Home

HTP EFT-399PU Instructions / Assembly

1. 12 G CLEARANGES FOR SERVICE ACCESS eee eee PH ICE HERE RM MCA R SEAU 12 D RESIDENTIAL GARAGE CLOSET AND ALCOVE 15 EW EXHAUST VENT AND INTAKE PIPE ack ents tB Rete e qom teint 15 PREVENT COMBUSTION AIR 15 REMOVING AN BOILER FROM A COMMON VENT treten 16 PART A PREPARE BOILER cssvsticccdsasasvsncnsasccsusts m ric UA TR n a RR RD CE BR DAR BERE E RAD DESDE 16 A REMOVE THE BOILER FROM 16 B WALL MOUNTING 17 G WALL MOUNTING INSTRUGCTIONS at cune vete e HH E OR HH tcr ee E t d E RED e etu ee eos 17 1 MOUNTING A WOOD STUDDED 2 MOUNTING TO A METALE ERAME elit I IPEESIelB addllcm 18 GENERAL PIPING INFORMATION 12er tee tete e t RR RR ente eee 19 BSREEIEF VALVES 2122 Rt mere ote niinc Rte tate 19 G BACKELOW Bnei sen bi tae ee aede ems 19 DESYSTEM WATER PIPING tt c e i E i c e lee te f tec mio te uem cet 20 E CIRCULATOR T ee es 20 F HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND M
2. lue If not replace the flue sensor SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F05 SUPPLY TEMP HIGH F05 PUMP ON This display indicates that the supply temperature of the boiler is excessive If accompanied by the red FAULT light and LOCKOUT flashing on the display this code indicates that the temperature on the supply sensor has exceeded 230 F and a serious safety issue exists The boiler will not restart until the cause of the excessive temperature is repaired by a technician and the RESET button is pushed on the display If the FAULT light is not illuminated and this message is displayed then the supply temperature of the boiler is at or above 210 F The message will clear automatically when the temperature drops below 194 F During the time that this message or lockout fault is displayed the pump will be on as indicated on the second line 1 Check circulator pump operation 2 Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Check the direction of flow off the boiler circulator See Piping Details in this manual 4 Troubleshoot the thermistor by following steps in Fault Code F06 RETURN TEMP HIGH F06 PUMP ON This display indicates that the return temperature of the boiler is excessive If accompanied by
3. SCREEN DESCRIPTION Function 1 Factory Program Mode MODE This screen indicates that the control is configured correctly Do not change this setting INDIRECT 1 Function 3 DHW Tank Max Temp DHW TANK MAX TEMP This is the maximum temperature that can be selected for the DHW indirect tank set point in the boiler menu Default 180 F 3 180 F Range 95 F to 180 F Function 6 DHW Post Pump Time The indirect pump has the ability to post purge energy from the boiler to run the pump after the set point has been MEE PUMP Du achieved Please note that nine ie PUE for a ine greater than 5 minutes ded Ade tank BU to be released back to the boiler heat exchanger Default 0 Minutes Range 0 10 minutes Function 7 Warm Weather Shutoff WARM WEATHER OFF When used with an outdoor sensor warm weather shut down will disable the boiler if the programmed outdoor 68 F 7 temperature is exceeded Default 68 F Range 41 F to 122 F Function 8 Min Outdoor Temp MIN OUTDOOR TEMP Sets the minimum outdoor design temperature for the system Default 5 F Range 49 F to 32 F 5 F 8 Function 9 Max Supply Temp MAX SUPPLY TEMP Sets the maximum design supply temperature based on the minimum outdoor design temperature Default 190 F 190 F 9 Range 77 F to 190 F Function 10 Max Outdoor Temp MAX OUTDOOR TEMP Sets the maximum outdoor design temperature for the system design Default 68 F Range 32 F to
4. 45 VENTING THROUGH AN EXISTING 46 1 VENTING Sete iets Seas tual rene i ea He er Ee E EHE ie E e EE HERES 2 VENTING ASA CHAS Bes L INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED 48 7 2 50 A GAS GONNEGCTION 1 ee Ret oe ede egeat 50 B GAS PIPING siet ect el e ime e ib et td aes ed d ct n ae ted t e 50 C CHECK INLET GAS PRESSURE ee E HEU bed eed dette ehe d tee etos 51 GAS VALVE n e htt te aeta tb e cc ede ee rites cree a 52 PART 8 FIELD WIRING ttn istanza ace 53 A INSTALLATION MUST COMPLY 2 53 BS FIELD WIRING TERMINATIONS n ict eim ce ie tete cit aere cc ced e eh 53 G FIEED WIRING iet tet cc He eb a ERE ee dte dette het dt tabat tet 53 D LINE VOLTAGE WIRING FOR STANDARD 53 A ARM CONNEGTIONS EU RUE EM SB Ua EE 54 LOW VOLTAGE CONNECTIONS FOR STANDARD 54 Gs THERMOSTAT eissi accesses tnt etnies hne t b eet de el aate Pe e ado G 54 H OUTDOOR SENSOR ere ERE bie Sai hn te 54 I INDIRECT SENSOR teen reato gate tcd p o cine eee 55 J OPTIONAL 0 1
5. EFT 55 110 EFT155 285 8 9 v co z EFT 399 Table 4 Boiler Pressure Drop 30 The chart below represents the various system design temperature rise through the boiler along with their respective flows and friction loss which will aid in circulator selection SYSTEM TEMPERATURE RISE CHART MORE 25 AT GPM GPM Head FT 42 EFT80 6 5 1 3 1 8 11 7 1 3 26 25 7 5 7 1 5 7 18 28 Erro 106 43 25 37 2 15 0 12 5 EFT285 268 70 214 3 399 375 95 300 71 250 Table 5 Boiler Flow Rates 1 8 2 8 4 3 2 5 3 7 7 0 9 5 In addition the heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator These minimum water volumes are listed in Table 6 below MINIMUM BOILER FLOW RATES MODEL MINIMUM FLOW RATE GPM EFT 55 2 EFT 80 EFT 110 3 EFT 155 4 EFT 199 6 EFT 299 8 EFT 399 13 Table 6 Minimum Heat Exchanger Water Volumes The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit To size simply add up the number of boilers and the required flow rates for the system design temperature Example 5 EFT 55 boilers with a design of 20 At degree temperature rise with each boiler having an individual flow rate of 5 3 GPM To correctly size the
6. 1 STOP Read the safety information above 5 Remove front cover Set the thermostat to lowest setting 6 Turn gas shutoff valve to off Handle will be across the piping do not force 3 Turn off all electric power to the appliance Wait five 5 minutes to clear out any gas If you then This appliance is equipped with an ignition device smell gas STOP Follow B in the safety which automatically lights the burner Do not try to information above on this label If you don t smell light the burner by hand gas go to next step Turn gas shutoff valve to on Handle will be GAS VALVE GAS VALVE in line with piping ON OFF Install Front Cover Turn on all electric power to appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS APPLIANCE 1 Set the thermostat to lowest setting 4 Turn gas shutoff valve to off Handle will be 2 Turn off all electric power to the appliance if service is across the piping Do not force to be performed 3 Remove Front Cover 5 Install Front Cover LP 175 Rev 4 3 11 08 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 product information A DANGER DANGER indica
7. 399 7 9 Table 3 CAUTION Undersized expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual boiler failure can result due to excessive make up water addition SUCH FAILURE IS NOT COVERED BY WARRANTY 2 The expansion tank must be located as shown in Part 5 Boiler Piping or following recognized design methods See expansion tank manufacturer s instructions for details 3 Connect the expansion tank to the air separator only if the air separator is on the side of the circulator Always install the system fill connection at the same point as the expansion tank connection to the system CAUTION DO NOT install automatic air vents on closed type expansion tank systems Air must remain in the system and return to the tank to provide an air cushion An automatic air vent would cause air to leave the system resulting in improper operation of the expansion tank DIAPHRAGM OR BLADDER EXPANSION TANK Always install an automatic air vent on top of the air separator to remove residual air from the system E CIRCULATORS CAUTION DO NOT use the boiler circulator in any location other than the ones shown in this manual The boiler circulator location is selected to ensure adequate flow through the boiler Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insufficient flow Sizing Space Heat
8. ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS cm at 25 C CHLORIDE Less than 100 ppm IRON Less than 0 5 mg L COPPER Less than 0 1 mg L SODIUM Less than 20 mg L HARDNESS Less than 7 Grains Table 1 Water Quality Requirements G FREEZE PROTECTION FLUIDS CAUTION NEVER use automotive or standard glycol antifreeze or ethylene glycol made for hydronic systems with this boiler Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems CAUTION Consider boiler piping and installation when determining boiler location NOTE Damages resulting from incorrect installation or from use of products not approved by HTP Inc ARE NOT covered by warranty 10 PART 2 BEFORE YOU START A WHAT S IN THE BOX Also included with the boiler e Temperature and Pressure Gauge Part 7500 098 Pressure Relief Valve Part 7250 080 for EFT 55 80 110 155 199 7350 066 for EFT 285 399 Wall Mount Bracket Part 7600 021 for EFT 55 80 110 7600 121 for EFT 155 199 285 7600 221 for EFT 399 Indirect Sensor Part 7250 325 Outdoor Sensor Part 7250 319 Intake PVC Tee with Screens Exhaust PVC Coupling with Screens Installation Manual Warranty CSD 1 Form H 3 Data Sheet NAT to LP Conversion Kit Included with NAT models B HOW BOILER OPERATES ELITE FT condensing technology inte
9. LP 387 MM 09 28 12 BALL VALVE TEMPERATURE PRESSURE GAUGE LP 387 NN 10 04 12 PRESSURE RELIEF VALVE OUTLET TOP INLET BOTTOM PRESSURE RELIEF VALVE AUTO AIR VENT BOILER DRAIN OUTLET INLET BOTTOM AUTO AIR VENT Eg BOILER DRAIN Figure 7 Near Boiler Piping NOTE This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes Top Bottom Supply Return Connections available on EFT 155 EFT 199 EFT 285 and EFT 399 Models ONLY BALL VALVE TEMPERATURE PRESSURE GAUGE LP 387 LL 09 28 12 22 NOTE In piping applications utilizing a single zone it is recommended that the installer use flow check valves with weighted seats at or near the boiler to prevent gravity circulation Piping symbol legend pp flanges w integral check valve gate valve pressure reducing valve diff pressure bypass globe valve ball valve Pa mixing valve swing check valve flow check valve temperature pressure gauge spring loaded check valve 3 way motorized hose bib boiler drain mixing valve ELITE FIRE TUBE BOILER 4 way motorized straight mixing valve rging valve TRV angle dreuitsstter pressure relief valve backflow preventer manual 3 way valve
10. WARNING Do not use solvents to clean any of the burner components The components could be damaged resulting in unreliable or unsafe operation Failure to do so could result in death or serious injury C CLEANING WATER SIDE OF HEAT EXCHANGER RESZEL Water temperature over 125 degrees can cause severe burns 5 instantly or death from scalds Children disabled and elderly are to at highest risk of being scalded See instruction manual before 27 setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available See chart below showing temperature burn rate 1 Make sure power is turned off to the boiler Run water through the hot water system to assure it is below room temperature 80 2 Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams within this manual Slowly open the ball valves and release pressure into a bucket Once pressure is released connect a hose to the water line to flush the boiler Scale removing solution may be used but must be approved for use with stainless steel and FDA approved for use in a potable water system 3 Thoroughly flush the heat exchanger before commissioning the boiler back in service D MAINTAINING THE CONDENSATE SYSTEM DANGER The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating
11. gap See Figure 36 1 Watch the igniter through the observation window provided 2 If there is no spark check the spark electrode for the proper 156 3 96 mm 3 Remove any corrosion from the spark electrode and flame rectifier probe 4 If there is a spark but no flame check the gas supply to the boiler 5 If there is a flame check the flame sensor 6 Check any flue blockage or condensate blocks 76 11 H gt 196 039 2 5 0 mil 1 mm 2 Figure 36 Proper Electrode Spacing LP 387 CC 04 06 12 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 Monitor the gas pressure to the boiler while in operation 2 Assure that the flame is stable when lit 3 Check to see if the 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 display It should be above 1 0 when the boiler is firing 5 If the signal reads less than 1 microamp
12. 28 K CAP FLANGE HITCH PIN m 1 COP ORNS INSERT STAINLESS STEEL SLIDE THE CONDENSATE LOCK PIN THROUGH THE ASSEMBLY ONTO THE DRAIN ADAPTER TO LOCK TUBE UNTIL THE HOLES THE CONDENSATE CUP TO THE __ N BARB aii ADAPTER LINE UP WITH to pressure switch THE GROOVE IN THE TUBE PLASTIC HOSE BARB ADAPTER CONDENSATE HOSE CLAMP GASKET CONDENSATE HOSE IMPORTANT NOTE CLAMP 7 BE SURE TO CONNECT CLEAR HOSE BOTTOM CAP FROM PRESSURE SWITCH HOSE O RING ON CONDENSATE ASSEMBLY PRIOR TO OPERATING HEATER CONDENSATE DRAIN BOITOM CAP 3 pec directly to INSERT mw VC drain line CONDENSATE ASSEMBLY BOTTOM CAP for cleaning LP 387 FF 11 08 11 CONDENSATE DRAIN TUBE LP 387 DD 11 3 11 2 Figure 15 1 Condensate Detail 15 2 Condensate Trap Installation CONDENSATE TRAP INSTALLATION INSTRUCTIONS A DANGER The condensate trap assembly MUST BE PROPERLY INSTALLED according to these instructions when operating the boiler Operating the boiler without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death 37 1 Ensure all parts shown in Figure 15 1 Condensate Detail are included with the condensate trap If any parts are missing DO NOT install the trap Replace the entire condensate assembly NOTE Before installation clean out the condensate collector with water to remove any foreign matter th
13. 40 9969666666666 did 8310813 00 0000010 120 VOLTS LINE VOLTAGE 9r 39N3INIANOO 00 LIE 13nO 3ON3INANOO ALTERNATE CONNECTION ALTERNATE CONNECTION ALTERNATE CONNECTION FOR PUMPS GREATER THAN PUMP FOR PUMPS GREATER PUMP FOR PUMPS GREATER PUMP 3 AMPS 120 MOTOR 3 AMPS 120V MOTOR 3 5 120 MOTOR Figure 34 Cascade Master and Follower Wiring J2 J eo POWER SWITCH FLUE TEMPERATURE SENSOR PROTECTED BY AN INTERNAL 6 3 AMP FUSE WATER PRESSURE SWITCH BLOCKEZ VENT PRESSURE SW HAY 5485 BUS 944 4 59 NEUTRAL CH PUMP DHW PUMP ORANGE SPARK CABLE TO SPARK ELECTRODE FLAME RECTIFICATION PROBE NOTE J REFERENCES FIELD CONNECTION BOARD LP 293 I Figure 35 Internal Connection Diagram LP 293 J 10 26 11 60 PART 9 START UP PREPARATION WARNING 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 CAUTION Chemical imbalance of your water can cause severe damage to your boiler and associated equipment and may also affect efficiency You may have to have your water quality professionally analyzed to determine whether you need to install a water softener It is important that the w
