Elite INSTALLATION START-UP MAINTENANCE PARTS Models* EL-80 / 110 / 150 / 220 / 299 / 301 / 399 *A suffix of “LP” denotes propane gas *A suffix of “N” denotes natural gas This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.
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. IMPROPER COMBUSTION ....................................................................................................................................................... 8 C. GAS ............................................................................................................................................................................................ 8 D. WHEN SERVICING THE BOILER...........................................................................................................
F. LONGER VENT RUNS ............................................................................................................................................................. 32 G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 33 H. SIDEWALL VENTING ........................................................................................................................................................
PART 9 – START-UP PROCEDURE ......................................................................................................................................... 58 A. CONTROL OVERVIEW ............................................................................................................................................................ 58 B. NAVIGATION OF THE DISPLAY ....................................................................................................................................
NOTE: If the boiler is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman: 1. FIRE 2. DAMAGE 3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. 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.
F. BOILER WATER CHEMISTRY* Sodium less than 20mGL. Water pH between 6.0 and 8.0 o Maintain water pH between 6.0 and 8.0. Check with litmus paper or have it chemically analyzed by water treatment company. o If the pH differs from above, consult local water treatment company for treatment needed. Hardness less than 7 grains o Consult local water treatment companies for unusually hard water areas (above 7 grains hardness).
Modulating Combustion System - The combustion system will modulate the output of the burner during operation to match the system demand and achieve the control set point while in operation. The set point can change by internal or external signals which enhance the overall performance of the system. Control – The integrated control system monitors the system and regulates fan speed to control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more.
4” Stainless Steel Outside Termination Vent Kit (Part # V2000) 6” Stainless Steel Outside Termination Vent Kit (Part # V3000) 3” Polypro Vent Kit (Part # 8400P-001) 3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003) U.L.
Failure to keep boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death. 4. Gas control system components must be protected from dripping water during operation and service. 5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as: System leaks Location that could cause the system and boiler to freeze and leak. Incorrectly-sized expansion tank 6.
Figure 3 - LP-285-B LP- 293 REV. 5.20.
Figure 4 D. RESIDENTIAL GARAGE INSTALLATION PRECAUTIONS If the boiler is located in a residential garage, per ANSI Z223.1: Mount the bottom of the boiler a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor. 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.
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 1 in this section when considering exhaust vent and intake pipe termination. Exhaust and intake must terminate near each other and may be vented vertically through the roof or out a side wall. Exhaust vent and intake piping methods are detailed in the Venting Section.
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.
The control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module may also provide low water protection (through the addition of an optional kit) by sensing the water level in the heat exchanger. An optional flow switch may be installed on the supply of the system to activate the boiler when there is enough flow. Some codes/jurisdictions may require additional external controls.
EL-80 EL-110 EL-150 EL-220 EL-299 / EL-301 EL-399 EXPANSION TANK SIZING 1.4 Gallons 1.7 Gallons 2.0 Gallons 2.6 Gallons 3.1 Gallons 3.7 Gallons Table 2 Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual boiler failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY. 2. The expansion tank must be located as shown in Part 4, Boiler Piping, or following recognized design methods.
the glycol solution in the system piping. Example: 50% by volume glycol solution expands 4.8% in volume for a temperature increase o o from 32 F to 180 F, while water expands 3% with the same temperature rise. G. PIPING DETAILS* *NOTE: Systems shown are primary/secondary piping systems. These recommended systems have a primary (boiler) loop, and secondary circuits for heating. The primary loop and secondary circuits have separate circulators.
Figure 7 – LP-293-Q NOTES: 1. This drawing is meant to show system piping concept only. o 2. A mixing valve is recommended if the DHW temperature is set above 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) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained above the minimum flow rates published on p. 28, this manual. 6.
Figure 8 – LP-293-O NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Piping shown is Primary/Secondary. 4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained above the minimum flow rates published on p. 28, this manual. 5. Installations must comply with all local codes. LP- 293 REV. 5.20.
Figure 9 – LP-293-P NOTES: 1. This drawing is meant to show system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Piping shown is Primary/Secondary. 4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained above the minimum flow rates published on p. 28, this manual. 5. Installations must comply with all local codes. LP- 293 REV. 5.20.
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.
