collector to remove any
foreign matter that may block the
condensate line.
n WARNING
When servicing is complete, you must
make sure this cap is replaced securely.
Failure to do so will cause venting issues
that will result in serious injury or death.
Fig. 6-1
Fig. 6-2
LP-293-R Rev. 7/08/09
CAUTION
NOTICE
The condensate line must remain unobstructed,
allowing free flow of condensate. If condensate
is allowed to freeze in the line or if the line is
obstructed in any other manor, condensate can
exit from the boiler tee, resulting in potential
water damage to property.
When installing 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.
Condensate from the Elite Heating Boiler® will
be slightly acidic (typically with a pH from 3.2 to
4.5). Install a neutralizing filter if required by
local codes.
28
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
Location of exit terminals of mechanical draft and direct-vent venting systems.
(Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002).
Fig. 6-3 Multiple Vents
Fig. 6-4 Multiple Vent Spacing*
*Note: Exhaust must extend out 1 foot. There should be no more than 2 vents and 2 intakes then a space of 36” to the
next set of vents.
*Note: There must be a minimum of 36” spacing between every 2 kit grouping.
Multiple “V” Series Vents
Fig. 6-6 Multiple Concentric Vent
Spacing – Vertical
Fig. 6-5 Multiple Stainless Steel Horizontal Vent Kit Installation – Front View
Fig. 6-7 Multiple Concentric Vent
Spacing – Horizontal
29
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
E. EXHAUST VENT AND INTAKE AIR VENT
SIZING
1. The exhaust vent and intake air vent pipes
are 3" for the Elite EL-80/110/155/220, and 4"
for the EL-299/399.
2. The total combined equivalent length of
exhaust vent and intake air pipe should not
exceed 200 feet.
a. The equivalent length of elbows, tees,
and other fittings are listed in the Friction
Loss Table 6-8.
a. The maximum equivalent length for the
increased diameter vent pipes is 275 feet,
which includes the combined 32 feet from
the boiler, 16 ft. (inlet) + 16 ft. (exhaust) =
32 ft. combined with transition total of 245
ft. upsize piping for longer vent runs.
Table 6-9
Table 6-8
Vent Transition Fitting
Friction Loss Equivalent for
Stainless or Plastic Piping and Fittings
Fitting Description
can be extended by increasing the diameter
of both exhaust vent and intake air vent pipe
equally. However, the transitions should
begin a minimum of 16 to 32 maximum
combined equivalent feet from the boiler on
both the intake and exhaust equally.
3"
4"
Size
Reducing Coupling
Final Vent Size
6"
3" venting
4" x 3"
4"
4" venting
6" x 4"
6"
6" venting
8" x 6"
8"
90° elbow short radius
3'
3'
3'
90° elbow long radius
2'
2'
2'
45° elbow
1'
1'
1'
Coupling
0'
0'
0'
Tee (intake only)
0'
0'
0'
V Series Vent Kit
1'
1'
1'
AL29 4C Vent Terminal
1'
1'
1'
Pipe (All materials)
1’
1’
1’
NOTE: EXTENDED VENT
RUNS WHEN TRANSITIONING
TO A LARGER DIAMETER
MUST ALWAYS TAKE PLACE
IN A VERTICAL POSITION
TO PREVENT CONDENSATE
BLOCKAGE.
*Friction loss for long radius elbow is 1 foot less.
b. For example: If the exhaust vent has two
short 90° elbows and 10 feet of PVC pipe
we will calculate:
Exhaust Vent Pipe Equivalent Length = (2x3)+10=16 feet
Further, if the intake air vent pipe has two
short 90° elbows, one 45° elbow and 10
feet of PVC pipe, the following calculation
applies:
Intake Air Vent Pipe Equivalent Length = (2x3)+1+10=17 feet
c. The intake air vent pipe and the exhaust
vent are intended to penetrate the same
wall or roof of the building.
d. You should keep an equivalent length
between the intake air vent pipe and the
exhaust vent. The minimum combined
equivalent length is 16 to 32 maximum
combined equivalent feet.
G. EXHAUST VENT AND INTAKE AIR PIPE
INSTALLATION
1. Use only solid PVC, or CPVC schedule 40 or
80 pipe and AL294C Stainless Steel. FOAM
CORE PIPING IS ONLY ALLOWED FOR
INTAKE PIPING.
2. Remove all burrs and debris from joints and
fittings.
3. All joints must be properly cleaned, primed,
and cemented. Use only cement and primer
approved for use with the pipe material.
Refer to the Venting Table 6-4.
n WARNING
All joints of positive pressure vent systems
must be sealed completely to prevent leakage
of flue products into the living space.
F. LONGER VENT RUNS
1. The maximum combined equivalent length
4. Horizontal lengths of exhaust vent must slope
30
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
back towards the boiler not less than ¼" per
foot to allow condensate to drain from the
vent pipe. If the exhaust pipe must be piped
around an obstacle that results in the creation
of a low point, condensate will collect in this
low point and form a blockage. This
condensate must be drained away using a
field-installed condensate drain assembly. 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. The
condensate drain piping should be a
minimum of ¾” PVC Rigid Piping, pitched at
a minimum of ¼” per foot away from the
boiler. (See Fig. 6-1, 6-2)
5. 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. When placing support
brackets on vent piping, the first bracket must
be within 1 foot of the appliance and the
balance at 4 foot intervals on the vent pipe.
The boiler venting must be readily accessible
for visual inspection for the first three feet of
the boiler.
6. Do not use the boiler to support any piping.
7. A screened straight coupling is provided with
the boiler for use as an outside exhaust
termination.
8. A screened inlet air tee is provided with the
boiler to be used as an outside intake
termination.
H. HEATER REMOVAL FROM A COMMON
VENT SYSTEM
At the time of removal of an existing heater, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to common venting system are not operating.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
31
size and horizontal pitch to determine if there
is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.
3. If practical, close all building doors, windows
and all doors between the space in which the
appliance remains connected to the common
venting system located and other spaces in
the building. Turn on clothes dryers and any
appliances 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 appliance being
inspected. Follow the lighting instructions.
Adjust the thermostat so the appliance 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
appliance remaining connected to common
venting system properly vents when tested as
outlined, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning
appliance to their previous condition of use.
7. Any improper operation of the common
venting system should be corrected so the
installation conforms with 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
Note: For Canadian Installations, it is required
that Non Metallic Vent Installations conform to
ULC S636. Where plastic venting is not allowed,
HTP recommends AL294C Stainless Steel
Venting be used for Exhaust venting installations and “B” vent for intake air.
Please refer to 6-7 below for U.L. Approved
Stainless Steel Vent Adapters.
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
I. DIAGRAMS FOR SIDEWALL VENTING
SIDEWALL VENTING W/TEE (INTAKE)
AND COUPLING (EXHAUST)
SIDEWALL
WITH
SIDEWALLVENTING
VENTING WITH
KIT KIT
1" MIN.
EXHAUST
VENT
EXHAUST
VENT
INLET/EXHAUST SCREEN
VENT KIT
12" MIN.
STRAIGHT
COUPLING
TEE
AIR INTAKE
VENT
TOP VIEW
INSERT INLET/EXHAUST SCREENS
PROVIDED INTO EACH END OF TEE
INTAKE AIR
VENT
1" MIN.
TOP VIEW
INSERT INLET/EXHAUST SCREENS
PROVIDED INTO STRAIGHT COUPLING
12" MIN.
STRAIGHT
COUPLING
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
TEE
VENT KIT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
OR GRADE, WHICHEVER
IS GREATER.
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
RIGHT SIDE
VIEW
EXTERIOR WALL
Figure 6-9
LP-293-D Rev. 9/22/08
MAINTAIN MIN.
12" CLEARANCE ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE
WHICHEVER IS GREATER.
RIGHT SIDE
VIEW
EXTERIOR WALL
Figure 6-10
LP-293-E Rev. 9/22/09
NOTE: Vent piping should be 12" over anticipated maximum snow level.
n WARNING
All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per
foot back to the heater (to allow drainage of condensate). When placing support brackets on vent piping,
the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe.
The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
32
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
J. DIAGRAM FOR VERTICAL VENTING
ROOF VENT WITH TEE (INTAKE)
AND COUPLING (EXHAUST)
EXHAUST VENT
(STRAIGHT COUPLING)
24" MIN.
10' - 0" MIN.
INTAKE AIR
VENT (TEE)
12" OVER MAXIMUM
SNOW LEVEL OR 24"
WHICHEVER IS GREATER
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
RIGHT SIDE
VIEW
EXTERIOR WALL
Figure 6-11
LP-293-F Rev. 2/23/09
n WARNING
All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per
foot back to the heater (to allow drainage of condensate). When placing support brackets on vent piping,
the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe.
The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
33
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
K. DIAGRAM FOR HORIZONTAL VENTING
RIZONTAL VENTING
E
A
D
MULTIPLE BOILERS
C
SINGLE BOILER
A. FOR EVERY 1" OF OVERHANG THE EXHAUST VENT MUST BE LOCATED 1" VERTICAL BELOW OVERHANG
(OVERHANG MEANS TOP OF BUILDING STRUCTUREAND NOT TWO ADJACENT WALLS (CORNER OF BUILDING)).
B. 12" SEPARATION BETWEEN BOTTOM OF EXHAUST OUTLET AND TOP OF AIR INTAKE (TYP.)
C. MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS
GREATER (TYP.)
D. MINIMUM 12" BETWEEN VENTS WHEN INSTALLING MULTIPLE VENTS
E. 12 " MIN. BEYOND INTAKE
Figure 6-12
VT-A Rev. 8/28/09
n WARNING
All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per
foot back to the heater (to allow drainage of condensate). When placing support brackets on vent piping,
the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe.
The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
34
Boiler Manual
PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
L. UNBALANCED FLUE/VERTICAL VENT
n WARNING
You are only allowed to install an unbalanced vent system when the exhaust vent is in the Vertical
Position ONLY.
