Elite Plus Heating Boiler INSTALLATION START-UP MAINTENANCE PARTS Models ELP-110 / ELP-199 This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.
IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch. Do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition. The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death.
B. LEVELING ................................................................................................................................................................................ 12 C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................. 13 D. RESIDENTIAL GARAGE INSTALLATION .....................................................................................................................
B. GAS PIPING ............................................................................................................................................................................. 42 C. CHECK INLET GAS PRESSURE ............................................................................................................................................. 43 PART 7 – FIELD WIRING ............................................................................................................................
B. BOILER CONFIGURATION ...................................................................................................................................................... 61 C. CENTRAL HEATING SETTINGS ............................................................................................................................................. 62 D. DOMESTIC HOT WATER SETTINGS ................................................................................................................................
INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given. USER – This manual is for use only by a qualified heating installer/service technician. Have this boiler serviced/inspected by a qualified service technician annually. FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS BOILER SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
Continual fresh make-up water will reduce boiler life. Mineral buildup reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen by make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once. If you have an old system with cast iron radiators, thoroughly flush the system (without boiler connected) to remove sediment.
CSD-1 Form H-3 Data Sheet B. HOW BOILER OPERATES ® Elite Plus condensing technology intelligently delivers highly efficient hydronic heating by adjusting for altitude and fuel (liquid propane or natural gas) without the need for conversion or physical adjustment.
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 boiler wiring. Condensation Collection System – This boiler is a high efficiency appliance, and will produce condensate. The collection system has a float switch to monitor and prevent condensate from backing into the combustion system.
This boiler is certified for indoor installations only. Do not install the boiler outdoors. Failure to install this boiler indoors could result in substantial property damage, severe personal injury, or death. 2. Check for nearby connections to: System water piping Venting connections Gas supply piping Electrical power Condensate drain 3. Check area around boiler. Remove any combustible materials, gasoline, and other flammable liquids.
C. CLEARANCES FOR SERVICE ACCESS See Figure 3 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the boiler without removing it from the space. Space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the boiler. The boiler cover must be securely fastened to prevent it from drawing air from the boiler room.
D. RESIDENTIAL GARAGE INSTALLATION If the boiler is located in a residential garage, per ANSI Z223.1: Mount the bottom of the boiler a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor. Locate or protect the boiler so it cannot be damaged by a moving vehicle. E. EXHAUST VENT AND INTAKE PIPE Vents must be properly supported. The boiler exhaust and intake connections are not designed to carry heavy weight.
G. REMOVING A BOILER FROM A COMMON VENT SYSTEM Do not install the boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing an existing boiler, the following steps must be followed. 1.
The National Standard Plumbing Code, the National Plumbing Code of Canada, and the Uniform Plumbing Code limit heat transfer fluid pressure to less than the minimum working pressure of the potable water system up to 30 PSI maximum. In addition, heat transfer fluid th must be water or another non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5 Edition. Failure to follow this warning could result in property damage, severe personal injury, or death.
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 (Part 4, Section G. Piping Details). 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.
Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) Allow clearance for basic service of boiler circulator, valves and other components. Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials.
Figure 5 – Single Boiler with Zone Valves, DHW Priority, and Outdoor Reset – Primary/Secondary - NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 6 – Single Boiler with Zone Valves and DHW Priority – Single Temperature – Standard Piping NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 7 – Single Boiler with Pumps and DHW Priority, Outdoor Reset – Primary/Secondary NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 8 – Single Boiler with Pumps and DHW Priority – Single Temperature – Standard Piping NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4.
Figure 9 – Multiple Boilers with Primary / Secondary Piping NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameters center to center spacing. 3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. 4. The minimum pipe size for connecting a SuperStor indirect water heater is 1” 5.
H. PIPING INSTALLATION This boiler should not be operated as a potable hot water heater. It should not be used as a direct hot water heating device. Basic steps are listed below that will guide you through the installation of the boiler. 1. Connect the system return marked “Boiler Return”. 2. Connect the system supply marked “Boiler Supply”. 3. Install a purge and balance valve or shut off valve and drain on the system return to purge air out of each zone. 4.