14. NOTE Isolate 120V wiring from 24V wiring to prevent any electrical noise F LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER 1 All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 30 2 Connect all low voltage field devices to the low voltage terminal strip located in the electrical junction box NOTE When making low voltage connections ensure no external voltage is present in the thermostat circuits If external voltage is present provide an isolated contact to prevent damage to the control G THERMOSTAT 1 Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box see Figure 31 Alternately any dry contact closure across these terminals will cause the boiler to run Take caution to ensure neither of the terminals becomes connected to ground 2 Mount the thermostat on an inside wall as central as possible to the area being heated but away from drafts or heat producing devices such as television sets that could influence the ability of the thermostat to measure room temperature 3 If the thermostat is equipped with an anticipator and it is connected directly to the boiler the anticipator should be set at 0 1 amps If the thermostat is connected to other device s the anticipator should be set to match the power requirements of the device s See the instruction manual of the connected device s for further informat
15. 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 leaks at once WARNING PROPANE BOILERS ONLY Propane suppliers mix an odorant with the gas to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas C FREEZE PROTECTION WHEN USED CAUTION NEVER use automotive or standard glycol antifreeze Do not use ethylene glycol made for hydronic systems System water including additives must be non toxic having a toxicity rating or Class of 1 as listed in Clinical Toxicology of Commercial Products Use only freeze protection fluids certified by fluid manufacturer as suitable for use with stainless steel boilers verified in the fluid manufacturer s literature Thoroughly clean and flush any system that has used glycol before installing the new boiler Provide the boiler owner with a material safety data sheet MSDS on the fluid used 1 Determine the freeze protection fluid quantity using total system water content following the fluid manufacturer s instructions Remember to include expansion tank water co
16. WARNING Failure to use the correct sensor may result in tank temperature being either above or below set point and could result in decreased performance substantial property damage or heightened risk of injuries due to scalds J OPTIONAL 0 10 VOLT BUILDING CONTROL SIGNAL 1 A signal from a building management system may be connected to the boiler to enable remote control This signal should be a 0 10 volt positive going DC signal When this input is enabled using the installer menu a building control system can be used to control the Set point temperature of the boiler The control interprets the 0 10 volt signal as follows when the signal is between 0 and 1 5 volts the boiler will be in standby mode not firing When the signal rises above 1 5 volts the boiler will ignite As the signal continues to rise towards its maximum of 10 volts the boiler will increase in set point temperature See Part 11 for details on the setting of function 16 2 Connect a building management system or other auxiliary control signal to the terminals marked 16 0 10 VOLT and 17 0 10 VOLT in the electrical junction box shown in Figure 31 Caution should be used to ensure that the 0 10 VOLT connection does not become connected to ground 3 Move jumper on connection board shown in Figure 31 from A to B 4 See Part 10 Section D Function 17 to program the 0 10 volt signal NOTE When 0 10 volt building management system is installed the
17. Connect DHW domestic hot water piping to indirect storage water heater as shown in Piping Details O MULTIPLE BOILERS 1 Connect multiple boilers as shown in Piping Details Part 5 Section G 2 All piping shown is reverse return to assure balanced flow throughout the connected boilers 3 Each connected boiler must have its own circulator pump to assure adequate flow 4 Connect DHW domestic hot water piping to indirect storage water heater as shown in Piping Details 5 The system flow secondary loop must be greater than the boiler s primary loop flow PART 6 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL A DANGER The boiler must be vented as detailed in this Venting Section Ensure exhaust vent and intake piping complies with these instructions regarding vent system Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured airtight and comply with all applicable code requirements as well as with the instructions provided in this manual Failure to properly install the vent system will result in property damage severe personal injury or death A GENERAL A DANGER 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 connec
18. MAINTENANGE PROCEDURES nete ei Hen OC ED CHIEDO OH REP 78 B COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER 79 CLEANING WATER SIDE OF HEAT 79 D MAINTAINING THE CONDENSATE 5 5 80 BOILER START UP 86 MAINTENANCE REPORT cicius ramis raa nr ko DE dS CA UC EA HE XD UR XA ER XR E D RA EK RR RU V EK REN NA CR RE 86 Up giapuedieoc QM HTP CUSTOMER INSTALLATION RECORD FORM inesse enne PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This boiler is for indoor installations only Clearance to combustible materials 6 top bottom and sides 0 back Left side has all boiler mechanical connections Front must have room for service 24 recommended A combustible door or removable panel is acceptable front clearance This boiler has been approved for closet installation Do not install this boiler directly on carpeting For installation on combustible flooring Category IV vent systems only WARNING 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 FAILUR
19. float type air vent zone valve union DHW tem perature sensor i Super Stor Ultra Outdoor temperature DHW Tank sensor aquastat heat exchanger diaphragm type expansion tank Lal x n X radiant manifold radiant manifold with valve actuators Figure 8 Piping Symbol Legend 24 Elite FT Standard Piping with Zone Valves amp DHW Priority Single Temp Models EFT 50 amp EFT 80 Only zone valves gt lt make up water purging valves anti scald mixing valve gm Super Stor Ultra indirect DHW Tank Figure 9 Standard Piping with Zone Valves and DHW Priority NOTES differential pressure bypass valve 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a SuperStor indirect water heater is 1 5 The minimum pipe size for connecting an EFT 55 or 80 1 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 mixing valve i
20. k Refill to correct pressure F CHECK THERMOSTAT CIRCUIT S 1 Disconnect the two external wires connected to the boiler thermostat terminals low voltage terminal strip 2 Connect a voltmeter across these two incoming wires with power supplied to the thermostat circuits Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage reading does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 63 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the boiler low voltage terminal strip Allow the boiler to cycle G CONDENSATE HEMOVAL 1 The boiler is a high efficiency condensing boiler Therefore the boiler has a condensate drain Condensate fluid is nothing more than water derived from combustion products similar to that produced by an automobile when it is initially started Condensate is slightly acidic typically with a pH of 3 to 5 and must be piped with the correct materials Never pipe the condensate using steel copper brass or other materials that will be subject to corrosion Plastic PVC or CPVC pipe are the only approved materials A condensate neutralizer if required by local authorities be purchased from H
21. 190 F 68 F 10 Function 11 Min Supply Temp MIN SUPPLY TEMP Sets the design supply water temperature based on the maximum outdoor design temperature Default 95 F Range 95 F 11 32 F to 190 F Function 12 Min Boiler Temp MIN BOILER TEMP Sets the design minimum heat curve temperature for central heat Default 68 F Range 32 F to 190 F 68 F 12 Function 13 CH Post Pump Time CH POST PUMP TIME Allows the user to set the boiler pump post purge time once the thermostat is satisfied Default 0 minutes Range 0 0 MINUTES 13 10 minutes Function 14 DHW Priority DHW PRIORITY Allows the user to set the maximum run time for the indirect fired water heater and the minimum run time for central 30 MINUTES 14 heating Default 30 minutes Range 0 60 minutes Function 15 Cascade Address CASCADE ADDRESS Bus addressing boilers maximum boilers allowed 8 in a cascade system Master Boiler address is 0 and Following 0 15 Boilers are addressed 1 thru 7 Default 0 Range 0 8 NOTE DO NOT USE ADDRESS 8 Function 16 Optional Inputs OPTIONAL INPUT Allows the user to select from optional inputs to control or monitor the system Default RETURN Range Off Booster RETURN SEN 16 Board 0 10 Volt DHW Sensor Return Sen Function 17 0 10 Volt Function 0 10 VOLT FUNCTION TEMPERATURE 17 Allows the user to control boiler modulation through temperature control Default Temperature Range Temperature or Fan Spe
22. EFT 155 199 285 1 25 EFT 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the boiler s primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 28 Elite FT Multiple Boilers with Primary Secondary Piping with Zone Circulators amp Indirect Circulator All EFT Models space heating zone circuit 2 NNI NINOS NO Pha Dp S circulators 4 UD make up water J purging closely spaced A valves tees J purging valves mixing valve Indirect Circulator system sensor Super Stor Ultra Indirect DHW Tank 777 Boiler Circulators 777 Figure 13 Multiple Boilers Primary Secondary Piping Circulators NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe sha
23. HTP PVC termination kit DO NOT mix AL 29 4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer PVC DWV for air intake applications ONLY Failure to follow these directions will result in substantial property damage severe personal injury or death WARNING DO NOT mix components from different venting systems without proper adapters The vent system could fail causing leakage of flue products into the living space Use only the approved pipe and fitting materials primer and cement and adapters specifically designed for the material used as listed in Table 10 Failure to do so could result in property damage severe personal injury or death WARNING Exhaust vent adaptors are not designed as load bearing devices and must not be used to support exhaust vent piping All vent pipes must be glued properly supported and the exhaust must be pitched minimum of 74 per foot back to the boiler to allow drainage of condensate Failure to properly support vent piping and follow the information in this statement could result in product damage severe personal injury or death WARNING For closet and alcove installations CPVC polypropylene or stainless steel venting material MUST BE USED Failure to follow this statement could result in product damage severe personal injury or death NOTE The use of double wall vent or insula
24. MUST 3 4 ERAT on 1100 CONDENSATE LY UM PIPING VERTICAL OR 1 X 3 4 PVC PIPE HORIZONTAL NEUTRALIZER 3 4 FLEXIBLE REDUCER SWEAT TUBING 3 4 PIPE SWEAT o0 ONNECTIONS THROUGHOUT LP 387 GG 3 4 PVC ign 11 04 11 HORIZONTAL LINES MUST PIPING SUPPORTS LP 387 HH SWEAT CONNECTIONS BE INSTALLED WITH A PITCH 11 04 11 THROUGHOUT OF 1 4 PER FOOT HORIZONTAL LINES MUST BE INSTALLED WITH A PITCH 554200 LITTLE GIANT OF 1 4 PER FOOT CONDENSATE PUMP N1100 CONDENSATE EXISTING DRAIN NEUTRALIZER Figure 16 Condensate Piping Suggestions NOTES 1 Condensate line must be pitched at least 1 4 per foot to properly drain If this cannot be done or a very long length of condensate hose is used you must increase the condensate line to a minimum of 1 ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line 2 Plastic pipe should be the only material used for the condensate line Steel brass copper or other materials will be subject to corrosion or deterioration 3 NEVER install condensate lines outside It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage Damages due to frozen or blocked condensate lines ARE NOT covered by warranty 4 Support of the condensate line may be necessary to avoid blockage of the condensate f
25. System Piping 1 See Piping Details Part 5 Section G In most diagrams the space heating system is isolated from the boiler loop by the primary secondary connection 2 Size the piping and components in the space heating system using recognized design methods HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND MULTIPLE BOILERS This boiler is designed to function in a closed loop hydronic system It is recommended to install a temperature and pressure gauge not included with the boiler to allow the user to monitor system pressure and outlet temperature from the boiler It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators Unless the system has a closed type expansion tank each boiler installation must have an air elimination device that will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc Allow clearance for basic service of boiler circulator valves and other components Observe the minimum 1 clearance around all uninsulated hot water pipes when openings around pipes are not protected by non combustible materials On a boiler installed above radiation level some states and local codes require a low water cut off device which is an optional part available through HTP Part 7600P 104 for EFT 55 110 models 7600P 990 for EFT 155 399 models Check with local codes
26. System Turn up thermostat to verify wiring connections operation 5 Record ionization d c High Fire uA Low Fire current 6 Indirect Verify safety and operation of the indirect water de dh water heater heater record settings 7 Convert the If necessary convert the boiler to the proper gas boiler type Locate the stickers in the appropriate locations on the boiler TU en d settings after gas conversion CO2 High Fire CO2 settings after gas conversion ppm High Fire ppm CO baw Fins Mail in the conversion registration 8 Record Record heating curve record steps system 8 9 10 11 settings Notes Table 30 MAINTENANCE REPORT CAUTION In unusually dirty or dusty conditions care must be taken to keep boiler cabinet door in place at all times Failure to do so VOIDS WARRANTY WARNING Allowing the boiler to operate with a dirty combustion chamber will hurt operation Failure to clean the heat exchanger as needed by the installation location could result in boiler failure property damage personal injury or death Such product failures ARE NOT covered under warranty The boiler requires minimal periodic maintenance under normal conditions However in unusually dirty or dusty conditions periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended Periodic maintenance should be performed once a yea
27. Table 27 PART 12 SHUTDOWN A SHUTDOWN PROCEDURE If the burner is not operating disconnect the electrical supply If the burner is operating lower the set point value to 70 F and wait for the burner to shut off Continue to wait for the combustion blower to stop so all latent combustion gases are purged from the system This should take a maximum of 40 to 90 seconds B VACATION PROCEDURE If there is danger of freezing change the set point to 70 F DO NOT turn off electrical power If there is no danger of freezing follow Shutdown Procedure C FAILURE TO OPERATE Should the burner fail to light the control will perform two more ignition trials prior to entering a lockout state Note that each subsequent ignition trial will not occur immediately After a failed ignition trial the blower must run for approximately 10 seconds to purge the system Therefore a time period of approximately 40 to 90 seconds will expire between each ignition trial If the burner lights during any one of these three ignition trails normal operation will resume If the burner lights but goes off in about 4 seconds check the polarity of the wiring See electrical connection section If the burner does not light after the third ignition trial the control will enter a lockout state This lockout state indicates that a problem exists with the boiler the controls or the gas supply Under such circumstances a qualified service technician should be contacted