UNBALANCED FLUE / VERTICAL VENT
EXHAUST VENT
(STRAIGHT COUPLING)
12" OVER MAXIMUM SNOW LEVEL
24" MIN. OR 24"
WHICHEVER IS GREATER.
INTAKE AIR
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
MAINTAIN MIN. 12"
CLEARANCE ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE,
WHICHEVER IS GREATER.
Figure 6-13
LP-293-T Rev. 9/24/09
n WARNING
All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per
foot back to the heater (to allow drainage of condensate). When placing support brackets on vent piping,
the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe.
The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
35
Boiler Manual
PART 7: GAS PIPING
n WARNING
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.
GAS SUPPLY
MANUAL SHUT OFF
(FIELD SUPPLIED)
If the leak test requirement is a higher test pressure than the maximum inlet pressure, you must
isolate the Elite Heating Boiler® from the gas
line. In order to do this, you must 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. (3.5 kPa), the gas valve must be
replaced. Never use an open flame (match,
lighter, etc.) to check gas connections.
Nominal
Iron Pipe
Size
(inches)
3/4
1
1 1/4
1 1/2
Internal
Diameter
(inches) 10 20
.824
278 190
1.049
520 350
1.380 1,050 730
1.610 1,600 1,100
3/4
1
1 1/4
1 1/2
.824
1.049
1.380
1.610
80
90
170
350
530
90
84
160
320
490
Length of Pipe (Feet)
30
152
285
590
890
40
130
245
500
760
50
115
215
440
670
60
105
195
400
610
70
96 BTU'S
180 PER
370 HOUR
560 x1,000
100
79
150
305
460
125
72
130
275
410
150
64
120
250
380
175 200
59 55 BTU'S
110 100 PER
225 210 HOUR
350 320 x1,000
}
}
B. GAS PIPING
UNION
DRIP LEG
PIPING SUPPORT
n WARNING
It is very important that you are connected to
the type of gas as noted on the rating plate.
“LP” for liquefied petroleum, propane gas or,
“Nat” natural or city gas. You must not do a gas
conversion on this boiler. All gas connections
must be approved by the local gas supplier, or
utility in addition to the governing authority,
prior to turning the gas supply on.
The gas connection on the Elite Heating Boiler®
is 3/4” for the EL-80/110/155 and 1” for the
EL-220/299/399. It is mandatory that this fitting is
used for connection to a field fabricated drip leg
as shown in the illustration above per the
National Fuel Gas Code. You must ensure that
the entire gas line to the connection at the Elite
Heating Boiler® is no smaller than the unit supplied connection. Once all the inspections have
been performed, the piping must be leak tested.
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.
4. It is important to support gas piping as the
unit is not designed to structurally support
large amount of weight.
5. Purge all gas lines thoroughly to avoid start
up issues with air in the lines.
6. Sealing compound must be approved for gas
connection. Care must be taken when
applying compound to prevent blockage or
obstruction of gas flow which my effect the
operation of the unit.
36
Boiler Manual
PART 7: GAS PIPING (CONTINUED)
n WARNING
Never use an open flame (Match or Lighter) to
check for Gas leaks. Use A soapy solution to
test gas connection for leaks. Failure to use
soapy solution test or check gas connection for
leaks can cause substantial property damage,
severe personal injury or death.
NOTICE
CSA or UL listed Flexible gas connections can
be used when installing The Elite Heating
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
adequately sized for the job. Follow local codes
for proper installation and service requirements.
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 unit. To check Gas Pressure
perform the steps listed below:
1. Before you connect to the inlet pressure you
must shut off the gas and electrical power to
unit.
2 Loosen the pressure tap with a small
screwdriver. Refer to Figures 7-2 for location.
3. Each unit is equipped with a needle valve that
will accept a 5/16 ID hose to connect to a
digital manometer or liquid gauge to
measure incoming pressure from 0-35” w.c.
See Figure 7-1.
4. Turn on the Gas and Power up the unit.
5. Put the unit into manual service mode
(Details on service mode in back of this
manual). In service mode, monitor pressure
to assure it does not drop below 1 inch from
its idle reading. If Gas Pressure is out of range
or pressure drop is excessive, contact the gas
utility, gas supplier, qualified installer or
service agency to determine correct action
that is needed to provide proper gas pressure
to the unit. If Gas Pressure is within normal
range proceed to Step 6.
6. Exit Service mode, then turn power off and
shut off gas supply at the manual gas valve
37
before disconnecting the hose from the gas
monitoring device. Tighten the screw on the
pressure tap tightly and turn gas on and
checks for leaks with soapy solution.
It is recommended that a soapy solution be used
to detect leaks. Bubbles will appear on the pipe
to indicate a leak is present. The gas piping must
be sized for the proper flow and length of pipe,
to avoid pressure drop. Both the gas meter and
the gas 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 is undersized or in need of service. You can attach a manometer to the incoming gas drip leg, by removing the cap and
installing the manometer. 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 regulator is used, it must be a minimum of 10 feet from
the Elite Heating 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 also in empty
tank situations. This 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.
Fig. 7-1
LP-205-W Rev. 7/24/09
Boiler Manual
PART 7: GAS PIPING (CONTINUED)
D. ELITE GAS VALVE
ELITE GAS VALVE
THROTTLE ADJUSTER
DETAIL A
SCALE 1 : 1
NOTE: IF FOR ANY REASON THE
THROTTLE NEEDS TO BE ADJUSTED,
IT IS VERY IMPORTANT THAT A
"COMBUSTION ANALYZER" BE USED
TO ENSURE SAFE AND PROPER
OPERATION. TURN THE ADJUSTER TO
THE (+) TO INCREASE THE GAS OR (-)
TO DECREASE THE GAS SUPPLY.
THIS ADJUSTMENT COULD AFFECT
CO/CO% LEVELS. MAKE SURE THE
LEVELS CORRESPOND TO THE CHART
IN COMBUSTION SETTINGS (FIG. 10-1)
GAS OUTLET
GAS OUTLET
PRESSURE TAP
GAS VALVE
A
OFFSET ADJUSTMENT
CAUTION: DO NOT REMOVE
THIS SCREW OR ATTEMPT TO
MAKE ANY ADJUSTMENT TO
THIS SCREW WITHOUT A
COMBINATION ANALYZER
GAS INLET
PRESSURE TAP
GAS INLET
GAS SHUT-OFF
VALVE
Fig. 7-2
LP-293-V Rev. 7/24/09
38
Boiler Manual
PART 8: FIELD WIRING
n WARNING
ELECTRICAL SHOCK HAZARD — For your
safety, turn off electrical power supply at service
entrance panel before making any electrical
connections to avoid possible electric shock
hazard. Failure to do so can cause severe
personal injury or death.
NOTICE
Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler must be
replaced, use only TEW 105 °C wire or
equivalent.
Boiler must be electrically grounded as required
by National Electrical Code ANSI/NFPA 70 —
latest edition.
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
All connections made to the Elite Heating
Boiler® in the field are done inside the electrical
junction box located on the side of the unit. The
electrical junction box is located on the left side
of Elite Heating Boiler®. Multiple knockout locations are available to route field wires into and
out of the electrical junction box.
The control used in the Elite Heating Boiler®
series of boilers is capable of directly controlling
2 pumps when in standard mode and 3 pumps
when configured as a cascade master boiler.
When configured as a standard unit, each pump
output can provide a maximum of 3 amps at 120
volts. If pumps used require 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 and DHW pump outputs sourcing 3 amps
each.
39
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.
C. LINE VOLTAGE WIRING FOR
STANDARD BOILER
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 8-1.)
2. A line voltage fused disconnect switch may
be required to be externally mounted and
connected according to local codes that may
apply.
3. Connect the central heating pump as shown
in Figure 8-1 to the terminals marked BOILER
HOT, BOILER NEUT, BOILER GND. The
connections shown are suitable for a
maximum continuous pump draw of 3 amps
at 120 volts. If a the pump requires more
current or voltage other than the 120 volts
supplied, an external motor starter or
contactor will be required.
4. If using DHW, connect the domestic hot water
pump as shown in Figure 8-1 to the terminals
marked DHW HOT, DHW NEUT, DHW GND.
The connections shown are suitable for a
maximum continuous pump draw of 3 amps
at 120 volts. If a pump that requires more
current or voltage other than 120 volts
supplied, an external motor starter or
contactor will be required.
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
D. 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 below.
Knock out locations
for low voltage
connections to
electrical junction box.
2. Connect all low voltage field devices to the
low voltage terminal strip located in the
electrical junction box (shown in Figure 8-1).
40
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
Elite Heating Boiler® CONTROL
Fig. 8-1
E. THERMOSTAT
1. Connect the room thermostat to the
terminals marked THERMOSTAT in the
electrical junction box (shown in figure 8-1)
Alternately, any dry contact closure across
these terminals will cause the Elite Heating
41
LP-293-NN Rev. 7/13/09
Boiler® unit to run. Caution should be used to
ensure neither of the terminals become
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
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
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
Elite Heating Boiler®, the anticipator should be
set at .1 amps. If the thermostat is connected
to other devices, the anticipator should be set
to match the power requirements of the
device it is connected to. See the instruction
manual of the connected devices for further
information.
F. OUTDOOR SENSOR
1. There is no connection required if an outdoor
sensor is not used in this installation.
3. 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.
4. 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: Follow
instructions provided with the sensor for
correct mounting instructions.
G. INDIRECT SENSOR
1. There is no indirect sensor connection
required if an indirect water heater is not
used in the installation.
2. The Elite Heating 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 Elite
Heating 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 settable 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.
3. Connect the indirect tank sensor (7250P-325)
to the terminals marked DHW SENSOR
(shown in figure 8-1) in the electrical junction
box. Caution should be used to ensure
neither of these terminals become connected
to ground.