Flow Rate 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 EL-80 * * * * * * * * * * * * * * * * * EL-110 * * * * * * * * * * * * * * * * * EL-150 * * * * * * * * * * * * * * * * * EL-220 21’ 23’ 24’ * * * * * * * * * * * * * * EL-299 EL-301 16.5’ 18’ 20’ 22’ 24’ 26’ 29’ 33’ 36’ * * * * * * * * EL-399 * * * 12.9’ 13.
J. CHECK/CONTROL WATER CHEMISTRY NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY. Sodium less than 20 mGL Water pH between 6.0 and 8.0 1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water treatment company. 2. If pH differs from above, consult local water treatment company for treatment needed.
Pressure relief valve: Factory supplied on Boiler. The pressure relief valve is sized to ASME specifications. Storage tank may require additional relief valves depending on local codes. MINIMUM PIPE SIZES EL 80/110/150/220 EL 299/301 EL 399 1” NPT or Copper 1 ¼” NPT or Copper 1 ½” NPT or Copper Table 8 K. FILL AND PURGE HEATING SYSTEM 1. Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain. 2.
N. ZONING WITH CIRCULATORS 1. When using circulator zoning, connect the boiler to the system as shown in Piping Details, Part 4, Section G. NOTE: The boiler circulator cannot be used for a zone. It must only supply the boiler loop. 2. Install a separate circulator for each zone. 3. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Piping Details. O. MULTIPLE BOILERS 1. Connect multiple boilers as shown in Piping Details, Part 4, Section G. 2.
Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance.
3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings. Cellular foam core piping may be used on air inlet piping only. NOTE: The use of double-wall vent or insulated material for the air inlet is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air. You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY.
DO NOT locate the exhaust vent or intake pipe terminals under a porch, balcony, or veranda. Avoid terminating exhaust vents near shrubs, air conditioners, or other objects that will obstruct the exhaust stream. DO NOT vent over a public walkway. Condensate could drip or freeze and create a nuisance or hazard. NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting installation and location to save time and cost.
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.
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. 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. It is very important that the condensate piping be no smaller than ½”.
The maximum equivalent length for increased diameter vent pipes is 275 ft, which includes the 16 ft from the boiler with a transition total of 259 ft upsize piping for longer vent runs. SIZE 3” Venting 4” Venting 6” Venting VENT TRANSITION FITTING REDUCING COUPLING 4” x 3” 6” x 4” 8” x 6” FINAL VENT SIZE 4” 6” 8” Table 11 Do not exceed the maximum lengths for increased diameter vent pipes. Excessive length could result in appliance shutdown and property damage. G.
DESCRIPTION 3” PVC CONCENTRIC VENT TERMINATION KIT 3” STAINLESS STEEL VENT TERMINATION KIT 4” STAINLESS STEEL VENT TERMINATION KIT 6” STAINLESS STEEL VENT TERMINATION KIT 3” POLYPRO VENT KIT Table 12 STOCK CODE KGAVT0601CVT V1000 V2000 V3000 8400P-001 H. SIDEWALL VENTING Figure 14 – Sidewall Venting with Tee (Intake) and Coupling (Exhaust) – LP-293-E NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY.
I. VERTICAL VENTING Figure 15 – Vertical Venting - LP-293-F NOTE: Vent piping should be 12” over anticipated maximum snow level. NOTE: Drawing is meant to demonstrate system venting ONLY. All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. 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.
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.
Do not install the boiler into a common existing vent with any other appliance. This will cause flue gas spillage or boiler malfunction, resulting in substantial property damage, severe personal injury, or death. Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions.
If an existing venting system is converted for use with this boiler, the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the boiler. Failure to do so could result in property damage and boiler failure. Such failure IS NOT covered under warranty. VENT / AIR INLET SIZE 2” 3” 4” Table 13 – Minimum Vent / Chase Sizing MINIMUM EXISTING VENT / CHASE SIZE 4” 5” 7” 2.
M. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE NOTE: This installation is intended for commercial applications. For residential applications, it is recommended to pipe intake combustion air from the outdoors. This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 3.
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- 293 REV. 5.20.
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 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.
6. Sealing compound must be approved for gas connections. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the unit. Failure to apply pipe sealing compound as detailed above could result in substantial property damage, severe personal injury, or death. Never use an open flame (match or lighter) to check for gas leaks. Use a soapy solution to test connection.
If an in-line regulator is used, it must be a minimum of 10 feet from the boiler. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines, or improper line sizing, will result in ignition failure. This problem is especially noticeable in NEW LP installations and empty tank situations. This situation can also occur when a utility company shuts off service to an area to provide maintenance to their lines.
Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death. PART 7 – FIELD WIRING To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made.
3. Connect the boiler pump as shown in Figure 26 to the terminals marked 1 – (HOT), 2 – (NEUT), and 3 – (GND). The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If the pump requires more current or voltage than the 120 volts supplied, an external motor starter or contactor will be required. E. ALARM CONNECTIONS The control includes a dry contact alarm output. This is an SPDT circuit, rated at 5 amps at 120 volts.
I. INDIRECT SENSOR There is no connection required if an indirect water heater is not used in the installation. 1. The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or an HTP 7250P-325 tank sensor.
3. It is recommended to use the shortest length cable that will reach between the boilers and create a neat installation. Do not run unprotected cables across the floor where they may become wet or damaged. Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet. 4. Route the communication cables through one of the knockouts in the cabinet. 5.
M. CASCADE MASTER PUMP AND SENSOR WIRING 1. Connect the system pump hot wire to the terminal marked 8. 2. Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal. 3. Connect a jumper wire from the 120 VOLT terminal to the 9 terminal. 4. Connect the boiler pump to the terminals marked 1 (HOT), 2 (NEUT) and 3 (GND). 5. Connect the system pipe sensor to the terminals marked 10 and 11. N. CASCADE FOLLOWER PUMP AND SENSOR WIRING 1.
Figure 29 – Cascade Master and Follower LP- 293 REV. 5.20.
Figure 30 LP- 293 REV. 5.20.
Figure 31 LP- 293 REV. 5.20.
Figure 32 LP- 293 REV. 5.20.
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.
2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions. NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY. B. CHECK FOR GAS LEAKS Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure.
a. Connect a hose to the purge valve and route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c. Close zone isolation valves. d. Open quick-fill valve on cold water make-up line. e. Open purge valve. f. Open the isolation valves one zone at a time. Allow water to run through the zone, pushing out the air. Run water until no noticeable air flow is present.
2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain. It is very important that the condensate line is sloped downward away from the boiler to a suitable inside drain. If the condensate outlet on the appliance is lower than the drain, you must use a condensate removal pump, available from HTP (554200).
this way, every boiler in the system has its individual safety controls intact and operational, even if the firing of the boiler is under control of the master boiler. PART 9 – START-UP PROCEDURE FOR YOUR OWN SAFETY READ BEFORE OPERATING 1. This boiler does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 2. BEFORE OPERATING: smell all around the boiler area for gas.
The ENTER key is also used to enable a function for editing. After the user navigates to the desired function, the user would hold down the ENTER key for one second. When the ENTER key is released, the function value will begin to blink. The function can now be changed using the ▼▲ ARROW keys. After the new value is displayed, the user then presses the ENTER key for 1 second to lock the new value of the function in. The value will then stop blinking.
DHW DIFF SET POINT o 7 F Function: Adjusts the indirect tank differential set point. Default: 7oF (Range: 1oF to 30oF). Function: Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit). TEMP DISPLAY C OR F o F Table 16 – Boiler Setting Screen Descriptions Clock Settings (NOTE: The clock will reset if the boiler is powered off for more than a week.
Function 3 DHW TANK MAX TEMP o 180 F 3 Function 6 DHW Tank Max Temp DHW POST PUMP TIME 0 MINUTES 6 The 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 the pump for a time greater than 5 minutes may cause tank energy to be released back to the boiler heat exchanger. Default: 0 Minutes (Range: 0 – 10 minutes).
Function 26 System Freeze Protect SYS FREEZE PROT PROTECT OFF 26 NOTE: This parameter is only present if the boiler is a cascade master. Allows the user to set the freeze protection when a system pump is used. Factory Default: OFF. Selection of temperature activates freeze protection. (Range: OFF, -40oF – 104oF).
PART 10 – START-UP PROCEDURES FOR THE INSTALLER Table 21 – NOTE: It is important to note that the user can adjust the heat curve down by lowering the central heating temperature. A. BOILER CONTROL STATUS MENU The boiler control also has the ability to review the status of the system. To access the status screens, simply press the right arrow . Once the first value is displayed, press the up arrow ▲ or down arrow ▼ to access additional information.