Tables 8 and 9 represent combined flow rates and pipe sizes when using multiple boilers to design the primary circuit manifold system. To size, simply add the number of boilers and the required flow rates for the system design temperature. Example: (5) ELP-199® boilers with a design of 20°Δt temperature rise with each boiler having an individual flow rate of 22 GPM. To correctly size the manifold feeding these (5) boilers, you would need a pipe size of 4”.
2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3. Flush system until water runs clean and you are sure piping is free of sediment. *NOTE: It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup. Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section of this manual.
Upon completion, make sure that the fill valve and zone valves are in automatic positions. You must also assure the purge and shut off valves are in open positions. L. GLYCOL ANTIFREEZE SOLUTIONS 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%.
A. GENERAL This boiler is certified as a “Category IV” appliance, and requires a special venting system. The vent system will operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting instructions below carefully.
The exhaust and intake components installed with this boiler must be used for near boiler piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID appliance warranty. PVC/CPVC pipe and fittings of the same diameter are considered interchangeable. Do NOT use Foam Core Pipe in any portion of the exhaust piping from this boiler. DO NOT connect PVC/CPVC to PP without an approved vent connector.
D. EXHAUST VENT AND INTAKE PIPE LOCATION Figure 11 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 11 NOTES: A. Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. B.
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the boiler could result in property damage, severe personal injury, or death. For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the boiler.
Figure 12 – Condensate Piping NOTES: 1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line. 2. Plastic pipe should be the only material used for the condensate line.
E. EXHAUST VENT AND INTAKE PIPE SIZING ALTITUDE CONSIDERATIONS TOTAL EQUIVALENT VENT LENGTH (TEL) ALL MODELS INSTALLATION ALTITUDE 3” VENT DIAMETER 4” INCREASED VENT DIAMETER 2” REDUCED VENT DIAMETER LESS THAN 5000 FT. 250 ft. – All Models 275 ft. – All Models 100 ft. – ELP-110* 250 ft. – ELP-110 GREATER THAN 5000 FT. 200 ft. – ELP-199 Table 12 – Altitude Considerations and Vent Length - *DO NOT REDUCE VENT DIAMETER ON ELP-199 MODELS 1.
SIZE 3” Venting VENT TRANSITION FITTING REDUCING COUPLING 4” x 3” FINAL VENT SIZE 4” Table 14 G. EXHAUST VENT AND INTAKE PIPE INSTALLATION All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space. Failure to do so could result in property damage, severe personal injury, or death. 1. Use only solid PVC or CPVC pipe, or a Stainless Steel or Polypropylene vent system, approved for use with Category IV boilers.
H. SIDEWALL VENTING W/ TEE (INTAKE) AND COUPLING (EXHAUST) Figure 14 – Sidewall Venting with Tee (Intake) and Coupling (Exhaust) – LP-293-E NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.
I. VERTICAL VENTING W/ TEE (INTAKE) AND COUPLING (EXHAUST) Figure 15 – Vertical Venting - LP-293-F NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate.
J. HORIZONTAL VENTING Figure 16 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C.
K. UNBALANCED FLUE / VERTICAL VENT Figure 17 – LP-293-T – Unbalanced Flue/Vertical Vent - NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe.
1. CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s concentric vent kits (2” Part # KGVAT0501CVT, 3" Part # KGAVT0601CVT). Refer to Concentric Vent Kit installation manual (Part # LP-166) for further concentric venting information and instructions. Concentric venting through an existing system must run vertically through the roof. See Table 16 for proper minimum vent sizing.
2. VENTING AS A CHASE When venting as a chase, follow all instructions included in Part 5 – Venting, Sections A – G of this manual, as well as the previous Concentric Venting section. See Figure 19 for chase venting demonstration. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B.
Figure 21 – 1, 21 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. LP-294 REV. 2.20.
PART 6 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 13" 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.
Use two wrenches when tightening gas piping at the boiler: One to prevent the boiler gas line from turning. Failure to prevent the boiler gas connection from turning could result in damage to gas line components, substantial property damage, severe personal injury, or death. CSA or UL listed flexible gas connections can be used when installing the boiler. Flexible gas connections have different capacities and must be sized correctly for boiler firing rates.