28. and the other connected boilers as followers The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating input from the connected boilers Each cascaded boiler will have its own pump to provide maximum flow and control heat exchanger flow rate Text Display and Operational LED Light Indicators The display allows the user to change system parameters and monitor system outputs Gas Valve Senses suction from the blower allowing gas to flow only if powered and combustion air is flowing Metal Integrated Venturi Controls air and gas flow into the burner Burner Constructed of high grade stainless steel the burner uses premixed air and gas fuel and provides a wide range of firing rates Spark Ignition The burner is ignited by applying high voltage through the system spark electrode This causes the spark from the electrode to ignite mixed gas off of the burner Supply Water Temperature Sensor This sensor monitors boiler outlet water temperature System Supply The control adjusts boiler firing rate so the supply temperature will match boiler set point Return Water Temperature Sensor This sensor monitors the boiler return water temperature System Return Sensor Monitors flue temperature and adjusts firing rate Temperature and Pressure Gauge Allows the user to monitor system temperature and pressure Electrical field connections with terminal strips The electric
29. area where machinery may damage the pipe e Follow required minimum clearances 36 WARNING 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 WARNING For each floor containing bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms as well as in the room that houses the boiler Detectors and alarms shall comply with NFPA 720 latest edition Failure to comply with requirements for detectors and alarms could result in property damage severe personal injury or death 3 Determine location of condensate piping This is a high efficiency boiler and therefore produces condensate a by product of the combustion process A condensate collection System with an internal float switch monitors condensate level to prevent it from backing up into the combustion system There is a flexible line that must be piped as shown in Figure 16 to a suitable drain NOTE Check with your local gas company to determine if combustion condensate disposal is permitted in your area In the state of Massachusetts condensate must be neutralized before entering a drain CONDENSATE ADAPTER CONDENSATE GASKET ADAPTER
30. boiler basis for boilers BOILER 5 095 addressed as 4 and 5 Press the V key once BOILER 6 0 This screen shows the current cascade power demand output on per connected boiler basis for boilers BOILER 7 095 addressed as 6 and 7 Table 25 Cascade Menu Screens C BOILER TEST MODE This function is intended to simplify the gas adjustment Listed in Table 26 are the recommended combustion settings for the gas type selected to run the boilers Automatic modulation does not take place when the controller is in test mode However the boilers will modulate down if the program set point is reached while running in test mode It is recommended you have the largest load possible to create a heat demand so the test mode operation will not be interrupted To enter test mode press the A and ENTER keys simultaneously To exit press and V simultaneously NOTE The boiler will automatically exit test mode after 20 minutes of operation SERVICE PUMP ON 3400 RPM 4 49P 72 COMBUSTION SETTINGS ON ALL MODELS NATURAL GAS PROPANE LP High High CARBON MONOXIDE CO lt 150 ppm lt 150 ppm CARBON DIOXIDE CO2 8 10 1090 9 10 Table 26 ELITE FT FAN SPEEDS MODEL IGNITION MIN MAX EFT 55 3800 1650 4050 EFT 80 3800 1850 5000 EFT 110 3800 1850 6050 EFT 155 4100 1850 5400 EFT 199 3800 1750 6050 EFT 285 4600 1800 6050 EFT 399 4200 1900 6950
31. immediately to properly service the boiler and correct the problem If a technician is not available depressing and holding the RESET button for more than 1 second will remove the lockout state so additional trials for ignition can be performed The unit will try to re light once every 6 minutes PART 13 TROUBLESHOOTING A BOILER ERROR CODE If any of the sensors detect an abnormal condition or an internal component fails during the operation of the boiler the display may show an error message and error code This message and code may be the result of a temporary condition in which case the display will revert to its normal readout when the condition is corrected or it may be a condition that the controller has evaluated as not safe to restart the boiler In this case the boiler control will be locked out the red FAULT light will be lit and the message LOCKOUT will be displayed on the readout on the lower line The Boiler will not start until a qualified technician has repaired the boiler and pressed the RESET button for more than 1 second If there is an error message displayed on the readout and the message LOCKOUT is not displayed and the FAULT light is not lit then the message is the result of a temporary condition and will disappear when the problem corrects itself IMPORTANT NOTE If you see error messages on your display readout call a technician immediately since the message may indicate a more serious problem will occu
32. or electrical inspector or others having statutory authority some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official may be the AHJ NOTE HTP Inc reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER A DANGER This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in substantial property damage severe personal injury or death This boiler must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the boiler and with local codes and utility company requirements In the absence of local codes preference should be given to the National Fuel Gas Code ANSI Z223 1 2002 INSTALLATIONS MUST COMPLY WITH Authority Having Jurisdiction local state provincial and national codes laws regulations and ordinances The latest version of the National Fuel Gas Code ANSI Z223 1 from American Gas Association Laboratories 8501 East Pleasant Valley Road Cleveland OH 44131 In Canada CGA No B149 latest version from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada 2R3 Also Canadian Electrical Code C 22 1 from Canadi
33. 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 SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F01 FLUE TEMP WAT LV F01 PUMP ON This display indicates that the flue temperature limit switch of the boiler has tripped or that the water level in the boiler is low this will only occur if the optional UL853 LWCO is installed This code indicates a serious safety issue The boiler will not restart until the flue cools down sufficiently or the water level is restored A tech nician must repair the cause of the problem and push the RESET button first on the low water cut off control box then on the display This situation is indicated by the red light on the display and the word LOCKOUT flashing on the display During this lockout fault the pump will be on as indicated on the second line of the display 1 If the boiler has a 01353 LWCO check if the red LED on the LWCO control box is illuminated If so correct the low water con dition and press the reset button on the LWCO control box to reset the LWCO The LED should change to green Press the reset button on the front panel of the boiler to reset the boiler control 2 Check the flue for obstructions or any sign of damage especially signs of excessive heat Repair as necessary Push the red reset button on the flue temperature switch located on the flue inside the rear acces
34. return temperature sensor of the boiler has failed This code indicates a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display This situation is indicated by the red light on the display and the word LOCKOUT flashing on the display During this lockout fault the pump will be on as indicated on the second line of the display 1 Check circulator pump operation 2 Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Troubleshoot thermistor by following steps in Fault Code F04 FLUE SENSOR F04 This display indicates that the flue temperature sensor of the boiler has failed This is a serious safety issue The boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display This situation is 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 PUMP ON indicated by the red light and the flashing word LOCKOUT on Do EE Table the display During this lockout fault the pump will be on as hould be to th p the t ture in th indicated on the second line of the display
35. the boiler Operating the boiler without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death WARNING When servicing is complete make sure the condensate collector cap is replaced securely Failure to do so will cause venting issues that will result in serious injury or death 1 Ensure the boiler is powered off 2 Remove the stainless steel lock pin to release the condensate trap Remove the clear plastic hose from the hose barb Remove the trap from the drain tube 3 Remove the bottom cap from the condensate trap 4 Flush trap with fresh water to remove debris from the trap NOTE Ensure the float moves freely within the trap If the float does not move DO NOT reinstall the trap 5 When the condensate trap is sufficiently clean reinstall the bottom cap on the trap NOTE Ensure all parts shown in Figure 37 1 Condensate Detail are installed with the condensate trap If any parts are missing DO NOT reinstall the trap Replace the entire assembly CONDENSATE ADAPTER CONDENSATE GASKET ADAPTER CAP FLANGE HITCH CAR ORING INSERT STAINLESS STEEL SLIDE THE CONDENSATE LOCK PIN THROUGH THE ASSEMBLY ONTO THE DRAIN ADAPTER TO LOCK TUBE UNTIL THE HOLES IN THE CONDENSATE CUP TO THE pum Aa pressure switch THE GROOVEIN THE TUBE PLASTIC HOSE BARB ADAPTER CONDENSATE CUP BODY CONDENSATE HOSE CLAMP GASKET CONDENSATE HO
36. the red FAULT light and LOCKOUT flashing on the display the return sensor temperature has exceeded 230 F and a serious safety issue exists The boiler will not restart until the cause of excessive temperature is repaired by a technician and the boiler is RESET If the red FAULT light is not illuminated then the return tem perature of the boiler is at or above 210 F The message will clear automatically when the temperature drops below 194 F During the time that this message or lockout fault is dis played the pump will be on as indicated on the second line 1 Check circulator pump operation 2 Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Check the direction of flow on boiler circulator See Piping Details in this manual 4 Troubleshoot thermistor by following steps in SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F09 NO FLAME ON IGN F09 PUMP ON The boiler tried to ignite four times during one heat call and failed The red FAULT light and LOCKOUT will flash on the display This code indicates a serious safety issue The boiler will not restart until the cause of ignition failure is repaired by a technician and he pushes the RESET button on the display During this lockout fault the pump will remain on as indicated on the second line of the display
37. to the boiler To check gas pressure perform the steps listed below 1 IMPORTANT Before you connect to the inlet pressure shut off the gas and electrical power to boiler 2 Loosen the pressure tap with a small screwdriver Refer to Figure 29 for location 3 Each boiler is equipped with a needle valve that will accept a 5 16 ID hose to connect to a digital manometer or liquid gauge designed to measure incoming pressure from 0 35 w c See 7 4 Turn on the gas and power up the boiler 5 Put the boiler into manual test mode details on test mode are in Part 11 Section D In service mode monitor pressure to assure it does not drop below 1 inch from its idle reading If gas pressure is out of range or pressure drop is excessive contact the gas utility gas supplier qualified installer or service agency to determine correct action that is needed to provide proper gas pressure to the boiler If Gas Pressure is within normal range proceed to Step 6 6 Exit test mode then turn power off and shut off gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device Tighten screw on the pressure tap and turn gas on Check for leaks with soapy solution Bubbles will appear on the pipe to indicate a leak is present WARNING Ensure the pressure tap screw is properly tightened to prevent gas leaks Failure to do so could cause substantial property damage severe personal injury or death The ga
38. 0 VOLT BUILDING CONTROL 55 K OPTIONAL 011353 LOW WATER CUT OFF 55 L WIRING OF CASCADE SYSTEM COMMUNICATION 6 55 M CASCADE MASTER PUMP AND SENSOR 56 CASCADE FOLLOWER PUMP AND SENSOR 57 PART 9 START UP asina atn aa trana asas asas ass assa assa ass asma asma sanas snas ss ass dana asa 60 A CHECK CONTROL WATER 60 B GHECICEOREGAS EBEAKS uen m ce be t a ee dde c cce ite e n e C 61 FREEZE PROTECTION WHEN USED dee ne 61 D FIEL AND TEST WATER SYSTEM nro e cert ee de p era n cid t et and 61 E PURGE AIR FROM WATER SYSTEM usen gei ER eB BRIE E UNDC 62 F CHECK THERMOSTAT CIRGUIT S tim te ette e n sel oe ra ete RR Dre Dre 62 ut eee b c ce e ottenere ete etel uar dae ee cra 63 FINAL CHECKS BEFORE STARTING rentre 63 k CASCADE SYSTEM n MR ER S bd HAEC eee Le ptis 63 J EOCKOUT GONDITION 3 ento Eni aie len eee i d sena 64 PART 10 START UP 64 A CONTROL OVERVIEW 3 2 2 et ect e eun tete lt t obse dcs e ete tour dioses e iude ri 64 N
39. 00005 ffjoooon Allows the user to set the left two digits of the amount of run hours before next service reminder Function 34 Month SERVICE SCHEDULE MONTH 00 00 2000 34 If the date function was selected this function allows the user to program the month If you selected the run hour function you will need to program 10 000 hours if required Hours SERVICE SCHEDULE 10000 s 0000 34 Allows the user to set the two middle digits of the amount of run hours for the next service reminder Function 35 Day SERVICE SCHEDULE DAY 00 00 2000 35 Allows the user to set the day of next service reminder Hours SERVICE SCHEDULE 100005 0000 35 Allows the user to set the 2 right digits of the amount of run hours for the next service reminder Function 36 Telephone TELEPHONE 000 000 0000 36 Allows the user to input a telephone number that will be displayed when maintenance is required Table 21 Maintenance Reminder Function Screens 69 G RESETTING THE MAINTENANCE SCHEDULE When the system control flashes MAINTENANCE REQUIRED it is advisable that you call for service After the service is performed reset the schedule for the next required service by using the following steps Press ENTER on the display for 3 seconds The Menu code will appear as 000 This does not change Press ENTER again SERVICE SCHEDULE RESET will be displayed Using the right arrow ke