H. OPTIONAL 0-10 VOLT BUILDING
CONTROL SIGNAL
1. A signal from a building management system
may be connected to the Elite Heating 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 either the set point temperature or the
heat output of the Elite Heating Boiler®. The
control interprets the 0-10 volt signal as
follows. When the signal is between 0 and 1
volt, the Elite Heating Boiler® will be in stand
by mode, not firing. When the signal rises
above 1 volt, the Elite Heating Boiler® will
ignite. As the signal continues to rise towards
its maximum of 10 volts, the Elite Heating
Boiler® will increase either in set point
temperature or firing rate depending on the
setting of parameter 17 in the installer menu.
See Part 11 for details on the setting of
parameters 16 and 17 for this option.
2. Connect a building management system or
other auxiliary control signal to the terminals
marked 0-10 VOLT + and 0-10 VOLT – in the
electrical junction box (shown in figure 8-1)
Caution should be used to ensure that the 010 VOLT + connection does not become
connected to ground.
I. OPTIONAL UL353 LOW WATER CUTOFF
INTERFACE KIT
1. If an optional UL353 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.
2. Remove the wire connected to the low water
cut-off probe on the boiler and connect it to
the orange wire from the newly mounted
LWCO Control Box.
3. Connect the single red wire from the control
box to the low water cut-off probe on the
boiler.
4. Route the rest of the wires through the hole
provided in the cabinet and down by the
42
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
main electrical enclosure.
5. Locate the two pigtails hanging from the
main electrical enclosure. Select the pigtail
which has a white, red, and brown wire in it.
If the pigtail is connected to a gas pressure
switch skip to step 7. If this pigtail is not
connected to a gas pressure switch, remove
the jumper plug from the end of the pigtail
and place the jumper plug into the mating
connector coming from the LWCO control
box.
6. Connect the pigtail to the remaining plug
coming from the LWCO control box.
Installation is complete.
7. If the pigtail located in step 5 is connected to
a gas pressure switch, disconnect it from the
gas pressure switch and connect the pigtail
to the mating connector coming from the
LWCO control box. Connect the gas pressure
switch to the remaining connector from the
LWCO control box.
J. WIRING OF CASCADE SYSTEM
COMMUNICATION BUS
1. 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.
2. 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 or where
they will 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.
3. Route the communication cables through
one of the knockouts in the cabinet.
4. 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
to. If you have connected the boilers to each
other properly, two of the boilers will have
one open connection port on them.
UNUSED COMMUNICATION
"B" JACK AVAILABLE TO
CONNECT TO VISION 2
UNUSED COMMUNICATION
"B" JACK AVAILABLE TO
CONNECT TO VISION 2 WITH
VISION 2/3 CAT 5 ADAPTER CABLE
(P/N 7350P-612)
7350P-612
ADAPTER CABLE
VISION 2
Fig. 8-2
43
LP-293-GG Rev. 8/11/09
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
Elite Heating Boiler® Cascade Master
Fig. 8-3
ELITE CASCADE MASTER PUMP AND
SENSOR WIRING
1. Place the Cascade Master Overlay Sticker
(included) onto the field connection board on
the boiler designated as the Cascade Master
Only.
2. Connect the system pump hot wire to the
terminal marked SYS PUMP.
3. Connect the system pump neutral to the
BOILER NEUT terminal and the pump ground
wire to the BOILER GND terminal.
4. Connect a jumper wire from the 120 VOLT
terminal to the SYS PUMP PWR terminal.
LP-293NN Rev. 7/13/09
5. Connect the boiler pump to the terminals
marked BOILER HOT, BOILER NEUT, and
BOILER GND
6. Connect the system pipe sensor to the
terminals marked SYS SENSOR.
7. Connect the outdoor sensor (if used) to the
terminals marked OUTDR. SEN
8. Connect the signal to start the system to the
terminals marked THERMOSTAT.
NOTE: This signal can come from a room
thermostat or a dry contact closure. No
power of any voltage should be fed into
either of these terminals.
44
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
Elite Heating Boiler® Cascade Follower
Fig. 8-4
ELITE CASCADE FOLLOWER PUMP
AND SENSOR WIRING
1. Connect the boiler pump to the terminals
labeled BOILER HOT, BOILER NEUT, BOILER
GND.
2. If you are using an indirect fired water tank
connected directly to the follower boiler
connect the pump for it to the DHW, HOT
DHW NEUT, and DHW GND terminals.
If you desire, an alarm bell or light can be connected to the alarm contacts of the follower boiler. Optionally 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.
45
LP-293-NN Rev. 7/13/09
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 NO
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.
Boiler Manual
PART 8: FIELD WIRING (CONTINUED)
Fig. 8-5
LP-293-J Rev. 10/1/09
46
Boiler Manual
PART 9. START-UP PREPARATION
To assure good extended service life, it is
recommended that you test your water quality
prior to installation. Listed below are some
guidelines.
n WARNING
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Damage to
elastomer seals and gaskets in the system could
occur, resulting in substantial property damage.
A. CHECK/CONTROL WATER CHEMISTRY
Water pH between 6.0 and 8.0
1. Maintain boiler water pH between 6.0 and 8.0.
Check with litmus paper or have it chemically
analyzed by water treatment company.
2. If the pH differs from above, consult local water
treatment company for treatment needed.
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’s instructions.
B. FREEZE PROTECTION (WHEN USED)
n WARNING
NEVER use automotive or standard glycol
antifreeze, even ethylene glycol made for
hydronic systems. Use only freeze-prevention
fluids certified by fluid manufacturer as suitable
for use with stainless steel boilers, verified in
fluid manufacturer’s literature.
Thoroughly clean and flush any system that has
has used glycol before installing the new Boiler.
Provide boiler owner with a material safety data
sheet (MSDS) on the fluid used.
Hardness less than 7 grains.
1. Consult local water treatment companies for
unusually hard water areas (above 7 grains
hardness).
Chlorine concentration less than 200 ppm
1. Using chlorinated fresh water should be
acceptable since drinking water chlorine
levels are typically less than 5 ppm.
2. Do not connect the boiler to directly heat
swimming pool or spa water.
3. Do not fill boiler or operate with water
containing chlorine in excess of 200 ppm.
Clean system to remove sediment
1. Determine freeze protection fluid quantity
using total system water content, following
fluid manufacturer’s instructions. Remember
to include expansion tank water content.
2. 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.
C. FILL AND TEST WATER SYSTEM
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 build up.
1. Fill system only after ensuring the water
meets the requirements of this manual.
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. Fill to 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 must
never exceed the relief valve pressure
setting.
3. Flush system until water runs clean and you
are sure piping is free of sediment.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids,
47
2. Close manual and automatic air vents and
boiler drain valve.
Boiler Manual
PART 9. START-UP PREPARATION (CONTINUED)
4. At initial fill and during boiler startup and
testing, check system thoroughly for any
leaks. Repair all leaks before proceeding
further.
n WARNING
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 heat exchanger, and
causing heat exchanger failure.
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.
n CAUTION
It is important that you purge the system of air
to avoid damage to the boiler.
D. PURGE AIR FROM WATER SYSTEM
1. Purge air from 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 makeup line.
e. Open purge valve.
f. One zone at a time, open the isolation
valves. Allow water to run through the
zone, pushing out the air. Run 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
say:
SERVICE PUMP CH
PUMP ON
11:47A
and the Central Heating Pump will come
on. If you then press the ▲ key the Central
Heating Pump will shut off, the display will
say:
SERVICE PUMP DH
PUMP ON
11:47A
and 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 say:
SERVICE PUMP DH
PUMP ON
11:47A
and the system pump will come on. Using
the ▼ and ▲ keys in this manner you can
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 control to normal operation.
i. After the system has operated for a
while, eliminate any residual air by using
the manual air vents located throughout
the system.
j. If purge valves are not installed in
system, open manual air vents in system
one at a time, beginning with lowest
floor. Close vent when water squirts out.
Repeat with remaining vents.
k. Refill to correct pressure.
48
Boiler Manual
PART 9. START-UP PREPARATION (CONTINUED)
E. CHECK FOR GAS LEAKS
n WARNING
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
leak at once.
n WARNING
Propane boilers only — Your propane supplier
mixes an odorant with the propane 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.
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 applied to
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 does occur under any condition,
check and correct the external wiring. (This is
a common problem when using 3-wire zone
valves.)
5. Once the external thermostat circuit wiring is
checked and corrected if necessary,
reconnect the external thermostat circuit
wires to boiler low voltage terminal strip
Allow the boiler to cycle.
G. CONDENSATE REMOVAL
1. The Elite Heating Boiler® is a high efficiency
condensing boiler, therefore, the unit has a
condensate drain. Condensate fluid is
nothing more than water vapor, derived from
49
combustion products, similar to an
automobile when it is initially started. The
condensation is slightly acidic (typically with
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 filter, if required by
local authorities, can be made up of lime
crystals, marble or phosphate chips that will
neutralize the condensate. This may be done
by the installer or you may purchase a
condensate neutralizer from Heat Transfer
Products, Inc. (P/N S7350-025)
2. The Elite Heating 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 Elite Heating Boiler
to a suitable inside drain. If the condensate
outlet on the appliance is lower than the drain,
you must use a condensate removal pump,
available from Heat Transfer Products
(#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 Startup Procedures within this manual
for proper steps to start boiler. (See Startup
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 condensate trap with water.
4. Verify electrical connections are correct and
securely attached.
Boiler Manual
PART 9. START-UP PREPARATION (CONTINUED)
5. Inspect intake piping and exhaust piping for
signs of deterioration from corrosion, physical
damage or sagging. Verify intake piping and
exhaust piping are intact and correctly
installed per Venting section and local code.
2. Programming The Master Boiler
1. Make sure there is no demand for heat
being supplied to the boiler
2. Apply power to the 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 not used)
3. Enter the System Menu following
instructions in Part 11 of this manual.
1. Make sure there is no demand for heat
being supplied to the master boiler
4. Verify that Cascade Address parameter
15 is set to 0. This makes the master
boiler address 0. NOTE: The Master
Boiler MUST be addressed as 0.