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve and cause substantial property damage, severe personal injury, or death. Ensure that the high gas pressure regulator is as least 6 – 10 feet upstream of the boiler.
D. LINE VOLTAGE WIRING FOR STANDARD BOILER 1. Connect incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V, Neutral, Ground (shown in Figure 27). 2. A line voltage fused disconnect switch may be required, externally mounted and connected according to local codes that may apply. 3. Connect the boiler pump as shown in Figure 27 to the terminals marked 1 – (HOT), 2 – (NEUT), and 3 – (GND).
2. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions. NOTE: For correct mounting procedures, follow instructions provided with the sensor. 3. Connect the sensor to terminals 12 and 13, as shown in Figure 27. NOTE: For correct mounting procedures, follow instructions provided with the sensor.
Figure 25 – Daisy Chain Wiring Configuration, with Optional Interface Module – LP-294-L 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 they are addressed.
Figure 27 – Single or Cascade Master and Cascade Follower Controls LP-294 REV. 2.20.
Figure 28 LP-294 REV. 2.20.
PART 8 – START-UP PREPARATION Thoroughly clean and flush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the fluid used. A. CHECK / CONTROL WATER CHEMISTRY Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also affect efficiency. You may have to have your water quality professionally analyzed to determine whether you need to install a water softener.
NEVER use automotive or standard glycol antifreeze. Do not use ethylene glycol made for hydronic systems. Use only generally recognized as safe freeze prevention fluids certified by fluid manufacturer as suitable for use with stainless steel boilers, verified in the fluid manufacturer literature. Thoroughly clean and flush any system that has used glycol before installing the new boiler. Provide the owner with a Material Safety Data Sheet (MSDS) on the fluid used. 2.
If you discover any evidence of a gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until the leak is repaired. Failure to comply could result in substantial property damage, severe personal injury, or death. E. CHECK THERMOSTAT CIRCUITS 1. Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip). 2.
H. CASCADE SYSTEM 1. If a single boiler is installed, skip this section. 2. Programming the Master Boiler: a. Make sure there is no demand for heat being supplied to the boiler (e.g. open thermostat). b. Set the bus master switch to the ON (left) position (factory default) on the master boiler and be sure the switch is set to OFF (right) on all followers (and the Interface Module, if used). This will ensure correct operation of the cascade bus. c. Apply power to the boiler. d.
A. CONTROL OVERVIEW The control is one of the primary safety devices of the boiler. It monitors the boiler safety sensors to assure safe and efficient operation, and has the capability to lock out and halt boiler operation when a fault or error is detected. Also, the control has many features associated with hydronic design. By properly customizing boiler operating parameters, the installer can provide safe, efficient heating and domestic hot water to the end user. B.
Figure 30 – Display Navigation Summary DISPLAY KEY DETAILS To enable editing, navigate to the desired parameter and 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 desired value is displayed, press the ENTER key for 1 second to lock the new value of the function in. The value will then stop blinking.
E. INITIALIZING SCREENS Once the boiler is powered, the control display will illuminate and these initialization screens will appear. SCREEN HTP, Inc. ---connecting--VERSION [XXXX] HTP, Inc. LambdaConstant --Initializing-VERSION [XXXX] Standby: No Demand o 85 F DESCRIPTION This screen appears directly after turning the power on, and tells the installer that the control is attempting to connect to the main board. Version [XXXX] refers to the software version of the display, and is apt to change.
SYSTEM TEST This screen is only shown during Test Mode, activated in the Installer Menu. It displays the Burning operation status, ionization current, supply and return temperature, and active control outputs. o Ion 60 uA Sup. 160 F o FPBSG Ret. 160 F Table 19 – Stand-Alone Boiler Main Screens B. CASCADE MASTER MAIN SCREENS NOTE: The following screens appear only if the boiler is the master in a cascaded system.