Press the ▼ key once. FLAME 0.0uA FAN SPEED 3497 RPM Press the ▼ key once. 0-10 V 0.0 V BOILER Press the ▼ key once. BUS COMM NO CONN This screen displays the boiler flame current on the top line. The second line displays the fan speed in the boiler. The top line displays the voltage on the optional input. This voltage is only relevant if an external 0-10 volt signal is being used to control the boiler. This display shows the status of the communication bus between multiple boilers.
B. CASCADE MENU This menu is accessed by pressing the key from the default menu or the key from the status menu. SCREEN DESCRIPTION CASCADE MASTER READY SYS PUMP OFF This screen tells the user that the boiler is configured as a Cascade Master Boiler and that the cascade system is ready to accept a demand for heat. The second line indicates the status of the system pump output of the cascade system.
MODEL 80 110 150 220 299/301 399 IGNITION 3000 3800 3800 3000 3000 3000 ELITE FAN SPEEDS MIN 1700 1700 1700 1450 1450 1600 MAX 4600 4950 5200 4900 5000 6650 Table 26 PART 11 – TROUBLESHOOTING A. BOILER ERROR CODE If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the boiler, the display may show an error message and error code.
This 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. 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.
Fault Code LOU 24 VOLT LOW PUMP ON LOU This display indicates that the 24 volt power supply on the control is damaged or overloaded. This code resets automatically if it is the result of an overload and that overload condition is removed. The second line indicates the status of the pump. Note that while 24 volt power is low, the pump output will be on. 1. Check line voltage. It must be between 100 and 128 volts. 2.
Fault Code F03 RETURN SENSOR F03 PUMP ON This display indicates that the return temperature sensor of the boiler has failed. This code indicates a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display. This situation is indicated by the red light on the display and the word LOCKOUT flashing on the display. During this lockout fault, the pump will be on as indicated on the second line of the display. 1.
Figure 33 Fault Code F10 FLAME LOSS F10 The flame was lost while the boiler was firing 3 times during 1 demand call. The red light will display and the word LOCKOUT will flash. This code indicates a serious safety issue. The boiler will not restart until the cause of flame loss is determined by a technician and he pushes the RESET button on the display. During this lockout fault, the pump will be on as indicated on the second line of the display. 1.
Fault Code F20 CONDENSATE FULL F20 PUMP ON The condensate trap is full. The red light will display and the word LOCKOUT will flash. This code indicates a serious safety issue. The boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display. During this lockout fault, the pump will be off as indicated on the second line of the display. 1. Check condensate lines for obstructions. 2. Check float switch in condensate reservoir. 3.
Table 28 PART 12 – MAINTENANCE A. MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the boiler. The installer must also inform the owner that a lack of proper care and maintenance of the boiler may result in a hazardous condition.
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 appliance wet). Flush the combustion chamber with fresh water until it runs clear from the condensate. At this point, the boiler should be ready to be re-assembled. a. Inspect gaskets. b. Re-install the burner assembly c. Replace and tighten the (6) 10MM nuts to the burner plate using staggered tightening sequence. (See detail) d.
3. Remove the bottom cap from the condensate trap. 4. Flush trap with fresh water to remove debris from the trap. NOTE: Ensure the float moves freely within the trap. If the float does not move, DO NOT reinstall the trap. 5. When the condensate trap is sufficiently clean, reinstall the bottom cap on the trap. NOTE: Ensure all parts shown in Figure 35, Condensate Detail, are installed with the condensate trap. If any parts are missing, DO NOT reinstall the trap. Replace the entire assembly.
Figure 36 LP- 293 REV. 5.20.
Figure 37 LP- 293 REV. 5.20.
Figure 38 – LP-293-A LP- 293 REV. 5.20.
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) Indirect water heater 7) Convert the boiler 8)Record system settings Notes: Check all piping and gas connections, verify all are tight Pressurize system (12 – 15 psi) Add water to prime condensate cup Percentage of glycol in system (0 – 50%) Verify near boiler piping is properly supported Leak test using locally approved methods (con
INSPECTION ACTIVITIES PIPING Near boiler piping Vent Gas SYSTEM Visual Functional Temperatures Temperatures ELECTRICAL Connections Smoke and CO detector Circuit Breakers Switch and Plug 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) Thermistors FINAL INSPECTION Check list Homeowner DATE LAST COMPLETED 1st YEAR 2nd YEAR 3rd YEAR 4th YEA
LP- 293 REV. 5.20.
LP- 293 REV. 5.20.
MAINTENANCE NOTES LP- 293 REV. 5.20.
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.