2. Apply power to the follower boiler you
are working on
I. CASCADE SYSTEM
1. If the boiler is used in a stand alone
configuration, skip this section.
5. Change Cascade Mode parameter 23 to
926 Boiler. This makes it the master
boiler.
6. Exit the installer menu
NOTE: The temperature set point of the master
must match the follower boiler set point in order
for the system to operate properly.
3. Follower Boilers
NOTE: READ THE NOTES BELOW
BEFORE PROGRAMMING FOLLOWER BOILERS:
• The boiler addressed as 1 will share its
alarm output with the master boiler
3. Enter the System Menu following
instructions in part 11 of this manual
4. Set Cascade Address parameter 15 to 1
for the first follower, 2 for the second
follower, etc. depending on which boiler
you are programming.
5. Change “CASCADE MODE” PARAMETER
to “926 BOILER”. This makes the boiler a
follower boiler and enables all data to be
transferred between boilers as needed
for the system to function to full
capability.
6. Exit the system menu
NOTE: The temperature set point of the follower must match the master boiler set point in
order for the system to operate properly.
PART 10. START-UP PROCEDURE
FOR YOUR OWN SAFETY READ
BEFORE OPERATING
1. This appliance 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
appliance 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 appliance.
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
50
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
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 appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.
5. The Elite Heating Boiler® shall be installed so
the gas ignition system components are
protected from water (dripping, spraying,
rain, etc.) during appliance operation and
service (circulator replacement, condensate
trap, control replacement, etc.)
A. CONTROL OVERVIEW
The Control is one of the primary safety devices
of the boiler. The control monitors the safety
sensors of the boiler to assure safe and efficient
operation. The boiler control has many features
to address configurations associated with
hydronic design. This section addresses the
programming features of the boiler control. It is
important to fully understand the capability of
the boiler control. This section addresses Boiler
Settings / System Settings / Maintenance
Settings and System Diagnostics to help customize your boiler control. The control is programmed to run with factory defaults that may
already fit your hydronic design and may 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 Elite 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
51
– Returns the user to the default display screen.
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 (see below)
ENTER MENU CODE
000
One of the zero’s 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 ENTER key to
accept the code entered and 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 parameter for editing. After the user navigates to the
desired parameter, the user would hold down
the ENTER key for one second. When the ENTER
key is released, the parameter value will begin
to blink. The parameter 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
parameter in. The value will then stop blinking.
ARROW Keys – The arrow keys (right and left)
◄ ► 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 parameters. 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.
ARROW Keys – The (up and down) ▲▼ arrow
keys are used to navigate between the various
parameters displayed in the menu. After the
parameter is enabled for editing by pushing the
ENTER key, the ▲▼ keys are used to adjust the
parameter upward or downward to the desired
value.
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
C. OPERATING INSTRUCTIONS
Before Operating the unit, it is important to
remove the cover and note that the gas line and
water lines should be 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.
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.
Turn on the Power to the boiler or boilers if a
cascade system used.
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.
Next, check the System Settings. Adjustments
and factory defaults that 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.
Create a demand on the boiler or boilers if a cascade system is used. The user can monitor system parameters when the boilers are operational.
If the boilers fails to start, refer to the troubleshooting section in the back of manual.
D. PROGRAMMING BOILER SETTINGS
Boiler Setting Program Access
Note: Programming of the boiler control is not
possible when the boiler is firing. Make sure any
input such as the thermostat is turned off, so the
boiler will remain idle to allow programming.
To access the Boiler Setting Program the user
will need to press the ENTER Key for 4 seconds
until the display shows the following:
ENTER MENU CODE
0000
Using the arrow keys on the display, log in the
Boiler Menu Access Code “600”. To confirm the
code, press the ENTER Key to access Boiler
Setting Program Navigation Menu.
ENTER MENU CODE
600
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. 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 RESET key. Listed
below are the boiler settings that can be programmed into the control.
CENTRAL HEAT
180 °F
Function: Allows the user to adjust the Boiler Set
Point from 50°F to 190°F (Factory Default 180°F)
CENTRAL DIFF SET
30 °F
Function: Allows the user to adjust the Boiler
Differential Set Point from 5°F to 30°F (Factory
Default 30°F).
DHW SET POINT
119 °F
Function: Allows the User to adjust the Indirect
Set Point from 70° F to 185°F (Factory Default
119°F)
DHW DIFF SET POINT
7 °F
Function: Allows the user to adjust the Indirect
Differential Set Point from 1° F to 30° F (Factory
Default 7°F)
TEMP DISPLAY C OR F
°F
Function: Allows the user to adjust the
Temperature Measurement in Fahrenheit to
Celsius (Factory Default is F = Fahrenheit)
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Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
Clock Settings
(Note: The clock will reset if the boiler is powered off for more than a week).
CLOCK MODE
08/28/2009
(12/24)
Fr 9:42A
Function: Changes the clock from 12 hour mode
(8:45 PM) to 24 hour mode (20:45). To change to
24 hour mode when this screen is displayed,
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
08/28/2009 Fr 10:01A
Function: Allows the user to adjust the Minute
Setting.
CLOCK DAY OF WEEK
08/28/2009 Fr 10:01A
Function: Allows the user to adjust the Day of
Week displayed.
CLOCK DATE MODE
08/28/2009 Fr 10:01A
Function: Allows the user to switch to European
date format (2009/08/28) from U.S. format
(08/28/2009).
CLOCK YEAR
08/28/2009 Fr 10:01A
Function: Allows the user to adjust the Year
Setting.
53
CLOCK MONTH
08/28/2009 Fr 10:01A
Function: Allows the user to adjust the Month
setting.
CLOCK DATE
08/28/2009 Fr 10:01A
E. PROGRAMMING THE SYSTEM SETTING
System Setting Program Access
Note: Programming of the boiler control is not
possible when the boiler is firing. Make sure any
input such as the thermostat is turned off, so the
boiler will remain idle to allow programming.
To access The System Setting Program the user
will need to press the ENTER Key for 4 seconds
until the display shows the following:
ENTER MENU CODE
0000
Using the arrow keys on the display, log in your
System Menu Access Code “925”. To confirm
code, press the ENTER KEY to access System
Setting Program Navigation menu.
ENTER MENU CODE
925
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 arrows keys on the display to navigate through the System Setting
Program. To change a setting, press the ENTER
KEY.System settings can be increased by pressing the UP ARROW and decreased by pressing
the DOWN ARROW on the display. Once settings have been set, press the RESET button to
store them. Listed below are the System
Settings that can be changed in the control.
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
Function 1
Factory Program Mode
MODE
INDIRECT
1
This screen indicates that the control is configured correctly. Do not change this screen.
Function 3
DHW Tank Max Temp
DHW TANK MAX TEMP
180°F
3
Description: Indirect Water Heater Maximum
boiler menu setting. This is the maximum temperature that can be selected for the DHW Set
point in the Boiler Menu.
Factory Default is 180°F (Range: 95°F to 185°F)
Function 5
DHW Diff Set point
DHW DIFF SET POINT 5
7°F
Description: Sets the amount of degrees below
the DHW tank temperature set point that you
want the boiler to ignite at. Same as DHW Diff
Set point in Boiler menu. Factory Default of 7°F
(Range: of 1°F to 18°F)
Function 6
DHW Post Pump Time
DHW POST PUMP TIME 6
0 MINUTES
Description: Indirect Pump has the ability to
post purge energy from the boiler to run the
pump after the set point has been achieved.
Please note that running pump for a time greater
than 5 minutes may cause tank energy to be
released back to the boiler heat exchanger
Factory default of 0 Minutes (Range from 0–10
minutes)
Function 7
Warm Weather Shutoff
WARM WEATHER OFF
68 °F
7
Description: Warm Weather Shut off will disable
the boiler if the programmed outdoor temperature is exceeded when used with an outdoor
sensor. Factory Default of 68°F (Range 41°F to
122°F)
Function 8
Min Outdoor Temp
MIN OUTDOOR TEMP
5 °F
8
Description: Allows the user to set the min. outdoor design temperature for the system Factory
Default is set to 5°F (Range –49° F to 32°F)
Function 9
Max Supply Temp
MAX SUPPLY TEMP
180 °F
9
Description: Allows the user to set the
Maximum Design Supply Temperature based on
the minimum outdoor design temperature.
Factory Default 180°F - Range (77° F to 190° F)
Function10
Max Outdoor Temp
MAX OUTDOOR TEMP
68 °F
10
Description: Allows the user to set the
Maximum Outside design temperature for the
system design. Factory default 68°F – Range
(32°F to 95°F)
Function 11
Min Supply Temp
MIN SUPPLY TEMP
95 °F
11
Description: Allows the user to set the design
supply water temperature based on the
Maximum outdoor design temperature. Factory
Default 95°F – Range (32°F to 190°F)
54
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
Function 12
Min Boiler Temp
MIN BOILER TEMP
68 °F
12
Description: Allows the user to set the design
supply water temperature based on the
Maximum outdoor design temperature. Factory
Default 95°F – Range (32°F to 190°F)
Function 13
CH Post Pump Time
CH POST PUMP TIME 13
0 MINUTES
Description: Allow the user to set the boiler
pump post purge time once the thermostat is
satisfied: Factory Default: 0 minutes – Range (0
– 10 minutes).
Function 14
DHW Priority
DHW PRIORITY
30 MINUTES
14
Description: Allows the user to set the
Maximum run time for the Indirect Fired Water
Heater and the Minimum run time for Central
Heating: Factory Default 30 Minutes – Range (0
– 60 Minutes)
Function 15
Cascade Address
CASCADE ADDRESS
O
15
Description: Bus addressing Boilers (Maximum
boilers allowed 8 in a cascade system) Master
Boiler will always be addressed = 0 and followers boilers will be addressed = 1 thru 7. Factory
Default 0 – Range (0–8).