40. 00P 502 PIPE GROMMET THERMISTOR w O RING PRESSURE SWITCH w SCREWS 7600P 005 7600P 028 DISPLAY ASSEMBLY FRONT COVER ASSEMBLY 7350P 129 7600P 101 FUSE 3 15A CUSTOMER CONNECTION BOARD LOW VOLTAGE WIRING HARNESS location shown 7250P 739 7250P 165 FLUE SWITCH 5 5 HOSE BARB w O RING 7000P 805 7450P 026 CLEAR HOSE PRESSURE SWITCHES FLUE TEMPERATURE SENSOR 7250P 378 7600P 100 FUSE 6 3A CONTROL BOARD 120V WIRING HARNESS location shown 7250P 653 7250P 080 IGNITOR LEAD CABLE NOT SHOWN PRESSURE RELIEF VALVE NOT SHOWN Figure 39 Replacement Parts 20 Switch on the Left is the Blocked Pressure Switch Switch on the Right is the Blocked Condensate Pressure Switch Both share same Part Number 83 EFT 155 199 285 399 PARTS BREAKDOWN ee MH A f EFI 155 EFT 199 EFI 285 DESCRIPTION 7500P 031 735 159 COMBUSTION BLOWER w GASKET 7500P 075 GASKET COMBUSTION BLOWER CHANNEL wiGASRET CREWS 7600P 105 7600P 106 GASKET BURNER 7600P 155 7600P 114 7600P 115 BURNER w GASKET 7600 087 FLAME RECTIFICATION PROBE 7350P 021 IGNITOR w GASKET SCREWS 7600P 910 7600P 911 BURNER DOOR 7600P 112 7600 113 BURNER DOOR 7600P 110 7600P 111 REFRACTORY BURNER DOOR 7250P 005 GASKET PROBES 7500P 067 6MM NUTS BURNER DOOR 7600P 090 7
41. 1 BURNER DOOR GASKET BURNER DOOR 7600P 070 REFRACTORY BURNER DOOR 7600 041 PLATE COMBUSTION BLOWER 5 7500P 075 GASKET BLOWER TO AIR CHANNEL 7250P 477 SCREWS AIR CHANNEL TO BLOWER 7600P 072 7600P 002 SIGHT GLASS w GASKET SCREWS HEAT EXCHANGER EFT 55 7600P 001 CHANNEL w SCREWS 7250 478 5 5 AIR CHANNEL TO HEAT EXCHANGER 7600P 003 7600P 004 7450P 025 HEAT EXCHANGER ONLY EFT 80 HEAT EXCHANGER ONLY EFT 110 GAS VALVE 7500P 074 GASKET BURNER 7600P 009 BURNER w GASKET EFT 110 Figure 38 Replacement Parts LP 387 J 7250P 140 GAS SHUT OFF VALVE LP 387 J 05 08 13 82 55 80 110 PARTS BREAKDOWN REPLACEMENT PART DESCRIPTION 7600P 007 WATER PRESSURE SWITCH 7450P 030 7600P 060 3 PVC ADAPTER 3 PVC VENT OUTLET ASSEMBLY 7600P 501 7600P 043 OUTLET PIPING ASSEMBLY PVC PLUG 7600P 045 7450P 122 COMBINATION SUPPLY HIGH TEMPERATURE SWITCH 926 CONTROL BOARD w RIBBON CABLE 7350P 070 FIELD CONNECTION BOARD AJOJN 7500P 087 7500P 037 o POWER SWITCH CONDENSATE OUTLET LP 387 N 09 28 12 ITEM amp 7600 036 DESCRIPTION PIPING BRACKET 7600P 500 7600P 006 INLET PIPING ASSEMBLY CONDENSATE ASSEMBLY 7600P 057 7250P 059 76
42. 5 3 10 23 feet BLOCKAGE The Exhaust Vent Equivalent Length the Intake Pipe Equivalent Figure 18 Length equal the Total Equivalent Length In this example the Total Equivalent Length is 43 feet c The minimum Total Equivalent Length is 15 feet F EXHAUST VENT AND INTAKE PIPE INSTALLATION WARNING joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space 1 Use only solid PVC or CPVC pipe AL29 4C Stainless Steel or a Polypropylene vent system approved for use with Category IV boilers FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST APPLICATIONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use only cement and primer approved for use with the pipe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is located where it will not be exposed to prevailing winds 5 In all roof venting applications exhaust discharge must point away from the pitch of the roof 6 To prevent water leakage install adequate roof flashing where the pipe enters the roof 7 Do not locate vent over public walkways driveways or parking lots Condensate could drip and freeze resulting in a slip hazard or damage to vehicles an
43. 600P 091 7600P 092 7600P 093 HEAT EXCHANGER w INSULATION 7600P 147 7600P 148 INSULATION HEAT EXCHANGER 7450P 025 7350P 033 7250P 140 7350P 079 SHUT OFF VALVE 7600P 136 7600P 236 PIPE CLAMP 7600P 902 7600P 903 INTLET PIPING ASSEMBLY 7600P 900 7600P 899 7600P 901 OUTLET PIPING ASSEMBLY 7100P 140 7600P 152 FLEXIBLE GAS LINE w GASKET 7600P 102 7600 912 AIR INLET BLOWER 7450P 115 GASKET BSPP CONNECTIONS 7450P 024 7450P 023 7450P 029 VENTURI w GASKET 7600P 072 SIGHT GLASS w GASKET SCREWS UD N LP 387 KK 05 23 13 Figure 40 Replacement Parts LP 387 KK EFT 155 199 285 399 MODEL PARTS BREAKDOWN 155 199 285 399 DESCRIPTION 1 7600P 007 7600P 007 WATER PRESSURE SWITCH 2 7450P 030 7600P 150 3 4 INLET ADAPTER 7600P 060 7600P 119 3 4 VENT OUTLET ASSEMBLY 7600P 043 PVC PLUG 7600P 045 COMBINATION SUPPLY HIGH TEMPERATURE SWITCH 7450P 122 926 CONTROL BOARD w RIBBON CABLE 7350P 070 FELD CONNECTION BOARD 7250 739 FLUE SWITCH 7500P 087 POWER SWITCH 7500P 037 CONDENSATE OUTLET 7250P 165 S S HOSE BARB w O RING 7450P 026 FLUE TEMPERATURE SENSOR 7250P 059 7250P 667 THERMISTOR w O RING 7600P 006 CONDENSATE ASSEMBLY 7600P 502 P
44. ACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING Fi L 5 5 7 L TORT ABOVE MAXIMUM POTENTIAL SNOW LEVEL LP 387 E 07 29 11 DP PF 7 P I Figure 20 LP 387 E NOTE Vent piping should be 12 over anticipated maximum snow level NOTE Drawing is meant to demonstrate system venting ONLY WARNING vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 1 4 per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler 43 H DIAGRAM FOR HORIZONTAL VENTING FRONT VIEW EXHAUST B 1 JN EXHAUST E i4 AIR INTAKE AIR INTAKE FRONT VIEW SIDE VIEW Figure 21 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 Maint
45. AVIGATION OF THE DISPLAY eee e le ec d e obe D E Eta cL 64 C OPERATING INSTRUCTIONS tete P e RR b toD e Late coe e eiat 65 D PROGRAMMING BOILER SETTINGS eset die ptc amnem us 65 E PROGRAMMING THE SYSTEM SETTING testet sr etr etr ennt 66 SYSTEM SETTING PROGRAM 66 RESETTING THE MAINTENANCE SCHEDULE sn 69 PART 11 START UP PROCEDURES FOR 1 1 01 1 69 A BOILER CONTROL STATUS MENU teo e eet ebd eb e de e 69 t ett obe abest d eden e ede den Li d o estf de s 71 2 ec et bate e Sec al ite ada ce diede 71 12 5 nia iR a drea GARA UL nu ER RAD RR ERG HORA NCC HK 72 A SHUTDOWN PROGEDURE 1 e ett b RUBRA ceto e Re 72 VAGATION PROGEDU RE teen ahora RE 72 C FAILURE TO OPERATE tob t et eL te Bal de e i e du 72 PART 13 EEanieU nieeoc 72 BOILER ERROR CODE uU ROVRO meme dE 72 BzBOILER ERROR i un Rm ERU Re LU ei e UE E us 73 ams E 73 DeoUSER INTERFACE DISPLAY anes iet t a ede e t dude en i t a a cot 73 PART 14 MAINTENANCE q 78 A
46. CADE NO FOLLOWER SYS PUMP OFF This screen is displayed when the boiler is configured as a Master Boiler and there are no connected follower boilers or the follower boilers are not powered The second line indicates status of the cascade system pump output This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the 4 key from the default screen CASCADE NO SENSOR SYS PUMP OFF This screen is displayed when the boiler is configured as a Master Boiler and there is no system temperature sensor connected or the system sensor is defective The cascade system will still function in this situation with reduced efficiency All boilers will run simultaneously rather than a staged fashion The second line indicates the status of the system pump output of the cascade system This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the 4 key from the default screen CASCADE TT 0123 567 SYS PUMP ON 12 47 Shows information about cascade status The TT in the center of the top line shows that the cascade demand is coming from the TT contact being closed You may also see DHW if the demand is from a DHW sensor or 0 10 if demand is from a 0 10 volt input The following numbers show which boiler addresses are currently communicating to the master If a boiler address is not used or communicating the number will not show on the display In the example a
47. Cascade Resistor Plug Installation Detail M CASCADE MASTER PUMP AND SENSOR WIRING 1 Connect the system pump hot wire to the terminal marked 8 2 Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal 3 Connect a jumper wire from the 120 VOLT terminal to the 9 terminal 57 4 Connect the boiler pump to the terminals marked 1 HOT 2 NEUT and 3 GND 5 Connect the system pipe sensor to the terminals marked 10 and 11 NOTE See Figure 32 for Cascade Master and Follower Wiring detail N CASCADE FOLLOWER PUMP AND SENSOR WIRING 1 Connect the boiler pump to the terminals labeled 1 HOT 2 NEUT and 3 GND 2 An alarm bell or light can be connected to the alarm contacts of the follower boiler The normally closed alarm contact may be used to turn a device off if the boiler goes into lockout mode The alarm contacts are rated 5 amps at 120 VAC To connect an alarm device connect the power for the device to the ALARM COM terminal Connect the alarm device hot wire to the ALARM NO terminal Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device To connect a device that should be powered off during a boiler lockout condition follow the same instructions as above except use the ALARM NC terminal rather than the ALARM NC terminal Note that in a cascade system the alarm output of the boiler addressed as 1 will also be active if the master bo
48. E TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS BOILER SERVICED INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH NOTE When inquiring about service or troubleshooting reference the model and serial numbers from the boiler rating label WARNING DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician The boiler MUST BE replaced if it has been submerged Attempting to operate a boiler that has been submerged could create numerous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air Operating a previously submerged boiler could result in property damage severe personal injury or death NOTE Boiler damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty WARNING Be sure to disconnect electrical power before opening boiler cabinet or performing service Failure to do so could result in an electrical shock that could result in property damage serious personal injury or death NOTE If the boiler is exposed to the following do not operate until all corrective steps have been made by a qualified serviceman 1 FIRE 2 DAMAGE 3 WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the c
49. ELITE FT INSTALLATION START UP MAINTENANCE PARTS Models 55 80 110 155 199 285 399 suffix of LP denotes propane gas A suffix of denotes natural gas CONTROLS amp Fu CERTIFIED us DA This manual must only be used a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in substantial property damage severe personal injury or death NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 120 Braley Rd P O Box 429 East Freetown MA 02717 0429 www htproducts com LP 387 REV 5 23 13 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 DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER BOILER WHAT TO DO IF YOU SMELL GAS e Donottry to light any boiler e Donottouch any electrical switch e Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier
50. NOTE The clock does not automatically adjust for Daylight Savings Time and requires manual adjustment E PROGRAMMING THE SYSTEM SETTING System Setting Program Access NOTE Programming the boiler control is not possible when the boiler is firing Make sure any input which can create a demand on the boiler such as the tank thermostat is turned off so the boiler will remain idle to allow programming SCREEN DESCRIPTION ENTER MENU CODE To access the boiler setting program press and hold the ENTER Key for 4 seconds until the display shows the screen 000 at left ENTER MENU CODE Using the arrow keys on the display log in your System Menu Access Code 925 To confirm code press ENTER 925 to access system setting program navigation menu Table 19 System Setting Access F SYSTEM SETTING PROGRAM NAVIGATION Once the System Menu Access Code is confirmed the user can begin to set the system setting menu Use the lt gt arrow keys the display to navigate through the system setting program To change a setting press ENTER System settings can be increased by 67 pressing the UP ARROW and decreased by pressing the DOWN ARROW on the display When done press ENTER Setting will stop blinking and you can move on to next setting Press RESET to exit programming and store settings Listed below are the boiler settings that can be programmed into the control
51. NOTICE The CSD 1 ASME Code Section CW 400 requires that hot water heating and supply boilers have a a UL 353 temperature control device b at least one 1 temperature actuated control to shut off the fuel supply when system water reaches a preset operating temperature c a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout and d its own sensing element and operating switch Certain AHus locales and states will require that commercial boiler installations meet the CSD 1 ASME Code Section CW 400 To meet this code HTP Inc has integrated a temperature control system into the 926 control provided with this heating appliance This control system complies with the requirements of CSD 1 Section CW 400 as a temperature operation control The control monitors the temperature difference between the inlet and the outlet sensor which is affected by boiler water flow If this temperature difference exceeds 55 F typically because of low water flow or very low heat load the control will reduce the maximum fan speed If the temperature difference exceeds 60 F the control will effectively sense there is little or no water flow or heat load and shut the boiler down The controller will restart automatically once the temperature difference has dropped below 55 F and the minimum off time anti cycle time has expired In addition if the control senses th
52. NTAKE INLET W SCREEN EXIS Ur d E 22 4 TIN 1 V E A f 2 i 15 SEALED AIR INLET W SCREEN SEALED SEAL LP 387 M 08 25 11 Figure 24 1 24 2 Concentric Venting NOTE Drawing is meant to demonstrate system venting ONLY CAUTION 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 47 VENT AIR INLET SIZE MINIMUM EXISTING VENT CHASE SIZE 3 5 4 77 Table 13 Minimum Vent Chase Sizing 2 VENTING AS A CHASE When venting as a chase follow all instructions included in Part 6 Venting of this manual as well as the previous Concentric Venting section See Figure 25 for chase venting demonstration FLUE EXHAUST LP 387 L 08 23 11 Figure 25 Existing Venting as Chase NOTE Drawing is meant to demonstrate system venting ONLY 48 L 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 c
53. RESSURE SWITCH w SCREWS 7350P 129 FUSE 3 15A CUSTOMER CONNECTION BOARD 7600P 904 7600P 905 LOW VOLTAGE WIRING HARNESS not shown 7600P 906 7600P 907 120V WIRING HARNESS not shown 7250P 378 FUSE 6 3A CONTROL BOARD 7600P 005 DISPLAY ASSEMBLY 7600P 128 7600P 228 FRONT COVER ASSEMBLY 7000P 805 CLEAR HOSE PRESSURE SWITCHES not shown 7250P 653 7350P 120 IGNITOR LEAD CABLE not shown 7250P 080 7350P 066 PRESSURE RELIEF VALVE not shown 7000P 805 PLASTIC TUBING PRESSURE SWITCHES not shown LP 387 JJ 06 05 12 ITEM ATTACHED TO PIPING ASSEMBLY Figure 41 Replacement Parts LP 387 JJ EFT 155 399 Models BOILER START UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED 1 pu Check all piping and gas connections verify all heating are tight system Pressurize system 12 15 psi PSI Add water to prime condensate cup Percentage of glycol in system 0 5095 96 Verify near boiler piping is properly supported 2 Check gas Leak test using locally approved methods consult pipe jurisdictional code book Check incoming gas pressure 3 5 to 14 W C in w c Static 2 the drop on light off No more than 1 TONS Dynamic CUT adjust if necessary carbon dioxide 9 CO2 High Fire 9 CO2 Lobo Mica adjust if necessary carbon monoxide ppm CO High Fire ppm CO 4 Verify