PART 11 – USER MENU SCREENS The User Menu is intended to provide basic system information and allow temperature adjustments within the parameters configured by the installer. To enter the User Menu, press the key at the Main Screen. Use the ▼▲ keys to scroll through the options. Use to view, ▼and ▲ to scroll through the screens, and press and hold ENTER for one second to access and change Boiler Settings. If no keys are pressed for 3 minutes, the control will return to the Main Screen. A.
SCREEN BOILER SETTINGS Central Heating Setpoint o Outdoor Reset 180 F DESCRIPTION This screen shows the current Central Heating setpoint. In a Cascaded System, “CH-Cascade” is displayed. “Outdoor Reset” is shown only in CH-mode 1 or 2 is used. “Outdoor Reset” indicates that the Central Heating setpoint cannot be changed. When “Outdoor Reset” is not used, the installer can adjust the central heating setpoint. o o The factory installed default setpoint is 180 F. Range: 104 – 200 F.
Use the ▼▲ keys to scroll through the options. Use the key to view. Press ENTER to select a value. When the value is flashing, press the ▼ key to decrease, and ▲ key to increase the value. Press ENTER again to save the value. If no keys are pressed for 3 minutes, the control will return to the Main Screen. See Part 11 for a description of all Installer Menu options. A. BOILER STATUS INSTALLER After selecting “Boiler Status Inst.” at the Installer Menu screen, the following options are available.
B. BOILER CONFIGURATION After selecting “Boiler Config” at the Installer Menu screen, the following options are available. SCREEN BOILER CONFIG Address Selection DESCRIPTION Allows Installer to choose a boiler address and set up a cascading system. Selecting “0” = no cascading system, “1” = managing boiler, “2 – 16” = follower boilers. Factory default is “0”. Range is 0 – 16. After setting Cascade Master address, wait about a minute for the “Cascade Master” Boiler Address 0 LED to light.
Pressing the ▼ or ▲ keys allows the Installer to view and/or adjust more data or return to the previous screen. (NOTE: This is the final normal Boiler Configuration screen. The following are for Cascaded systems only.) This screen describes what the boiler will do in an emergency situation, e.g. when the BOILER CONFIG communication between boilers is lost. For example: This setting could be used in a 4 boiler Permit Boiler system to enable only 2 boilers to run in emergency mode, preventing overshoots.
Pressing the ▼ or ▲ keys allows the Installer to view and/or adjust more data or return to the previous screen. CH SETTINGS Allows the installer to avoid fast overshoot of temperatures by sending the boiler into low fire after Step Down ignition and increasing power via step modulation until the boiler eventually fires at maximum Modulation power. This function can be switched ON and OFF. Default is ON.
o o CASCADE SETTINGS Allows the installer to set the system setpoint differential. Default is 9 F. Range: 1 – 15 F. Start Differential to System Setpoint o 9 F Pressing the ▼ or ▲ keys allows the Installer to view and/or adjust more data or return to the previous screen. CASCADE SETTINGS Prevents the system from overshooting temperatures by stopping all boilers once the stop o o Stop Differential differential is met. Default is 5 F. Range: 1 – 15 F.
F. SYSTEM TEST All functions of Test Mode are stopped after 30 minutes if not stopped manually. In cascade mode, the boiler address must be set to “0” before activating the system test.
Fan Speed Carbon Monoxide PPM Carbon Dioxide (CO2) Table 32 COMBUSTION SETTINGS ON ALL MODELS Natural Gas Low Ignition High Low 5 – 50 60 - 100 < 150 5 – 50 8 - 10% 8 ½ - 10 ½% 8 ½ - 10 ½% Propane LP Ignition 60 - 100 9 - 10 ½% High < 150 9 - 11% PART 13 – START-UP PROCEDURE A. INSTALLER MENU Once the boiler has established communication, advance to the Installer Menu. The Installer Menu allows the installer to access the pump purge capability of the boiler, and configure installations.
(NOTE: Gas Type selection is necessary only if LP gas is used. Natural gas is the system default.) LAMBDA CONSTANT MENU SCREEN LambdaConstant Gas Type Selection NG Table 35 – Selecting the Gas Type 1. 2. 3. These settings should only be modified by qualified personnel. DESCRIPTION Options: NG - Natural gas, Methane LPG - Liquid Propane Gas Default is NG. To change Gas Type, press the ENTER key at this screen. Once Gas Type blinks, push the ▼ or ▲ keys to the appropriate gas.