Function 16
Optional Inputs
OPTIONAL INPUT
RETURN
16
Description: The control system allows the user
to choice from varies optional inputs to control
or monitor the system. Factory Default =
RETURN /Selection (Off / Booster 0–10 Volt /
Return / DHW Sensor, Return Sen)
55
Function 17
0-10 Volt Function
0-10 VOLT FUNCTION17
TEMERATURE
Description: Allows the user to control the boiler modulation through either temperature control or controlling the fan speed: Factory Default
= Temperature / Selection (Temperature control
or Fan Speed)
Function 18
Step Modulation Mode
STEP MODULATE MODE18
ON
Description: Allows the user to turn ON the step
modulation which regulates the burner output in
6 steps in one minute intervals. Step modulation
will start at the lost modulation rate of the boiler
and work up one (1 Minute) at a time. Factory
Default OFF / Selection (OFF to ON)
Function 19
Boiler DHW Temp
BOILER SUPPLY DHW 19
180 °F
Description: Allows the user to program the
boiler supply water temperature to the indirect
Heat Exchanger during a demand cycle. Factory
Default 180°F / Range (119°F to 190°F)
Function 20
Water Safety Input
WATER SAFETY INPUT
WATER PRESSURE
20
Description: The user can select varies water
safety inputs used in the boiler system. Factory
Default: Water Pressure / Selection (None / Low
Water Cut off / Flow Switch / Water Pressure)
Function 21
Error Outdoor Sensor
ERROR OUTD SENSOR 21
ON
Description: Allows the user to set the control to
display and error message if an outdoor sensor
is open or shorted – Note: This error does not
stop the boiler from running. Factory Default
OFF / Selection (ON/OFF/PHOEN ON) Last
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
option only used on Phoenix Water Heaters.
Adjust Boiler Output %
Function 22
ADJ BOILER OUTPUT 22
100%
Description: Allows the user to adjust the boiler
output down from 100% to 50%. Factory Default
100% / Range (100% to 50%)
Cascade Mode
Function 23
CASCADE MODE
926 BOILERS
23
Description: Allows the user to select cascade
mode. Factory Default: Vision 3.
Cascade Rotation
Function 24
CASCADE ROTATION
48HOURS
24
Cascade DHW Mode
NOT USED
NOT USED
25
Description: Not used
Function 26
SYS FREEZE PROT
OFF
Description: Allows the user to set the control to
display and error message if the system sensor
is open or shorted – Note: This error does not
stop the boiler from running. Factory Default ON
/ Selection (ON /OFF).
Function 28
26
Description: Allows the user to set the freeze
protection when a system pump is used. Factory
Default: OFF / Selection of temperature activates Freeze (Range –47°F to 68°F)
Note: This parameter is only present if the boiler is a cascade master.
Freeze Protection
FREEZE PROTECTION 28
OFF
Description: Allows the user to set the freeze
protection on the boiler. Factory Default: ON
Selection (Range ON or OFF)
DHW Modulation Mode
DHW MODULATE MODE 29
NORMAL MOD
Description: This parameter controls how the
boiler modulates for a DHW demand. In Normal
Mod mode, the boiler will modulate down from
high fire when there is a DHW demand. In Low
Mod mode the boiler will modulate up from low
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 Modulation / Selection
Range (Normal Mod or Low Mod)
Function 30
System Pump Freeze Protect
Error System Senor
ERROR SYSTEM SENS 27
ON
Function 29
Description: This parameter sets the amount of
hours before the first boiler in the cascade firing
rotation will be changed. Note: if this parameter
is set to 0, the firing order of the boilers will not
rotate.
Default: 48 hours, selection range: 0-240 hours.
Function 25
Function 27
Extra Boiler Mode
EXTRA BOILER MODE 30
OFF
Description: Boiler is a cascade master boiler.
This 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% to
100%)
56
Boiler Manual
PART 10. START-UP PROCEDURE (CONTINUED)
Function 31
System Sensor Mode
SYSTEM SENSOR MODE31
OFF
Description: 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)
Function 32
Service Schedule
SERVICE SCHEDULE
OFF
32
Description: Allows the user to select a service
date or time based on the boiler run hours to
program the boiler maintenance schedule.
Factory Default OFF / Selection (Date or Run
Hours) NOTE: Without setting this function,
Functions 33/34/35/36 will not display.
Function 33
Year
SERVICE SCHEDULE
YEAR 00/00/2000
33
Hours:
33
Description: This parameter sets the 2 left digits
of the amount of run hours for the next service
reminder
57
SERVICE SCHEDULE
MONTH 00/00/2000
34
Description: If you selected the date function
you will need to program the month or if you
selected the run hour function you will need to
program 10,000 hours if required.
SERVICE SCHEDULE
10000’s 00O
0000h
34
Description: This parameter sets the 2 middle
digits of the amount of run hours for the next
service reminder
Function 35
SERVICE SCHEDULE
DAY 00O
0000
35
Description:
Description: This parameter sets the year of the
next service reminder
SERVICE SCHEDULE
10000’s O
000000h
Function 34
SERVICE SCHEDULE
1’S 0000O
00h
35
Description: This parameter sets the 2 right digits of the amount of run hours for the next service reminder.
Function 36
TELEPHONE #
000 000 0000
36
Description: Allows the user to input a telephone number that will be displayed when
maintenance is required.
Boiler Manual
PART 11: START-UP PROCEDURES FOR THE INSTALLER
NOTICE
It is important to note that the user can adjust the heat curve down by adjusting the central heating
temperature to a lower setting.
CENTRAL HEATING CURVE
Factory Default
201˚
CENTRAL HEATING CURVE
Plot your Curve
212
212
203
203
194
194
185
185
FUNCTION 9
176
176
DEFAULT RESET CURVE
149
131
122
113
104
95
FUNCTION 11
77
FUNCTION 10
86
68
59
50
SUPPLY OUTLET TEMPERATURE (F)
167
158
FUNCTION 8
SUPPLY OUTLET TEMPERATURE (F)
167
158
149
131
122
113
104
95
86
77
68
59
50
41
41
32
32
-59
-41
-24
-9
0
9
27
63
45
5˚
81
99
-59
-41
68˚
0
9
27
63
45
81
99
Fig. 11-2
A. ELITE CONTROL STATUS MENU
The Elite Controller also has the ability to review
the status of the system. To access the Status
screens simply press the right arrow key ►
Once the first value is displayed then press the
UP arrow key ▲ or Down arrow key ▼ to access
additional information. At any point you may
press the ‘RESET’ button to exit the Status
screen. Listed below are the Status screens.
SUPPLY
RETURN
-9
OUTSIDE TEMPERATURE (F)
OUTSIDE TEMPERATURE (F)
Fig. 11-1
-24
180°F
150°F
This screen is displayed after pressing the ► key
as described above. This screen displays 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
SUPPLY
180°F
122°F
This 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.
58
Boiler Manual
PART 11: START-UP PROCEDURES FOR THE INSTALLER (CONTINUED)
Press the ▼ key once
DHW SET
DHW
Press the ▼ key once
119°F
117°F
This screen displays the current domestic hot
water temperature set point on the top line. The
actual temperature measured by the domestic
hot water tank sensor (HTP 7250P-325) is displayed on the bottom line. If a mechanical aquastat is used in place of the recommended sensor, the second line will display ‘OFF’ in place of
the temperature if the aquastat is measuring
close to its set temperature or ‘ON’ in place of
the temperature if the aquastat temperature too
low.
Press the ▼ key once
OUTDOOR
FLUE
11°F
95°F
This screen displays the current outdoor temperature 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.
Press the ▼ key once
FLAME
FAN SPEED
0.0uA
3497 RPM
This screen displays the boiler flame current on
the top line.
The second line displays the speed of the fan in
the boiler.
Press the ▼ key once
0-10 V
0.0 V
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.
59
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 boiler configuration and if it is the master
boiler, and other boilers are connected to the
communication bus and power is on to them,
then this screen will show the address of each
boiler connected to the bus.
Press the ▼ key once
POWER ON
CH ON
0H
0H
The top line of this display indicates the amount
of hours the boiler has power applied to it in the
life of the boiler
The second line indicates how many hours the
burner has been on for a central heat demand in
the life of the boiler
Press the ▼ key once
DHW ON
GOOD IGNIT
0H
1X
The top line of this display indicates the amount
of hours the burner has been on for a domestic
hot water demand in the life of the boiler. The
second line indicates how many times the burner has successfully ignited in the life of the boiler.
The following 10 screens display the last ten
lockout faults that the boiler had. The faults are
displayed from most recent to oldest by
depressing the ▼ key.
FAULT HISTORY
10
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 if one has occurred and
Boiler Manual
PART 11: START-UP PROCEDURES FOR THE INSTALLER (CONTINUED)
the bottom line will display the date and time
that the fault occurred
Press the ▼ key once
FAULT HISTORY
20
08/28/2009 Fr 5:19A
This screen displays the second oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
30
08/28/2009 Fr 5:19A
This screen displays the third oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08/28/2009
40
5:19A
This screen displays the fourth oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08/28/2009
50
5:19A
This screen displays the fifth oldest lockout fault
the boiler controller had. The top line will alternate between the words ‘FAULT HISTORY’ and
the actual fault encountered if one has occurred
and the bottom line will display the date and
time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08/28/2009
60
5:19A
This screen displays the sixth oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08 28 2009
70
5:19A
This screen displays the seventh oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08 28 2009
80
5:19A
This screen displays the eighth oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
Press the ▼ key once
FAULT HISTORY
08 28 2009
90
5:19A
This screen displays the ninth oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
60
Boiler Manual
PART 11: START-UP PROCEDURES FOR THE INSTALLER (CONTINUED)
Press the ▼ key once
FAULT HISTORY
08 28 2009
10:01A
This screen displays the tenth oldest lockout
fault the boiler controller had. The top line will
alternate between the words ‘FAULT HISTORY’
and the actual fault encountered if one has
occurred and the bottom line will display the
date and time that the fault occurred
B. ELITE HEATING BOILER TEST MODE
This Function is intended to simplify the gas
adjustment if needed. Listed in Figure 11-3 are
the recommended combustion settings for the
gas type selected to run the Elite Boilers.