54. SA C22 1 Canadian Electrical Code Part 1 and any local codes B FIELD WIRING TERMINATIONS All connections made to the boiler in the field are done inside the electrical junction box located on the left side of the boiler Multiple knockout locations are available to route field wires into and out of the electrical junction box See Figure 30 C FIELD WIRING The control used in the boiler is capable of directly controlling 1 pump in standard mode and 2 pumps when configured as a cascade master boiler As a standard boiler each pump can provide a maximum of 4 amps at 120 volts If a pump requires more than this amount of power an external contactor or motor starter is needed If the boiler is configured as a cascade master the system pump output is a dry contact output capable of switching 5 amps at 120 volts in addition to the boiler pump output sourcing 4 amps each The electrical junction box has separate clearly marked terminal strips for line voltage and low voltage wiring Special jacks are provided for trouble free cascade system wiring using standard or CAT5 patch cables NOTE If local electrical codes or conditions require an additional service KNOCKOUT LOCATIONS itch the install t ide and install a fused di tor 15 x FOR LOW VOLTAGE CONNECTION 222 M C TO ELECTRICAL JUNCTION BOX Figure 30 Knockout Locations D LINE VOLTAGE WIRING FOR STANDARD BOILER NOTE A terminat
55. SE IMPORTANT NOTE 7 CLAMP 5 BE SURE TO CONNECT CLEAR HOSE CAP FROM PRESSURE SWITCH TO HOSE BARB O RING ON CONDENSATE ASSEMBLY PRIOR TO OPERATING HEATER CONDENSATE DRAIN BOITOM CAP 5 coast directly to INSERT drain line CONDENSATE ASSEMBLY BOITOM CAP for cleaning LP 387 FF 11 08 11 CONDENSATE DRAIN TUBE LP 387 DD 11 3 11 Figure 37 1 Condensate Detail 37 2 Condensate Trap Installation 81 WARNING Do not install the condensate assembly if a component is lost or missing Replace the entire assembly Failure to follow this warning could result in property damage serious personal injury or death 6 Fill the condensate trap with fresh water prior to reassembly on the boiler 7 Slide the condensate trap adapter onto the drain tube until the holes line up with the groove 8 Insert stainless steel hitch pin to lock condensate adapter to the drain tube 9 Reattach the clear plastic hose to the hose barb WARNING Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch Failure to follow this warning could result in property damage serious personal injury or death 10 If a condensate neutralizer kit is installed with the boiler check the assembly when cleaning the condensate trap and replenish the limestone chips if necessary When replacing the limestone chips take care to ensure
56. T SIZE SOFT 3 32 HARD 3 16 CAUTION If the boiler is not installed vertically plumb improper and unsatisfactory operation may occur causing excessive condensation build up nuisance fault codes and unnecessary maintenance 2 MOUNTING TO A METAL FRAME a The provided mounting bracket must be mounted to the center of at least 2 studs using standard steel or stainless steel toggle bolts 3 16 diameter or larger and at least 2 long for direct mounting on stud for EFT 55 110 models and 3 8 diameter or larger and at least 2 long for EFT 155 399 models for direct mounting on at least 18 gauge studs Be sure the bracket is level and mark the hole location of the top bracket height and horizontal stud location Ensure the marked holes are located in the center of the building frame studs b 2 is the minimum toggle bolt length if the bracket is directly on stud Increase length for any materials covering the studs c Predrill holes on the marked stud locations The predrilled holes should be in diameter for 3 16 bolts and in diameter for 3 8 bolts to allow for the collapsed wings of the toggle to slide through Ensure that the predrilled holes are straight and square to the wall Failure to do so could lead to insufficient support of out of level boiler See Figure 6 d Using the predrilled holes mount the hanger bracket to the building frame studs with the toggle bolts Ensure that the bolt toggles a
57. TE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires routed in a grounded metal conduit If using shielded cable the shielding should be connected to the common ground of the boiler INDIRECT SENSOR There is no connection required if an indirect water heater is not used in the installation 1 The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or an HTP 7250P 325 tank sensor When a tank sensor is used the boiler control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user set point by more than the user selectable offset The demand will continue until the sensor measures that the indirect water heater temperature is above the set point 2 Connect the indirect sensor 7250P 325 to the terminals marked DHW SENSOR shown in Figure 31 in the electrical junction box WARNING Caution should be used to ensure neither of these terminals becomes connected to ground NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires routed in a grounded metal conduit If using shielded cable the shielding should be connected to the common ground of the boiler
58. TP 7450P 212 2 The boiler is equipped with a female socket weld fitting connection that must be piped to a local drain It is very important that the condensate line is sloped downward away from the boiler to a suitable inside drain If the condensate outlet on the boiler is lower than the drain you must use a condensate removal pump available from HTP 554200 This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow which if not corrected could cause property damage 3 If a long horizontal run is used it may be necessary to create a vent in the horizontal run to prevent a vacuum lock in the condensate line 4 Do not expose the condensate to freezing temperatures 5 It is very important you support the condensation line to assure proper drainage H FINAL CHECKS STARTING BOILER 1 Read Start Up Procedure Part 10 in this manual for proper steps to start boiler See Start Up Report to record steps for future reference 2 Verify the boiler and system are full of water and all system components are correctly set for operation 3 Fill the condensate trap with water 4 Verify electrical connections are correct and securely attached 5 Inspect exhaust vent and intake piping for signs of deterioration from corrosion physical damage or sagging Verify exhaust vent and intake piping are intact and correctly installed per Ven
59. The boiler MUST BE replaced if it has been submerged Attempting to operate a boiler that has been submerged could create numerous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air Operating a previously submerged boiler could result in property damage severe personal injury or death NOTE Boiler damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty CAUTION Observe the position of each wire and label before removing Wiring errors may cause improper and dangerous operation Verify proper operation after servicing 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 NOTE If system return temperatures are maintained below the dew point condensation will form on the inside of the boiler cabinet and cause some internal sheet metal components to rust D USER INTERFACE DISPLAY Cascade Control FAULT Codes SCREEN Fault Code EO3 System Sensor Failure DESCRIPTION POSSIBLE REMEDY Disconnect the system sensor from the wiring and measure the resistance of it Compare the measured resistance to the table
60. ULTIPLE seen 20 G PIPING DETAILS E E EDS nb E BE 21 H PIPING INSTAEEATION 2 et Eee eee hd et abet d efte 29 CIRCULATOR SIZING en o t et OR ent eh bn m siete ev ere 29 J CHECK CONTROL WATER 2 30 K FILE AND PURGE HEATING SYSTEM 22 42 5025 eei e e Lec Rt Dec RARE ibe acr bn tend 31 Le GLYCOL ANTIFREEZE S inet ecu ba aui eis 32 M ZONING WITH ZONE VALVE Socken hinian Suis beh bei ban bee tea idee dede cet dd tdeo 32 NzZONING WITH GIRCULATORS 2 tiroteo ete s cete etd n te ie e ee ct e 32 QMULTIPEE BOIEERS iue RUE UE eua uisi E ERU Baa 32 PART 6 VENTING COMBUSTION AIR AND CONDENSATE 33 A CGENERBAL nnm dite ote de dic exstet doce Te Lut 33 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE 34 C REQUIREMENTS FOR INSTALLATION IN 34 D EXHAUST VENT AND INTAKE 35 E EXHAUST VENT AND INTAKE PIPE 39 EXHAUST VENT AND INTAKE PIPE 40 G DIAGRAMS FOR SIDEWALL 0 41 H DIAGRAM FOR HORIZONTAL 43 DIAGRAM FOR UNBALANCED FLUE VERTICAL 44 J DIAGRAM FOR VERTICAL
61. UPLING a 7 12 MIN VENT KIT INTAKE EXHAUST TOP VIEW L SCREEN SHOWN INTAKE TEE VENT KIT EXTERIOR WALL EXHAUST ake 12 MIN EXHAUST STRAIGHT COUPLING SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING ABOVE MAXIMUM POTENTIAL SNOW TORU ABOVE MAX POTENTIAL SNOW LEVEL 11 71 RIGHT SIDE VIEW RIGHT SIDE VIEW LP 387 F 08 01 11 LP 387 D 08 01 11 LA Figure 19 Sidewall Venting with Tee Intake and Coupling Exhaust Standard Equipment and with Optional Kit NOTE Vent piping should be 12 over anticipated maximum snow level NOTE Drawing is meant to demonstrate system venting ONLY WARNING vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler 42 SIDEWALL VENT WITH CONCENTRIC VENT TERMINATION KIT EXTERIOR WALL IMPORTANT INTAKE LEG MUSTBE FACING UP 1 MIN I E SUPPORT BR
62. ailure to use full port ball valves could result in a restricted flow rate through the water boiler Mixing valve Field supplied A mixing valve is recommended when storing domestic hot water above 115 F Unions Field supplied Recommended for boiler serviceability DO NOT USE DIELECTRIC UNIONS ONLY BRASS COPPER OR STAINLESS STEEL Pressure relief valve Factory supplied on Boiler The pressure relief valve is sized to ASME specifications Storage tank may require additional relief valves depending on local codes MINIMUM PIPE SIZES EFT 55 EFT 80 EFT 110 1 NPT or Copper EFT 155 EFT 199 EFT 285 1 or Copper EFT 399 1 NPT or Copper Table 9 K FILL AND PURGE HEATING SYSTEM 1 Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain 2 Close the other side of the balance and purge valve or shut off valve after the drain 3 Open the first zone balance and purge or drain valve to let water flow out of the hose If zone valves are used open the valves one at a time manually NOTE You should check zone valve manufacturer s instructions prior to opening valves manually so as not to damage the zone valve 4 Manually operate fill valve regulator When water runs out of the hose you will see a steady stream without bubbles Close the balance and purge valve or drain to stop the water from flowing Disconnect the hose and connect it to next zone to be purg
63. ain 12 minimum clearance above highest anticipated snow level or grade whichever is greater D Minimum 12 between vents when installing multiple vents E 12 minimum beyond air intake WARNING All vent pipes must be glued properly supported and the exhaust pitched a minimum of 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 of the boiler and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler 44 I DIAGRAM FOR UNBALANCED FLUE VERTICAL VENT EXHAUST VENT STRAIGHT COUPLING 12 OVER MAXIMUM SNOW 24 MIN LEVEL OR 24 WHICHEVER IS GREATER lnc LP 387 T 09 19 11 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 22 LP 293 T Unbalanced Flue Vertical Vent NOTE Drawing is meant to demonstrate system venting ONLY WARNING vent pipes must be glued properly supported and the exhaust pitched a minimum per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping
64. al cover allows easy access to the line voltage and low voltage terminals strips which are clearly marked to facilitate wiring of the boiler 11 Condensation Collection System This boiler is a high efficiency boiler and will produce condensate The collection system has a float switch which monitors the condensation level and prevents condensation from backing up into the combustion system Inside the collection system there is a built in trap which seals the combustion system from the connected drain This condensate should be neutralized to avoid damage to the drainage system or piping Outdoor Sensor The outdoor sensor monitors outdoor temperature and adjusts boiler set point to provide greater efficiency 0 10 Volt Input Allows Installer to connect a BMS Building Management System to control the boiler Condensate Check System The check system prevents exhaust from the heat exchanger from backing up into cabinet Pump Service Mode Allows manual operation of pumps to commission system and check pump operation The Vision System Optional Allows the user to supply mixed temperatures in up to eight zones The Vision system controls the temperature to each zone by employing three way mixing valves The Vision also controls the output temperature of the boiler to assure accurate temperature delivery to all connected zones C OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP e Syst
65. al purposes C MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approval side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the ap
66. alyzer capable of measuring CO and CO Failure to follow this instruction could result in fire explosion property damage severe personal injury or death 53 PART 8 FIELD WIRING WARNING To avoid electrical shock turn off all power to the boiler prior to opening an electrical box within the unit Ensure the power remains off while any wiring connections are being made Failure to follow these instructions could result in component or product failure serious injury or death Such product failure IS NOT covered by warranty WARNING ELECTRICAL SHOCK HAZARD Turn off electrical power supply at service entrance panel before making any electrical connections Failure to do so can result in severe personal injury or death CAUTION Wiring must be N E C Class 1 If original wiring supplied with the boiler must be replaced use only UL Listed 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 Latest Edition CAUTION In order to ease future servicing and maintenance it is advised to label all wires Wiring errors can cause improper and dangerous operation Failure to follow these instructions could result in property damage or personal injury A INSTALLATION MUST COMPLY WITH 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada C
67. an Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada LAW 5N6 4 Code for the installation of Heat Producing Boilers latest version from American Insurance Association 85 John Street New York NY 11038 The latest version of the National Electrical Code NFPA No 70 NOTE The gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition WARNING The hydronic supply and return connections of these products are for installation in closed loop systems ONLY Use of this product in any manner other than described in this manual may result in premature product failure substantial property damage severe personal injury or death Damage or failure of this product or the system in which it is installed due to unauthorized use IS NOT COVERED BY WARRANTY NOTICE In accordance with Section 325 f 3 of the Energy Policy and Conservation Act HTP Inc has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases These features include modulating combustion system that adjusts firing rate based on heat demand e Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor The outdoor sensor is supplied by HTP Inc with this boiler This boiler does not include a standing pilot