Pump modes are displayed during selection in 2 lines. Options: 0 - CH and DHW pump BOILER CONFIG 1 - General pump with 3 WV Pump Mode 2 2 - Manifold with CH Gen and DHW pump Manifold with CH 3 - Manifold with Gen pump and 3WV DHW and Gen. pump 4 - Manifold with Sys Pump DHW ext Default is 2. Table 37 – Boiler Config Quick Start-Up 2. CENTRAL HEATING SETTINGS Return to the Installer Menu by pushing the key. Enter the CH Settings Menu by pushing ▼ once, then .
CH/DHW Priority sets the heating priority of the boiler. The following options can be selected: Time - Priority changes after time. CH-Prio - Central heating always takes priority. DHW-Prio - Domestic hot water always takes priority. Defaults is DHW-Prio, and 30 minutes. Range: 1 – 60 Minutes. Table 39 – DHW Settings Quick Start-Up DHW SETTINGS CH/DHW Priority >Switch DHW-Prio Time 30min Once the CH/DHW Priority is set, press ENTER to save.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air.
A13 A14 A14 State error Rom error Rom error C 19 20 21 Internal software error Internal software error Internal software error A15 Air sw not open 22 Air pressure switch not working A16 15MS XRL error 23 3 timing errors A17 Air sw not closed 24 Air pressure switch not working A18 Max Temp. Error 25 A19 Stack error 26 A20 Flame out too late 27 Flame still present 10 sec.
E52 E55 E59 E60 E63 RETURN OPEN DHW OPEN SUPPLY SHORTED RETURN SHORTED DHW SHORTED 73 76 80 81 84 Return sensor open DHW sensor open Supply sensor shorted Return sensor shorted DHW sensor shorted E65 FLUE SHORTED 86 Flue sensor shorted E66 RESET BUTTON 87 Reset button error E72 APPLIANCE SELECTION 93 Appliance selection error E38 GAS PRESSURE ERROR 107 Gas too low depending on BCU settings E97 FLUE BLOCK ERROR 108 Flue gas pressure error Check the return sensor and connection.
DISPLAY CODE INT. CODE ERROR Flame goes off at down modulation after good ignition No Code No Code DESCRIPTION POSSIBLE SOLUTION Check appliance type settings. Check ionization pin position. Clean pin. Check gas pressure during modulation. Check air pressure chart peak at low fire.
The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).” Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator (N95).
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 boiler wet). Flush the combustion chamber with fresh water until it runs clear from the condensate line. At this point, the boiler should be ready to be re-assembled. a. Inspect gaskets. b. Gently slide the burner assembly into the heat exchanger. Reattach the wire harness to the blower.
Figure 32 LP-294 REV. 2.20.
Figure 33 – LP-294-B LP-294 REV. 2.20.
BOILER START-UP REPORT LIGHT OFF ACTIVITIES 1) Fill the heating system 2) Check gas pipe 3) Check combustion 4) Verify system operation 5) Record ionization current 6) Record system settings 7) Indirect water heater DATE COMPLETED ________________ Check all piping and gas connections, verify all are tight Pressurize system (12-15 PSI) Add water to prime condensate cup What percentage of propylene glycol is installed in the system (0-50%)? Verify near boiler piping is properly supported Leak test usi
Vent Gas SYSTEM Visual Functional Temperatures Temperatures ELECTRICAL Connections Smoke and CO detector Circuit Breakers CHAMBER/BURNER Combustion Chamber Spark Electrode Flame Probe CONDENSATE Neutralizer Condensate hose GAS Pressure Pressure Drop Check gas pipe for leaks COMBUSTION CO/CO2 Levels SAFETIES ECO (Energy Cut Out) Water Pressure Switch Thermistors FINAL INSPECTION Check list Homeowner Check condition of all vent pipes and joints. Ensure all vent piping is properly supported.
LP-294 REV. 2.20.
LP-294 REV. 2.20.
MAINTENANCE NOTES LP-294 REV. 2.20.
HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