Automatic Modulation does not take place when
the controller is in Test Mode. The boilers will
modulate down if the program set point is
approached while running in test mode. It is recommended you open as many heating zones as
possible to create a heat demand so the test
mode operation will not be interrupted. To exit
the test mode, Press the ‘Up’ and ‘Down’ arrow
keys simultaneously. NOTE: The boiler will automatically exit the service mode after 20 minutes
of operation.
C. TEST MODE ACCESS
To Activate the test mode Press the up arrow ▲
and ENTER key together for 1 second. The boiler will go through the ignition sequence then the
user will adjust the Fan Speed by pressing the
up arrow key ▲ to increase the fan speed or the
down arrow key ▼ to decrease the fan speed.
SERVICE RUN 3400 RPM
PUMP ON
4:49P
COMBUSTION SETTINGS ON ALL MODELS
Natural Gas
Propane LP
low
high
low
high
Carbon Monoxide
0–20 ppm 70 ppm–135 ppm 0–20 ppm 80 ppm–150 ppm
(CO %)
Carbon Dioxide
8½% – 9½% 8½% – 9½% 9½% – 10½% 9½% – 10½%
(CO2 %)
Fig. 11-3
PART 12: TROUBLESHOOTING
A. ELITE HEATING BOILER® ERROR CODE
If any of the sensors detect an abnormal condition or an internal component fails during the
operation of the Elite Heating Boiler®, the display may show an error message and error
code. This message and code may either 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 the
result of 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 steadily and the message “LOCKOUT” will be displayed on the readout on the lower line. The Elite heating Boiler
will not start until a qualified technician has
repaired the boiler and pressed the RESET button for more than 1 second. If there is an error
message displayed on the readout and the message “LOCKOUT” is not displayed and the
61
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 be indicating that more
serious problems 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. USER INTERFACE DISPLAY.
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 format.
The alarm output will also be activated. Most
fault conditions will also cause the CH pump
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
to run in an attempt to cool the boiler.
2. Note the fault message that is displayed and
refer to Table 12-2 for an explanation of the
fault 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 unit for a period of time to
assure correct operation and no reoccurrence of fault message.
n WARNING
When servicing or replacing any components of this
boiler be certain that:
• The gas is off.
• All electrical power is disconnected
n DANGER
When servicing or replacing components that are in
direct contact with the 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 off
n WARNING
Do not use this appliance if any part has been under
water. Improper or dangerous operation may result.
Contact a qualified service technician to inspect the
boiler and to repair or replace any part of the boiler
that has been under water prior to placing the boiler
back in operation.
n CAUTION
This appliance has wire function labels on all internal
wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.
n CAUTION
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.
D. USER INTERFACE DISPLAY
Fault Code FOU
OUTDOOR SENSOR
PUMP ON
FOU
Description:
This display indicates that the outdoor sensor is
defective, either shorted or open, or the outdoor
temperature is below –40 degrees Fahrenheit.
NOTE: The installer must choose YES for
parameter 21 to enable this feature. The boiler
will continue to operate when this error is displayed but the control will ignore the outdoor
reset feature and run at the programmed boiler
temperature. The bottom line of the display will
indicate the status of the pump.
Remedy:
Inspect wiring from outside sensor for damage
or shorted connections repairing as necessary.
Measure resistance of outdoor sensor and compare to resistance chart. If not within range on
chart, shorted or open, replace sensor
Fault Code E07
FLUE TEMP HIGH
PUMP OFF
E07
Description:
This display indicates that the flue sensor temperature is excessive and above 210 deg. F.
When this code is displayed the boiler will not
respond to a demand for heat. When the flue
temperature decreases below 194 Deg. F, the
display will return to normal and allow the boiler to respond for a demand to heat. The bottom
line of the display indicates the status of the
pump. The pump will remain off when this error
is displayed.
Remedy:
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,
62
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
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 problem
persists, inspect the target wall in the combustion chamber and replace it if cracked or damaged.
Fault Code E19
LINE VOLTAGE
PUMP OFF
E19
Description:
This display indicates that the line voltage frequency is out of range. This could happen if the
boiler is being powered from a small gasoline
powered generator which is not functioning correctly or overloaded.
Remedy:
Inspect power wiring to boiler and repair as necessary. If connected to line voltage, notify power
company. If connected to alternate power
source such as generator or inverter make sure
line voltage frequency supplied by the device is
60 Hz.
Fault Code FLU
HIGH FLUE PRESS
PUMP ON
FLU
Description:
This display indicates that there is excessive flue
pressure. This code will reset automatically after
the high pressure condition is resolved. The second line indicates the status of the pump.
Remedy:
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 unit
WARNING: Do not use jumper to remedy
this error. Faulty switch MUST be replaced.
Failure to do so could result in serious injury
or death.
63
Fault Code PRO
LOW WATER PRESS
PUMP OFF
PRO
Description:
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.
Remedy:
1. Assure that the system pressure is above 10
psig.
2. Check for leaks in the system piping.
Fault Code LOU
24 VOLT LOW
PUMP ON
LOU
Description:
This display indicates that the 24 volt power
supply on the control is damaged or overloaded. This code will reset 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.
Remedy:
1. Check line voltage. Must be between 100128 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 10 pin Molex connector from customer connection board. If the message
clears, then the problem is with external sensor wiring. Examine external sensor wiring
for shorts to ground repairing as necessary.
If message is still present and the boiler is so
equipped, disconnect the UL 353 low water
cutoff to see if message clears. Replace
faulty part. Check low voltage wire harness
in boiler for shorts to ground.
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
4. If message only occurs when burner tries to
light, check gas valve for excessive current
draw.
5. If message is present with the low voltage
harness disconnected from the 926 control
board, replace the 926 control board.
Fault Code E03
SYS SUPPLY SENSOR E03
PUMP ON
Description:
This display indicates that the system supply
sensor has failed or is not connected. This code
will not cause the boiler or boilers to stop functioning but when this code is displayed, cascaded boilers will not cascade normally and not run
in their most efficient mode. This code will reset
automatically when the sensor is replaced or the
wiring is repaired. If Installer parameter 27 is set
to ‘NO’ this message will not be displayed when
the system sensor fails. The second line of the
readout indicates the status of the pump. The
pump will run normally based on demand on
the system.
Remedy:
1. Check wiring to system sensor. Repair as
necessary
2. Check sensor resistance. Compare to the
table in Fig. 12-4 in manual. Replace if not
correct.
Fault Code FL
LOW WATER FLOW
PUMP OFF
FL
Description:
This display indicates that there is low water flow
in the boiler. This code should never be displayed
on the Elite boiler since there is no flow switch in
the product. This code will display on VWH products only. This code will reset automatically when
the water flow is high enough for the boiler to run
safely. The second line indicates the status of the
pump. The pump should always be on when this
code is displayed. When there is a demand, the
control will start the pump, wait for the flow
switch to indicate flow then try to ignite the boiler.
This display occurs after the pump is energized for
several seconds and the flow is still too low.
Remedy:
1. Check to see if boiler pump is functioning.
Repair as necessary.
2. Be sure water is flowing in the system.
Check for valves that should be open,
plugged filter screens, etc.
3. Check flow switch and wiring. Repair as necessary.
Fault Code F00
WATER HIGH TEMP
PUMP ON
F00
Description:
This display indicates that the water in the boiler
has overheated. This code indicates a serious
safety issue and the boiler will not restart until it
cools down sufficiently and a technician repairs
the cause of the 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 of the
display in an effort to cool down the boiler.
Remedy:
1. Check circulation 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 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.
Fault Code F01
FLUE TEMP/WAT LV F01
PUMP ON
Description:
This display indicates that the flue temperature
limit switch of the boiler has tripped or that the
water level in the boiler is low 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
64
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
level is restored and technician repairs the
cause of the problem and pushes the RESET
button on both device and the display. This situation 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 of the
display.
Remedy:
1. If the boiler has a UL353 LWCO, check to see
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 red reset button
on flue temperature switch located on the
flue inside the rear access door of the boiler.
NOTE: 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 problem persists, inspect the target wall in the
combustion chamber and replace it if
cracked or damaged.
Fault Code F02
SUPPLY SENSOR
PUMP ON
F02
Description:
This display indicates that the supply 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 illuminating 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.
65
Remedy:
1. Check the electrical connection to the thermistor on the outlet manifold. Verify 5 VDC
by checking in Molex connector. If no 5 VDC,
check harness. If harness is OK, replace control. NOTE: Boiler will reset automatically.
Verify thermistor values by referencing chart
in this manual.
2. Replace thermistor if necessary.
Fault Code F03
RETURN SENSOR
PUMP ON
F03
Description:
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 illuminating 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
Remedy:
1. Check circulation 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
FLUE SENSOR
PUMP ON
F04
Description:
This display indicates that the flue 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 illuminating 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
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
Remedy:
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 chart in fig 12-2 of
this manual. The temperature on the chart
should be close to the same as the temperature
in the flue. If it is not, replace the flue sensor.
Fault Code F05
SUPPLY TEMP HIGH F05
PUMP ON
Description:
This display indicates that the supply temperature of the boiler is excessive. If this code is
accompanied by the illuminated red ‘FAULT’
light and ‘LOCKOUT’ flashing on the display then
this code indicates that the temperature on the
supply sensor has exceeded 230 deg. 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 he pushes
the RESET button on the display.
If the red ‘FAULT’ light is not illuminated, but this
message is displayed then the supply temperature of the boiler is at or above 210 Deg. F. The
message will clear automatically when the temperature drops below 194 Deg. F. During the
time that this message or lockout fault is displayed, the pump will be on as indicated on the
second line of the display.
Remedy:
1. Check circulation 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 direction of flow on boiler circulator.
(See Piping Details in this manual.)