68. aptor NOTE To prevent combustion air contamination see Table 2 in this section when considering exhaust vent and intake pipe termination Exhaust vent and intake pipe must terminate near each other and vented vertically through the roof Venting methods are detailed in the Venting Section Do not attempt installation using any other means Be sure to locate the boiler so exhaust vent and intake pipe can be routed through the building and properly terminated The exhaust vent and intake piping lengths routing and termination method must all comply with methods and limits given in the venting section F PREVENT COMBUSTION AIR CONTAMINATION Install intake piping for the boiler as described in the Venting section Do not terminate exhaust in locations that can allow contamination of intake air PRODUCTS TO AVOID AREAS LIKELY TO HAVE CONTAMINANTS Spray cans containing fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric or acid Furniture refinishing areas and establishments Cemen
69. at may block the condensate line WARNING Do not install the condensate assembly if a component is lost or missing Replace the entire assembly Failure to follow this warning could result in property damage serious personal injury or death 2 NOTE The installer should fill the condensate trap with tap water prior to assembly on the boiler 3 Slide the condensate trap adapter onto the drain tube until the holes line up with the groove 4 Insert stainless steel lock pin to lock condensate adapter to the drain tube 5 Connect the clear hose from the pressure switch to the hose barb WARNING Do not operate the boiler without the clear hose attached from the hose barb to the pressure switch Failure to follow this warning could result in property damage serious personal injury or death NOTE The use of 24 PVC or CPVC pipe are acceptable materials for condensate piping However use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement If pipe is used deburr and chamfer pipe to allow proper mating to the drainage assembly 5 Run condensate drain hose to 1 PVC or CPVC drain pipe See Figure 16 NOTE DO NOT cement drain hose to the PVC drainage pipe NOTE To allow for prope
70. at the outlet water temperature has reached 210 the boiler is put into a hard lockout and requires manual reset to restart Installers should review the regulations of the AHJ local and state code authorities and utility companies which pertain to this type of boiler BEFORE performing installation TABLE OF CONTENTS PART 1 GENERAL SAFETY 8 A PREGAUTIONS 5 teni e iate n qe dime rp t v Eon e ea red 8 B IMPROPER 5 lt ECHO bep eds 8 d ate b aeter d e E e E S CR ae See a 8 D WEHEN SERVICING THE BOIBER siint tele e cc nete dette ned tae ate S 8 E BOILER SYSTEM keane Sie ee eee geben UG e aes det eene 8 F BOILER WATER CHEMISTRY ge eoa denn ed m d nter 9 G FREEZE PROTECTION FLEUIDS ob EEUU EDGE 9 PART 2 BEFORE YOU START 10 A WHAT SIN THE BOX uicti ceret ates ene ed e c eerte ce n e ae Tb D d ck a lr Ye dC o 10 5 tee iav en e i bali eine nC RF e 10 OPTIONAL EQUIPMENT ntt det tea en iia ide pete ie ca eiae err 11 PART 3 PREPARE BOILER LOCATION 11 A BEFORE LOCATING THE BOILER sist nice ocd e ER c ns 11
71. ater chemistry on both the domestic hot water and central heating sides are checked before installing the boiler as water quality will affect the reliability of the system Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other imbalance IS NOT covered by the warranty To assure good extended service life it is recommended that you test your water quality prior to installation Listed below are some guidelines WARNING Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Sodium less than 20 mGL Water pH between 6 and 8 1 Maintain boiler water pH between 6 and 8 Check with litmus paper or have chemically analyzed by water treatment company 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 100 ppm 1 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm 2 Do not use the boiler to directly heat swimming pool or spa water 3 Do not fill boiler or ope
72. ator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 26 Elite FT Primary Secondary Piping with Pumps amp DHW Priority Outdoor Reset All EFT Models TT LEUTE LLL HELL LLL TTT UCT COC CCC gt lt 9 22 D LTS O 4 make up water x E Ay D nm spaced tees purging valves _anti scald mixing valve outdoor temperature sensor Super Stor Ultra indirect DHW Tank Figure 12 Primary Secondary Boiler Piping Pumps and DHW Priority Outdoor Reset NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a SuperStor indirect water heater is 1 5 The minimum pipe size for connecting an EFT 55 80 110 1
73. ay indicates the amount of hours the burner has been on for domestic hot water demand GOOD 1X in the life of the boiler The second line indicates how many times the burner has successfully ignited in the life of the boiler Press the V key once SYS CH ON Oh SYS DWH ON Oh This screen displays how many hours the boiler has run to meet central heat and DWH demand Table 23 Boiler Control Status Menu Screens The following 10 screens display the last ten boiler lockout faults The faults are displayed from most recent to oldest by pressing the V key SCREEN DESCRIPTION Press the V key once FAULT HISTORY 1 This screen displays the last lockout fault the boiler controller had The top line will alternate between the words FAULT HISTORY and the actual fault encountered The bottom line displays the date and time the fault 07 27 2009 Mo 5 19A occurred Press the V key once FAULT HISTORY 2 This screen displays the second oldest lockout fault that occurred in the boiler controller The top line will 28 2 Fr 519A alternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display 08 28 2009 r 5 19 the date and time that the fault occurred Press the V key once FAULT HISTORY 3 This screen displays the third oldest lockout fault that occurred in the boiler controller The top line will alternate 08 28 2009 Fr 5 19A between t
74. boiler a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor e Locate or protect the boiler so it cannot be damaged by a moving vehicle WARNING For closet or alcove installations a two pipe venting system must be used Failure to follow this warning could result in substantial property damage severe personal injury or death WARNING The space must be provided with correctly sized combustion ventilation air openings for all other boilers located in the space with the boiler Do not install the boiler in an attic Failure to comply with these warnings could result in substantial property damage severe personal injury or death NOTE For installations using room air for combustion refer to the boiler venting section Part 6 in this manual E EXHAUST VENT AND INTAKE PIPE WARNING Vent pipes must be properly supported The boiler exhaust and intake connections are not designed to carry heavy weight Vent support brackets must be within 1 of the boiler and the balance at 4 intervals Venting must be readily accessible for visual inspection for the first 3 from the boiler The boiler is rated ANSI Z21 13 Category IV pressurized vent likely to form condensate in the vent and requires a special vent System designed for pressurized venting You must also install air intake piping from outdoors to the boiler flue ad
75. bon monoxide detectors shouid bo installed outside pach sleeping aren Never operato the heater unless it is vented tho outdoors DANGER Failure to follow all instructions can result in flue gas spillage and carbon Analyze the entire vent monoxide emissions causing severe personal injury or death sure that condensate trapped in a section of vent C pipe and du therefore reduce the open cross When removing an existing boiler the following steps must be followed sectional area of the vent 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch to Figure 3 CO Warning Label 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 common venting system and other spaces in the building Turn on clothes dryers and any boilers not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum speed Do not operate a summer exhaust fan Close all fireplace dampers 4 Place in operation the boiler being inspected Follow the lighting instructions Adjust the thermostat so the boiler will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candl
76. bove boiler address 4 is not communicating When a boiler in the system is firing its address number will alternate with a to signify it is firing The bottom line shows the status of system pump output contacts Press the V key once This screen shows the overall cascade power output The range of this value is the number of boilers CASCADE PWR 10096 communicating with the Master x 100 For example if 8 boilers are connected and communicating the PRESENT 01234567 maximum cascade power is 80096 The second line shows which boiler addresses are communicating with the Master Press the V key once CASCADE SYST 118 F This screen shows the current system temperature sensor reading on the top line and the cascade system CASCADE SET 190 F temperature setting on the bottom Press the V key once BOILER 0 100 This screen shows the current cascade power demand output on a per connected boiler basis for boilers BOILER 1 56 addressed as 0 and 1 In the screen above boiler 0 is being commanded to fire at 100 and boiler 1 at 56 If this were a 2 boiler system the CASCADE PWR screen above would read 156 Press the V key once BOILER 2 0 This screen shows the current cascade power demand output on per connected boiler basis for boilers BOILER 3 096 addressed as 2 and 3 Press the V key once BOILER 4 0 This screen shows the current cascade power demand output per connected
77. by hand 2 BEFORE OPERATING smell all around the boiler area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any boiler Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department Turn off gas shutoff valve located outside of the boiler so that the handle is crosswise to the gas pipe If the handle will not turn by hand don t try to force or repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 4 Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been damaged 5 The boiler shall be installed so the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service circulator replacement condensate trap control replacement etc Failure to follow these instructions could result in property damage serious personal injury or death WARNING 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 immedia
78. call the fire department Installation and service must be provided by a qualified installer service agency or the gas supplier ron YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped f you cannot reach your gas supplier call the fire with an ignition device which automatically lights the department burner Do not try to light the burner by hand Use only your hand to turn the gas control knob B BEFORE OPERATING smell all around the appliance Never use tools If the handle will not turn by hand area for gas Be sure to smell next to the floor don t try to repair it call a qualified service technician because some gas is heavier than air and will settle on Force or attempted repair may result in a fire or the floor explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Immediately call a qualified service technician Do not try to light any appliance to inspect the appliance and to replace any part of the control system and any gas control which has been Do not touch any electric switch under water do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions oceano INSTRUCTIONS
79. chips are no smaller than 12 to avoid blockage in condensate piping for piping details refer to condensate neutralizer installation instruction 11 Check condensate piping for sagging and or leakage Repair any sags or leaks before restoring power to the boiler CAUTION It is very important that the condensate piping be no smaller than 72 To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched 77 per foot to allow for proper drainage CAUTION The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condensate can exit from the tee resulting in potential water damage to property 12 If the boiler has a condensate pump ensure the pump operates properly before considering maintenance complete EFT 55 80 110 PARTS BREAKDOWN Pp aci DESCRIPTION 7100P 140 GAS LINE w WASHER PART DESCRIPTION 7600P 102 AIR INLET ASSEMBLY 7450P 115 FIBER WASHER FLEXIBLE GAS LINE 7600P 010 7600P 087 7350P 021 BURNER w GASKET EFT 55 80 IONIZATION ELECTRODE w GASKET SCREWS IGNITOR w GASKET SCREWS 7450P 022 5 VENTURI w FIBER WASHER 7450P 141 6 12MM SCREWS VENTURI 7500P 195 COMBUSTION BLOWER w GASKET 7600P 077 7600P 07
80. ction 24 Cascade Rotation CASCADE ROTATION Sets the amount of hours before the first boiler in the cascade firing rotation will be changed NOTE If this parameter is 48 HOURS 24 set to 0 the firing order of the boilers will not rotate Default 48 hours Range 0 240 hours Function 25 Cascade DHW Mode NOT USED Not used on this product NOT USED 25 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 40 F 104 F Function 27 Error System Sensor ERROR SYSTEM SENS Allows the user to set the control to display an error message if the system sensor is open or shorted NOTE This ON 27 error does not stop the boiler or boilers from running Factory Default ON Range ON OFF Function 28 Freeze Protection FREEZE PROTECTION Allows the user to set freeze protection on the boiler Factory Default ON Range ON OFF ON 28 Function 29 DHW Modulation Mode DHW MODULATE MODE NORMAL MOD 29 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 s
81. ctions 17 Figure 4 Pallet with Mounting Bracket Affixed Figure 5 Boiler Mounted to Bracket B WALL MOUNTING CONSIDERATIONS These boilers are wall mounted Use only the wall mounting instructions included in this manual Ensure the wall that the boiler is intended to be mounted on is comprised of cement brick block or wooden studs spaced 16 apart from center Ensure the wall is capable of supporting at least 250 Ibs 115 kg for EFT 55 110 models 300 Ibs 136 kg for EFT 155 285 models and 500 Ibs 227 kg for EFT 399 If flooding is possible elevate the boiler to prevent floodwater from reaching the boiler Ensure the boiler is installed in a location that minimizes the risk of water damage due to leaking valves pumps unions etc WARNING The mounting location must be capable of carrying the weight of the boiler and its related components If the mounting location cannot support a minimum of 250 108 115 kg it is recommended to locate the boiler in a mounting location that can support the minimum weight Failure to comply with the above and properly mount the boiler could result in substantial property damage severe personal injury or death C WALL MOUNTING INSTRUCTIONS WARNING This boiler is too heavy for one person to lift It is highly recommended to install the boiler with two people Use caution as to not drop the boiler which could damage the boiler and cause pro