4. Troubleshoot thermistor by following steps
in |F02|
Fault Code F06
RETURN TEMP HIGH F06
PUMP ON
Description:
This display indicates that the return temperature of the boiler is excessive. If this code is
accompanied by the illuminated red ‘FAULT’
light and ‘LOCKOUT’ flashing on the display then
this code indicates that the temperature on the
return sensor has exceeded 230 deg. 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 he pushes
the RESET button on the display.
If the red ‘FAULT’ light is not illuminated, but this
message is displayed then the return temperature of the boiler is at or above 210 Deg. F. The
message will clear automatically when the temperature drops below 194 Deg. F. During the
time that this message or lockout fault is displayed, the pump will be on as indicated on the
second line of the display.
Remedy:
1. Check circulation 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 direction of flow on boiler circulator.
(See Piping Details in this manual.)
4. Troubleshoot thermistor by following steps
in |F02|
Fault Code F09
NO FLAME ON IGN
PUMP ON
F09
Description:
The boiler tried to ignite four times during one
heat call and failed ignition all four times. This
code indicates a serious safety issue and the
boiler will not restart until the cause of no ignition is determined by a technician and he pushes the RESET button on the display. 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 of the display
Remedy:
1. Watch the igniter through the observation
window provided.
2. If there is no spark, check the spark electrode
for the proper ¼” gap. Use 2 quarters togeth66
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
3.
4.
5.
6.
er as a gauge to hold ignitor against to check
gap distance. (See Fig. 12-3 in manual)
Remove any corrosion from the spark electrode and flame rectifier probe.
If there is a spark but no flame, check the gas
supply to the boiler.
If there is a flame, check the flame sensor.
Check any flue blockage or condensate
blocks.
.177 "
4.5mm
play. 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.
Fault Code F11
FALSE FLAME SIG
PUMP ON
Elite Spark Electrode
Gap Spacing
Top View
Fig. 12-1 NOTE: If receiving an F09 fault code,
check the gap spacing between points on
the electrode.
Fault Code F10
FLAME LOSS
F10
Description:
The flame was lost while the boiler was firing 3
times during 1 demand call. This code indicates
a serious safety issue and the boiler will not
restart until the cause of the flame loss is determined by a technician and he pushes the RESET
button on the display. 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
of the display.
Remedy:
1. Monitor the gas pressure to the unit while in
operation.
2. Assure that the flame is stable when lit.
3. Check to see if the display readout changes
from “GAS VALVE ON” to “RUN” within a
few seconds after the boiler ignites
4. Check the FLAME signal on the status dis67
F11
Description:
There is flame when the boiler control is not
telling the boiler to run. 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. 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 of the display.
Remedy:
1. Look into window. If there is flame, turn the
gas off to the unit at the service valve and
replace 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 ignitor and the flame rectification probe.
3. If the flame signal is not present after turning
off the gas supply, check the gas valve electrical connection.
4. Check for Condensate backup. Repair condensate system as necessary. If condensate
has 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 wall falls against the rectifier probe, it
may conduct the signal to ground, giving a
false reading.
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
Fault Code F13
FAN SPEED ERROR
PUMP ON
F13
Description:
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. 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. 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 of the display.
Remedy:
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.
Fault Code F20
CONDENSATE FULL
PUMP ON
F20
Description:
The condensate trap is full of condensate. 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. The red light on the display illuminating and the word LOCKOUT flashing on the display. During this lockout fault, the
pump will be off as indicated on the second line
of the display.
Remedy:
1. Check condensate lines for obstructions
2. Check float switch in condensate reservoir.
3. Check wiring from condensate reservoir to
926 control and repair as necessary
Fault Code.F31
PROGRAM ERROR
F31
Description:
There was an error while programming the control and the control’s memory is corrupt. The
boiler control will not function in this state and
the pump will be off as indicated on the bottom
line of the display. The only way for this error to
occur is if a technician is programming the control and the programming function fails. The
only way to recover from this error is to program the control again. 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.
Remedy:
Control must be re-programmed. If programming does not solve problem, control must be
replaced.
Fault Code PP
CONTROL PROGRAMED
PP
Description:
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 to begin use of the control.
Remedy:
Press S4 reset for at least 1 second.
68
Boiler Manual
PART 12: TROUBLESHOOTING (CONTINUED)
Resistance Tables
Supply Temperature Sensor 7250P-324
Outdoor Sensor (7250P-319)
Outside Temperature (°F) Resistance (ohms)
–22
171800
–13
129800
–4
98930
5
76020
14
58880
23
45950
32
36130
41
28600
50
22800
59
18300
68
14770
77
12000
86
9804
95
8054
104
6652
113
5522
Boiler Sensor (7250P-667)
Indirect Sensor (7250P-325)
Water Temperature (°F)
Resistance (ohms)
32
32550
41
25340
50
19870
59
15700
68
12490
77
10000
86
8059
95
6535
104
5330
113
4372
122
3605
131
2989
140
2490
149
2084
158
1753
167
1481
176
1256
185
1070
194
915
203
786
212
667
Fig. 12-2
PART 13: 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 heater.
Installer must also inform the owner that the lack
of proper care and maintenance of the heater
may result in a hazardous condition.
69
n WARNING
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 manual.
Failure to do so could result in death or serious
injury.
Boiler Manual
PART 13: MAINTENANCE (CONTINUED)
n WARNING
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
(Group1).”:
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 the job site
conditions. Current NIOSH recommendations
can be found on the NIOSH website at
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
THE MOD CON
*Before beginning this procedure, you must have on
hand the following items:
– a nylon, stainless steel or brass brush (not
steel)
– “Rydlyme” (recommended for best
results) (available on line
www.rydlyme.com) or “CLR” (available at
most hardware stores)
– Gloves, eye protection
1. Shut down the Elite Heating Boiler® by using the
following steps:
a. Close the gas valve, shut down the unit
and wait for the unit to be cool to the
touch
b. Disconnect the condensate piping from
the outside connection, (not from the
Elite Heating Boiler® side), so the flow
from condensate reservoir can be
observed.
c. Disconnect electrical connections from
the gas valve, spark electrode and flame
rectification probe and combustion blower.
d. Remove the (4) screws on the aluminum
¾” NPT connector on the right side of the
gas valve.
e. Disconnect the wiring connected to the
combustion blower motor.
f. Remove the (6) 10MM nuts from the
burner plate assembly.
g. Pull the entire burner plate assembly with
blower still attached towards you, while
removing or pushing aside any wiring to
allow the removal of the assembly.
2. Using a spray bottle filled with the recommended product “RYDLYME” or “CLR”, spray liberally
on the coils, making sure the solution penetrates
and funnels down through the condensate system. If the condensate system is blocked, let the
chemical penetrate for at least 15 minutes or
until it drains.
3. Use the nylon, stainless steel or brass brush (do
not use steel) and scrub coils to remove any
buildup, then vacuum the debris from the coils.
WARNING: Follow precautions above
4. Spray the coils with clear water, making sure to
confine the spray to the area being cleaned (Try
to avoid getting the back ceramic wall of the unit
wet). Flush the combustion chamber with fresh
water until clear water runs from the condensate. At this point, the Mod Con should be ready
to be re-assembled.
a. Inspect gaskets.
70
Boiler Manual
PART 13: MAINTENANCE (CONTINUED)
b. Re-install the burner assembly
c. Replace and tighten the (6) 10MM nuts to
the burner plate using staggered tighten-
71
ing sequence. (See detail)
d. Re-connect all wiring connections
e. Inspect gas valve to assure O-ring is in
place. Replace the (4) screws on the aluminum connector on the gas valve. Turn
the gas back on. (IMPORTANT: CHECK
FOR GAS LEAKS)
g. Turn the Elite Heating Boiler® power back
on and create a demand on the boiler.
When boiler is lit, observe condensate
flow from the boiler. Be sure the boiler is
operating properly.
h. Re-connect the condensate piping to the
outside condensate connection.
Boiler Manual
PART 13: MAINTENANCE (CONTINUED)
22
23
22
24
17
5
2
6
7
1
8
9
10
32
18
19
13
20
18
34
4
3
30
32
12
21
31
15
14
29
20
11
16
25
33
27
28
Fig. 13-1
26
ITEM
#
1
EL-80
EL-110
EL-150
EL-220
7450P-001
7450P-002
7450P-003
7450P-004
BOILER MODULE
2
7250P-160
7250P-160
7250P-160
7250P-160
CERAMIC TARGET WALL
3
7500P-109
7500P-109
7500P-109
7500P-109
M4 FLAT WASHER
4
7250P-704
7250P-704
7250P-704
7250P-704
M4 X 8 FLAT HEAD SCREW
Description
5
7450P-006
7450P-006
7450P-006
7450P-006
BURNER DOOR
6
7450P-005
7450P-005
7450P-005
7450P-005
BURNER DOOR REFRACTORY
7
7450P-009
7450P-010
7450P-011
7450P-012
BURNER
8
7500P-074
7500P-074
7500P-074
7500P-074
GASKET - BURNER
9
7450P-008
7450P-008
7450P-007
7450P-007
AIR CHANNEL
10
7250P-206
7250P-206
7250P-206
7250P-206
M5 X 14MM TORX SCREWS - AIR CHANNEL
11
7500P-075
7500P-075
7500P-075
7500P-075
GASKET - AIR CHANNEL/BLOWER
12
7500P-031
7500P-031
7500P-031
7350P-159
COMBUSTION BLOWER
13
7250P-478
7250P-478
7250P-478
7250P-478
M5 X 12MM SOCKET CAP SCREW
14
7450P-022
7450P-023
7450P-024
7450P-024
AIR/GAS MIXER
15
7450P-141
7450P-141
7250P-478
7250P-478
SCREWS - AIR/GAS MIXER
16
7450P-115
7450P-115
7450P-115
7450P-115
WASHER - AIR/GAS MIXER
17
7500P-067
7500P-067
7500P-067
7500P-067
M6 NUT - BURNER DOOR
18
7250P-005
7250P-005
7250P-005
7250P-005
GASKET - PROBE/ELECTRODE
19
7350P-020
7350P-020
7350P-020
7350P-020
SPARK ELECTRODE (w/GASKET)
20
7250P-069
7250P-069
7250P-069
7250P-069
SCREW M4 X 8MM - PROBE/ELECTRODE
21
7350P-022
7350P-022
7350P-022
7350P-022
FLAME RECTIFICATION PROBE (w/GASKET)
22
7250P-667
7250P-667
7250P-667
7250P-667
THERMISTOR
23
7250P-096
7250P-096
7250P-096
7250P-096
WATER PRESSURE SWITCH - NPT THREAD
24
7250P-019
7250P-019
7250P-019
7250P-019
ECO - HIGH LIMIT SENSOR
25
7450P-139
7450P-139
7450P-139
7450P-138
FLARE X BSP FITTING
26
7100P-140
7100P-140
7100P-140
7450P-140
FLEXIBLE GAS LINE
27
7450P-154
7450P-154
7450P-154
7450P-143
FLARE X NPT FITTING
28
7450P-025
7450P-025
7450P-025
7350P-033
GAS VALVE
29
7350P-167
7350P-167
7350P-167
7350P-167
CONDENSATE OVERFLOW SWITCH
30
7500P-057
7500P-057
7500P-057
7500P-057
CONDENSATE HOSE
31
7450P-200
7450P-200
7450P-200
7450P-200
CONDENSATE COLLECTOR BODY
32
7250P-210
7250P-210
7250P-210
7250P-210
HOSE CLAMP
33
7450P-144
7450P-147
7450P-144
7450P-147
PAN HEAD SCREW - GAS VALVE
34
7350P-063
7350P-063
7350P-063
7350P-063
#10 x 1/2" SELF TAPPING SCREW - CONDENSATE
LP-293-C
REV. 9/29/09
72
Boiler Manual
PART 13: MAINTENANCE (CONTINUED)
1
33
32
2
32
15
6
5
7
31
8
9
17
27
10
26
18
4
19
3
27
13
23
17
12
20
25
13
19
14
22
24
11
16
29
21
Fig. 13-2
73
30
28
Item
No
1
EL-299
EL-399
7450P-014
7450P-015
BOILER MODULE
2
7250P-160
7250P-160
CERAMIC TARGET WALL
3
7500P-109
7500P-109
M4 FLAT WASHER
4
7250P-704
7250P-704
M4 X 8 FLAT HEAD SCREW
BURNER DOOR
Description
5
7450P-006
7450P-006
6
7450P-005
7450P-005
BURNER DOOR REFRACTORY
7
7450P-013
7350P-031
BURNER
8
7500P-074
7500P-074
GASKET - BURNER
9
7450P-007
7450P-007
AIR CHANNEL
10
7250P-206
7250P-206
M5 X 14MM TORX SCREWS - AIR CHANNEL
11
7500P-075
7500P-075
GASKET - AIR CHANNEL/BLOWER
12
7250P-727
7350P-159
COMBUSTION BLOWER
13
7250P-478
7250P-478
M5 X 12MM SOCKET CAP SCREW
14
7450P-029
7450P-029
AIR/GAS MIXER
15
7500P-067
7500P-067
M6 NUT - BURNER DOOR
16
7450P-115
7450P-115
WASHER - AIR/GAS MIXER
17
7250P-005
7250P-005
GASKET - PROBE/ELECTRODE
18
7350P-020
7350P-020
SPARK ELECTRODE (w/GASKET)
19
7250P-069
7250P-069
SCREW M4 X 8MM - PROBE/ELECTRODE
20
7350P-022
7350P-022
FLAME RECTIFICATION PROBE (w/GASKET)
21
7350P-033
7350P-033
GAS VALVE
22
7450P-147
7450P-147
M5 X 8MM PAN HEAD SCREW
23
7450P-200
7450P-200
CONDENSATE COLLECTOR BODY
24
7350P-063
7350P-063
#10 x 1/2" SELF TAPPING SCREW
25
7350P-167
7350P-167
CONDENSATE OVERFLOW SWITCH
26
7500P-057
7500P-057
CONDENSATE HOSE
27
7250P-210
7250P-210
HOSE CLAMP
28
7450P-140
7450P-140
FLEXIBLE GAS LINE
29
7450P-138
7450P-138
FLARE X BSP FITTING
30
7450P-143
7450P-143
FLARE X NPT FITTING
31
7250P-019
7250P-019
ECO - HIGH LIMIT SENSOR
32
7250P-667
7250P-667
THERMISTOR
33
7250P-096
7250P-096
WATER PRESSURE SWITCH - NPT THREAD
LP-293-N
REV. 9/29/09
Boiler Manual
PART 13: MAINTENANCE (CONTINUED)
Fig. 13-3
LP-293-A
REV. 8/28/09
74
75
Notes:
7) Indirect water heater
6) Record System Settings
5) Check Combustion
Verify safety and operation of the Super-Stor Indirect water heater, record setttings
____de
____*8
____ppm CO
Check and adjust (if necessary) carbon monoxide content
Record heating curve, record steps
____% CO2
Check and adjust (if necessary) carbon dioxide content
Turn up thermostat to verify wiring connections
4) Verify System Operation
____ μA
____in w.c.
What is the "drop" on light off (No more than 1" W.C.)
Check μA reading at d7 on the status menu (see start-up section)
____in w.c.
____%
_____PSI
Static
____dh
____*9
High Fire
High Fire
High Fire
____*10
____ppm CO
____%CO2
____ μA
_______________
Dynamic
Date completed
Check incoming gas pressure (3.5" to 14" W.C.)
Leak test using locally approved methods (consult jurisdictional code book)
Verify near heater piping and flue are properly supported
What percentage of propylene glycol is installed in the system (0-50%)
Add Water to prime condensate system
Pressurize System (12-15 PSI)
Check all piping and gas connections, verify they are all tight
3) Record Ionization Current
2) Check Gas Pipe
1) Fill the heating system
Light Off Activities
BOILER START UP REPORT
____*11
Low Fire
Low Fire
Low Fire
Boiler Manual
Check condition of all vent pipe and joints and supports. Note any deterioration and replace.
Make sure there are no obstructions such as shrubbery or plants.
Check gas piping, test for gas leaks and signs of aging, make sure all pipes are supported properly.
Vent
Gas
Test all functions of the system (Heat, DHW, Safeties)
Verify safe settings on Super-Stor indirect fired water heater and Anti-Scald Valve.
Verify safe program temperature in Boiler Settings.
Verify temperature settings programmed into the heating curve (See Part 13)
Functional
Temperatures
Temperatures
Check to see that the circuit breaker is clearly labeled, exercise circuit breaker
Verify ON/OFF switch and convenience plug are both functional
Verify devices are installed and working properly, change batteries if necessary
Circuit breakers
Switch and Plug
Smoke and CO detector
Check burner tube, and combustion chamber coils, clean according to maintenance section of manual
Clean with Scotch Brite pad, Set gap at .177””/4.5mm (see Fig 14-2 Part 14 in Troubleshooting section)
Clean with Scotch Brite pad, Check flame current in ?A (d7 on status menu in Start-up Procedures)
record high fire (7-9 typical) and low fire (6-8 typical)”
Combustion Chamber
Spark Electrode
Flame Probe
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS.
Vacuum Debris from Combustion Chamber if Necessary
Combustion Chamber
Chamber and Burner
Check wire connections, make sure they are tight. Verify programmed Outdoor Reset Curve in System
Setting Section of this manual.
Connections
Electrical
Do a full visual inspection of all system components. Pay close attention to clearances of venting.
Make sure intake and exhaust screens are clean and clear of obstructions.
Visual
System
Check heater and system piping for any sign of leakage, verify proper support
Near Heater Piping
Piping
Inspection Activities
BOILER INSPECTION AND MAINTENANCE SCHEDULE
1st Year
2nd Year
3rd Year
Date last completed
4th Year*
Boiler Manual
76
77
Check piping for leaks, and verify they are all properly supported
Check gas pipe for leaks
Check wiring, verify through ohms reading (see chart part 14 Fig. 14-3)
Thermistors
Review, with the homeowner what you have done
Homeowner
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS.
Tech Sign Off
Verify that you have completed the entire check list WARNING: FAILURE TO DO SO COULD RESULT
IN DEATH OR SERIOUS INJURY.
Check List
Final Inspection
Check continuity on Flue and Water ECO, replace if corroded
ECO (Energy Cut Out)
Safeties
Check CO/CO2 Levels
Check levels of CO and CO2 in Exhaust (See start up section 12 fig 12-1 for ranges) record at high and
low fire
Measure drop in pressure on light off (no more than 1" W.C.)
Pressure Drop
Combustion
Measure incoming gas pressure (from 3.5" to 14" W.C.)
1. Check entire condensate system making sure there are no obstructions in the flow
2. Make sure the condensate pump is working property, verify all connections.
3. Clean out condensate neutralizer, use Wet / Dry Vacuum. Check for all potential obstruction issues.
Replenish marble chips or lime crystals if needed (no smaller than ¾) Refill system with water
WARNING: You must verify flow of condensate and make sure the cap is connected properly before
leaving boiler unattended.
Check condensate neutralizer, making sure there is a sufficient quantity. Replenish if necessary.
Pressure
Gas
Condensate System
Condensate Neutralizer
Condensate
Inspection Activities
BOILER INSPECTION AND MAINTENANCE SCHEDULE (CONTINUED)
INIT
DATE
1st Year
DATE
INIT
2 Year
INIT
DATE
3 Year
Date last completed
INIT
DATE
4 Year*
Boiler Manual
LP-172
REV. 2/16/06
78
LP-172
REV. 2/16/06
79
MAINTENANCE NOTES
80
MAINTENANCE NOTES
81
MAINTENANCE NOTES
82
© 2003–2009 Heat Transfer Products, Inc.
www.HTproducts.com
LP-293 REV. 10/01/09
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