82. d Condensate Removal E EXHAUST VENT AND INTAKE PIPE SIZING 1 The exhaust vent and intake pipes are 3 for EFT 55 80 110 155 199 285 models and 4 for the EFT 399 2 The total equivalent length of exhaust vent and intake pipe should not exceed 200 feet for all models EXCEPT the EFT 285 Total equivalent length for the EFT 285 should not exceed 150 feet a The equivalent length of friction loss in elbows tees and other fittings are listed in Table 11 FRICTION LOSS EQUIVALENT FOR STAINLESS OR PLASTIC PIPING AND FITTINGS FITTING DESCRIPTION 3 4 90 elbow short radius 5 5 90 elbow long radius 4 4 45 elbow 3 3 Coupling 0 0 Tee intake only 0 0 V Series Vent Kit 1 1 AL20 4C Vent Terminal 1 1 Pipe All Materials 1 1 Table 11 Friction loss for long radius elbow is 1 less NOTE Consult Polypropylene venting instructions for friction loss and pressure drop equivalents 40 b For example If the 3 exhaust vent has two short 90 elbows and 10 feet of PVC pipe we will calculate Exhaust Vent Equivalent Length NOTE EXTENDED VENT 2x5 10 20 feet RUNS WHEN TRANSITIONING TO A LARGER DIAMETER Further if the 3 intake pipe has two short 90 elbows one 45 elbow Hi BON 10 feet of PVC pipe the following calculation applies Intake Pipe TO PREVENT CONDENSATE Equivalent Length 2x
83. d machinery 8 Due to potential moisture build up sidewall venting may not be the preferred venting option To save time and cost carefully consider venting installation and location 9 Horizontal lengths of exhaust vent must slope back towards the boiler not less than per foot to allow condensate to drain from the vent pipe 10 The exhaust vent must terminate where vapors cannot make accidental contact with people or pets or damage shrubs or plants 11 In vacant chimney applications install and seal a rain cap over existing chimney openings 12 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 13 Do not use the boiler to support any piping 14 A screened straight coupling is provided with the boiler for use as an outside exhaust termination 15 A screened inlet air tee is provided with the boiler to be used as an outside intake termination The following information on Table 12 lists optional exhaust intake terminations available from HTP DESCRIPTION STOCK CODE 3 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0601CVT 3 POLYPRO VENT KIT 8400P 001 3 STAINLESS STEEL TERMINATION KIT V1000 4 STAINLESS STEEL TERMINATION KIT V2000 Table 12 41 G DIAGRAMS FOR SIDEWALL VENTING SIDEWALL VENTING WITH TEE INTAKE SIDEWALL VENTING WITH KIT AND COUPLING EXHAUST zi 2 EXHAUST EXHAUST STRAIGHT CO
84. d put safe operation at risk Ensure that the boiler installation location adheres to the information included in this manual Failure to do so could result in property damage serious personal injury or death CAUTION Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty 1 Installation Area Mechanical Room Operating Conditions e Ensure ambient temperatures are higher than 32 F 0 C and lower than 104 F 40 C e Preventthe air from becoming contaminated by the products places and conditions listed in this manual Part 3 Section F e Avoid continuously high levels of humidity 12 e Never close existing ventilation openings CAUTION The service life of the boiler s exposed metallic surfaces such as the casing as well as internal surfaces such as the heat exchanger are directly influenced by proximity to damp and salty marine environments In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other boiler components In these environments boilers must not be installed using direct vent systems which draw outdoor air for combustion Such boilers must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized WARNING This boiler is certified for indoor ins
85. d to the desired value C OPERATING INSTRUCTIONS Before operating the boiler it is important to remove the cover and verify that the gas line and water lines are connected to boiler and fully purged If you smell gas STOP Follow the safety instructions listed in the first part of this section If you do not smell gas follow the next steps 1 Turn down the thermostats before applying power to the boiler If 0 10 volt or other inputs are used make sure that they are set so there is no call for heat while programming 2 Turn on the power to the boiler or boilers if a cascade system used 3 Next check the boiler settings Adjustment and factory defaults are outlined within this section If a cascade system is used it is important that all the boilers have the same boiler settings 4 Next check the system settings Adjustments and factory defaults are outlined within this section If a cascade system is used it is important that the Master Boiler is programmed with the correct system settings 5 Create a demand on the boiler or boilers if a cascade system is used The user can monitor system functions when the boilers are operational 6 If the boilers fail to start refer to the troubleshooting section in the back of this manual D PROGRAMMING BOILER SETTINGS Boiler Setting Program Access NOTE Programming the boiler control is not possible when the boiler is firing Make sure any input which can create a demand on the boile
86. der boiler piping and installation when determining boiler location B LEVELING CAUTION In order for the condensate to properly flow out of the collection system the boiler must be installed level The location must also support the boiler when it is full of water C CLEARANCES FOR SERVICE ACCESS See Figure 1 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the boiler without removing it from the space 13 24 000 FRONT CLEARANCE SIDE CLEARANCE SIDE CLEARANCE LP 387 Q 09 19 11 Figure 1 Required Clearances A WARNING Space must be provided with combustion ventilation air openings correctly sized for all other boilers located in the same space as the boiler The boiler cover must be securely fastened to prevent it from drawing air from the mechanical room This is particularly important if the boiler is in a room with other boilers Failure to comply with the above warnings could result in substantial property damage severe personal injury or death CAUTION Always take future maintenance into consideration when locating the boiler If the boiler is located in an installation location with limited clearances it may be necessary to remove the boiler from the space to perform maintenance Failure to consider maintenance when determining installation location could result in proper
87. dicates that the flue sensor tem perature is excessive and above 210 F When this code is displayed the boiler will not respond to a demand for heat When the flue temperature decreases below 194 F the display will return to normal and allow the boiler to respond to a heat demand The bottom line indicates the status of the pump The pump will remain off when this error is displayed Check the flue for obstructions or any sign of damage especially signs of excessive heat Repair as necessary Run the boiler and check the flue temperature with an external thermometer If the flue temperature on the thermometer does not agree with the flue temperature displayed in the status menu inspect the wiring to the flue temperature sensor in the boiler and repair as necessary If the wiring is intact replace the flue sensor If the flue temperature is excessive on the status menu and the test thermometer reads the same check and adjust combustion controls on the boiler If the problem persists inspect the target wall in the combustion chamber and replace it if cracked or damaged Blocking Code E19 LINE VOLTAGE PUMP OFF E19 This display indicates that the line voltage fre quency is out of range This could happen if the boiler is being powered from a small gasoline powered generator that is not functioning cor rectly or overloaded Inspect power wiring to boiler and repair as necessary If connected to line voltage notify th
88. e This boiler is designed and shipped to assure the highest efficiency operation possible Such high efficiency is achieved by limiting heating circuit water temperature to 140 when there is no anticipated heat load based upon the outdoor sensor and the Outdoor Reset Curve sensor response curve in the boiler software e This feature may be over ridden as described below in specific installations e boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems for systems with total input of 300 000 BTU hr or greater See statement below for an important notice on the use of the override In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE e external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil
89. e correct value Use the lt gt arrow keys to select the next digit to change and again use the A keys to change the value Repeat until the correct code is entered Press the ENTER key to accept the code entered If the code is correct the readout will change to the appropriate screen If the programming code is not accepted the readout will continue to display as shown above The ENTER key is also used to enable a function for editing After the user navigates to the desired function the user would hold down the ENTER key for one second When the ENTER key is released the function value will begin to blink The function can now be changed using the Y A ARROW keys After the new value is displayed the user then presses the ENTER key for 1 second to lock the new value of the function in The value will then stop blinking LEFT AND RIGHT ARROW KEYS are used to navigate between the default display status display analog and cascade dis plays if they are enabled The 4 gt keys are also used in programming modes to change between the programmable functions It is recommended you use the Menu Maps in the back of this manual and the detailed menu instructions printed in this section to help in menu navigation UP AND DOWN ARROW KEYS Y A are used to navigate between the various functions displayed in the menu After the function is enabled for editing by pushing the ENTER key the V A keys are used to adjust the function upward or downwar
90. e or smoke from a cigarette 6 After it has been determined that each boiler remaining connected to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas burning boiler to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 PART 4 PREPARE BOILER WARNING UNCRATING BOILER 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 A REMOVE THE BOILER FROM PACKAGING Remove all sides of the shipping crate and the wooden block that holds the boiler in place during shipping Slide the boiler from the mounting bracket which is affixed to the skid Figure 4 and 5 Remove the mounting bracket from the crate Figure 5 Take care to place the boiler in a safe location prior to installation to prevent damage to the mechanical conne
91. e power company If connected to an alternate power source such as generator or inverter make sure the line voltage frequency supplied by the device is 60 Hz Table 28 Fault and Blocking Code Screens 78 Outdoor Sensor 7250P 319 Supply Temperature Sensor 7250P 324 Outside Temperature F Resistance ohms Boiler Sensor 7250P 667 Indirect Sensor 7250P 325 12999 ps 76m 5980 4550 32 O 299 2200 89 1896 8 Mme 3 9 Table 29 PART 14 MAINTENANCE A MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the boiler The installer must also inform the owner that a lack of proper care and maintenance of the boiler may result in a hazardous condition 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 the manual Failure to do so could result in death or serious injury 79 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 Inte
92. e 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 o SUPPLY 122 F measured by the supply sensor is displayed on the bottom line Press the V key once CH DEMAND OFF This screen displays the central heat demand set for the cascade system BOILER Press the V key once 0 1 0 SIGNL Shows if 0 10 volt is enabled Press the V key once CAS SET 1909 NOTE This screen will appear only when in Master Boiler mode SYSTEM 112 F This screen displays the cascade set point maximum 190 F on the top line The system sensor value reading is on the second line The control will cascade the boilers up to this set point depending on demand 70 Press the V key once DHW SET 119 F DHW 117 F This screen displays the domestic hot water temperature set point on the top line The actual temperature measured by the tank or return line sensor HTP 7250P 325 is displayed on the bottom line If a mechanical aquastat is used in place of the recommended sensor the second line will display OFF in place of the temperature if the aquastat measures close to its set temperature or ON in place of the temperature if the aquastat temperature is too low Press the V key once OUTDOOR 11 F The current outdoor temperature is displayed
93. ed Function 18 Step Modulation Mode STEP MODULATE MODE Allows the user to turn ON the step modulation which regulates burner output in six steps at one minute intervals Step modulation will start at the last modulation rate of the boiler and work up one minute at a time Default OFF Selection ON 18 OFF or ON Function 19 Boiler DHW Temp BOILER SUPPLY DHW Allows the user to program the boiler supply water temperature to the indirect heat exchanger during a demand cycle 180 F 19 Default 180 F Range 119 F to 190 F Function 20 Water Safety Input WATER SAFETY INPUT WATER PRESSURE 20 The user can select various water safety inputs used in the boiler system Default Flow Switch Range None Low Water Cut off Flow Switch Water Pressure Function 21 Error Outdoor Sensor ERROR OUTD SENSOR OFF 21 Allows the user to set the control to display an error message if an outdoor sensor is open or shorted NOTE This error does not stop the boiler from running Factory Default OFF Range ON OFF PHOEN ON Function 22 Adjust Boiler Output ADJ BOILER OUTPUT 100 22 Allows the user to adjust the boiler output down from 100 to 50 Factory Default 100 Range 100 50 68 Function 23 Cascade Mode CASCADE MODE Allows the user to select cascade mode Factory Default Vision 3 Range 926 Boilers Vision 3 VISION 3 23 Fun
94. ed 5 Repeat this procedure for additional zones one at a time 32 CAUTION For installations that incorporate standing iron radiation and systems with manual vents at the high points follow the previous section and starting with the nearest manual air vent open the vent until water flows out Then close the vent Repeat the procedure working your way toward the furthest air vent It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present Annual cleaning of the strainer may be necessary Upon completion make sure that the fill valve and zone valves are in automatic positions You must also assure the purge and shut off valves are in open positions L GLYCOL ANTIFREEZE SOLUTIONS e Glycol in hydronic applications should include inhibitors that prevent the glycol from attacking metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level e glycol solution should be tested at least once a year as recommended by the glycol manufacturer e 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 396 over the same temperature rise Allowances must be made in system design for expansion A30 mixture of glycol will result in a BTU output loss of 15 with a 5 increase
95. em Sensor Part 7250P 324 e Indirect Tank Sensor Part 7250P 325 Concentric Vent Kit Part KGAVT0601CVT 3 Stainless Steel Outside Termination Vent Kit Part V1000 4 Stainless Steel Outside Termination Vent Kit Part V2000 6 Stainless Steel Outside Termination Vent Kit Part V3000 3 Polypro Vent Kit Part 8400P 001 3 Polypro Pipe 33 length Part 8400P 002 49 5 length Part 8400P 003 e U L 353 Compliant Low Water Cut Off Interface Kit with Manual Reset Part 7600P 104 for EFT 55 80 110 7600P 990 for all other models e Alarm System Part 7350P 602 to monitor any failure e PC Connection Kit Part 7250P 320 e Condensate Neutralizer Part 7450P 212 e Condensate Removal Pump Part 554200 e Flow Switch Kit Part 7450P 213 e Vision II Part 7250P 322 These additional options may be purchased through your HTP distributor PART 3 BOILER LOCATION CAUTION Carefully consider installation when determining boiler location Please read the entire manual before attempting installation Failure to properly take factors such as boiler venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury A BEFORE LOCATING THE BOILER WARNING Incorrect ambient conditions can lead to damage to the heating system an
96. ere 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 F11 PUMP ON There is flame when the control is not telling the boiler to run The red light will display and the word LOCKOUT will flash This code indicates a serious safety issue The boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display During this lockout fault the pump will be on as indicated on the second line of the display 1 Look into window If there is flame turn the gas off to the boiler at the service valve and replace the gas valve 2 If the flame signal on the status menu is greater than 1 0 when the burner is not lit replace the spark igniter and the flame rectification probe 3 If the flame return sensor is not present after turning off the gas supply check the gas valve electrical connection 4 Repair condensate system as necessary If condensate has backed up and partially filled the combustion chamber the refractory wall may be damaged and should be replaced 5 Turn the gas on at the service valve after correct
97. erify through ohms reading FINAL INSPECTION Check list Verify that you have completed entire check list WARNING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Homeowner Review what you have done with the homeowner TECH SIGN OFF Table 31 Continue annual maintenance beyond the 4 year as required 88 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts the installer or service agent shall be a plumber gas fitter licensed by the Commonwealth When installed in the Commonwealth of Massachusetts or where applicable state codes may apply the unit shall be installed with a CO detector per the requirements listed below 5 08 Modifications to NFPA 54 Chapter 10 1 Revise NFPA 54 section 10 5 4 2 by adding a second exception as follows Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed and shall be equipped with a manually reset device that will automatically shut off the gas to the burner in the event of a sustained 2 Revise 10 8 3 by adding the following additional requirements For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust ve
98. ers of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 25 Elite FT Primary Secondary Piping with Zone Valves amp DHW Priority Outdoor Reset All EFT Models zone valves EA D lt 9 make up water closely differential spaced pressure tees bypass CD 7 valve purging valves anti scald mixing valve outdoor IRR RR RRR LER RRR ELE EE EE temperature sensor 1 mmuamamuumamumuumumuue Super Stor Ultra indirect DHW Tank Figure 11 Primary Secondary Boiler Piping Zone Valves and DHW Priority Outdoor Reset NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a SuperStor indirect water heater is 1 5 The minimum pipe size for connecting an EFT 55 80 110 1 EFT 155 199 285 1 25 EFT 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circul
99. ese cables are readily available at any office supply computer electronic department or discount home supply store in varying lengths If you possess the skills you can also construct custom length cables 3 It is recommended to use the shortest length cable that will reach between the boilers and create a neat installation Do not run unprotected cables across the floor where they may become wet or damaged Avoid running communication cables parallel and close to or against high voltage 120 volt or greater wiring HTP recommends that the maximum length of communication bus cables not exceed 200 feet 4 Route the communication cables through one of the knockouts in the cabinet 5 Connect the boilers in a daisy chain configuration as shown below It is best to wire the boilers using the shortest wire runs rather than trying to wire them in the order that they are addressed The communication bus jacks on the customer connection panel are interchangeable so you can use either one or both in any order to connect the cable M Figure 32 LP 387 W If you have connected the boilers to each other properly there will be no open communication connection ports Cascade Bus Cascade Bus Remove Cascade Bus Move Cascade Bus Termination Plug Termination Plug Termination Plug Termination Plug to J4 Stand Alone Cascade Master Intermediate Final Cascade Boiler Cascade Follower Follower Figure 33
100. essure This code resets automatically after the high pressure condition is resolved The sec ond line indicates the status of the pump 1 Assure that the flue is not blocked 2 Check the switch wiring by applying a jumper in place of the Switch If the code clears with the jumper in place REPLACE the flue switch and connect the wires to the new switch BEFORE running boiler WARNING Do not use jumper to remedy an FLU error Faulty switch MUST be replaced Failure to do so could result in serious injury or death Fault Code LOU 24 VOLT LOW 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 shorts to ground 1 Check line voltage It must be between 100 and 128 volts 2 If available connect PC and using HTP service software check the 24v supply display in the lower left corner of the screen The number displayed here must be greater than 128 and should be no greater than 250 Use this as a troubleshooting guide as you follow the steps below 3 Remove the 10 pin Molex connector from customer connection board If the message clears then the problem is with the external sensor wiring Examine the external sensor wiring for shorts
101. for 21 additional requirements If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle Chilled water medium must be piped in parallel with and isolated from the boiler Freeze protection for new or existing systems must use glycol that is specifically formulated for this purpose Antifreeze must include inhibitors that will prevent the glycol from attacking the metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level The System should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping Example 50 by volume glycol solution expands 4 8 in volume for a temperature increase from 32 F to 180 F while water expands 3 with the same temperature rise G PIPING DETAILS CAUTION Mixing valves are required for the protection of low temperature loops PRESSURE RELIEF VALVE TEMPERATURE PRESSURE GAUGE INLET OUTLET TOP LP 387 OO0 10 04 12 BALL VALVE TEMPERATURE PRESSURE PRESSURE GAUGE RELIEF VALVE BOILER DRAIN INLET AUTOMATIC AIR VENT
102. g in substantial property damage e not use homemade cures or boiler patent medicines Substantial property damage damage to boiler and or serious personal injury may result e Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen from make up water can cause internal corrosion in System components Leaks in the boiler or piping must be repaired at once F BOILER WATER CHEMISTRY e Sodium less than 20mGL e Water pH between 6 and 8 o Maintain water pH between 6 and 8 Check with litmus paper or have it chemically analyzed by water treatment company o Ifthe pH differs from above consult local water treatment company for treatment needed e Hardness less than 7 grains o Consult local water treatment companies for unusually hard water areas above 7 grains hardness e Chlorine concentration less than 100 ppm o Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm o connect the boiler to directly heat swimming pool or spa water o Do not fill boiler or operate with water containing chlorine in excess of 100 ppm NOTE It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in Part 13 Section B of this manual
103. he words FAULT HISTORY and the actual fault encountered if one has occurred The bottom line displays the date and time a fault occurred Press the V key once FAULT HISTORY 4 This screen displays the fourth oldest lockout fault that occurred in the boiler controller The top line will alternate between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the 08 28 2009 Fr 5 19A fault occurred Press the V key once FAULT HISTORY 5 This screen displays the fifth oldest lockout fault that occurred in the boiler controller The top line will alternate between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the 08 28 2009 Fr 5 19A fault occurred Press the V key once FAULT HISTORY 6 This screen displays the sixth oldest lockout fault that occurred in the boiler controller The top line will alternate between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the 08 28 2009 Fr 5 19A fault occurred Press the V key once FAULT HISTORY 7 This screen displays the seventh oldest lockout fault that occurred in the boiler controller The top line will 08 28 2009 Fr 5 19A alternate between the words FAULT HISTORY and the fault encountered The bottom line displays the date Bu and time the fault occurred Press the V key once FAULT HISTORY 8 This screen displays the eighth oldest lockout fault that occu
104. hort cycling when a large boiler and small indirect tank are used together Factory Default NORMAL MOD Range NORMAL MOD LOW MOD Function 30 Extra Boiler Mode EXTRA BOILER MODE Allows for a non HTP boiler to be controlled when the cascade output has risen above the percent of the cascade firing OFF 30 rate set in this parameter Factory Default Off Range 50 100 Function 31 System Sensor Mode SYSTEM SENSOR MODE Suppresses the NO FOLLOWER message on the display if the boiler is used as a cascade master boiler with no OFF 31 follower boilers connected Factory Default OFF Range ON OFF Function 32 Service Schedule Allows the user to select a service date or time based on the boiler run hours to program the boiler maintenance Tuc schedule Factory Default OFF Range Date or Run Hours NOTE Without setting this function Functions 33 34 35 36 will not display Table 20 System Setting Menu Screens NOTE For the following functions you must have your maintenance function turned on To change press ENTER The left most digit will begin to blink Use the up A or down arrows to change the digit Use the 4 gt arrow keys to switch between digits When you ve made your selection press ENTER again SCREEN DESCRIPTION Function 33 Year SERVICE SCHEDULE YEAR 00 00 2000 33 Allows the user to set the year of the next service reminder Hours SERVICE SCHEDULE 1
105. hut down the Boiler by using the following steps a Turn off power to the boiler Turn thermostats down to ensure there is no call for heat or disconnect thermostat connections from terminals Close the gas valve inside the boiler cabinet Wait for the boiler to be cool to the touch b Disconnect the wires plugged into the fan spark electrode flame rod and gas valve c Disconnect the flexible gas lines from the venture attached to the fan d Loosen the nuts that hold the burner plate to the heat exchanger e Remove the combustion assembly f Spray water or solution into the combustion assembly and monitor the flow through the combustion system g Liquid should flow freely through each tube If there is an obstruction increase the flow on the tube to force blockage out h Once complete reinstall combustion assembly with gaskets and secure nuts Tighten properly i Reconnect all wire and piping connections Once connected apply power and disconnect the wire harness with the white blue red black wires to run fan and dry combustion assembly Let fan run for five minutes When finished reconnect harness to the fan j Connect the thermostat wires to the field connection board or turn up thermostat to fire the combustion system Check for leaks in the combustion system Observe operation for 5 to 10 minutes If boiler is operating properly condensate is flowing normally and no gas leaks are detected combustion coil cleaning is complete
106. iler has a lockout condition The alarm output of boilers addressed as 2 7 will only activate an alarm if a lockout condition occurs on that specific boiler NOTE See Figure 34 for Cascade Master and Follower Wiring detail 58 MOVE RESISTOR PLUG HERE IN FINAL CASCADED BOILER REMOVE RESISTOR PLUG TO RESISTOR PLUG WIRE INTERMEDIATE CASCADE INSTALLED HERE FOLLOWERS CASCADE MASTER CASCADE FOLLOWER CATS iL CAT 5 CONNECTION POINTS T3 CAT 5 CONNECTION POINTS 0710 YOU O O O O 0 10 m J4 INPUT CASCADE BUS ZONE CONTROL ONLY CASCADE BUS ZONE CONTROL ONLY TH FACTORY SET TO FACTORY SET TO 0 10 g 0 10 2 0 10V ds THERMOSTAT THERMOSTAT MM OUTDOOR SEN OUTDOOR SEN OUTDOOR SEN FROM OPTIONAL DHW SENSOR SYSTEM SM 00000 00000 cr SENSOR SAS Walviv 19 1 00 ANG 6 SAS Naviv SYSTEM 5 AMP RELAY PUMP PWR SYSTEM PUMP E EX BOILER CND OPTIONAL V 4 BOILER HOT BOILER GND BOILER __ BOILER NEUT M HH GROUND 120 VOLTS LINE VOLTAGE GREEN GROUND GREEN GROUND WHITE NEUTRAL WHITE NEUTRAL BLACK HOT BLACK HOT UNE VOLTAGE z LINE VOLTAGE IN 120 VAC IN 120 cno did X71106 13 24 gt
107. in head against the system circulator A 50 mixture of glycol will result in a BTU output loss of 30 with a 50 increase in head against the system circulator WARNING 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 5090 CAUTION It is highly recommended to carefully follow the glycol manufacturer s recommended concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer coefficients M ZONING WITH ZONE VALVES 1 When zoning with zone valves connect the boiler to the system as shown in Piping Details Part 5 Section G The primary secondary piping shown ensures the boiler loop will have sufficient flow It also avoids applying the high head of the boiler circulator to the zone valves 2 Connect DHW domestic hot water piping to indirect storage water heater as shown in Piping Details N ZONING WITH CIRCULATORS 1 When using circulator zoning connect the boiler to the system as shown in Piping Details Part 5 Section G NOTE The boiler circulator cannot be used for a zone It must only supply the boiler loop 2 Install a separate circulator for each zone 3
108. in this This screen shows that there is a problem with the system sensor circuit The circuit PUMP OFF SYS SUPPLY SENSOR E03 could be open or shorted Possible reasons for this error are There is no system sensor connected to the Master Boiler The system sensor is faulty There is a short circuit in the system sensor wiring possibly from a staple placed through the wire or damage to the wire causing both conductors to touch The system sensor wiring is open due to defect or damage manual to see if it corresponds to the temperature of the sensor If the resistance does not agree with the sensor replace the sensor If the sensor is OK disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter Repair or replace as necessary If this error is present all boilers in the cascaded group will run and ignite simultaneously when there is a heat demand Each boiler will modulate to maintain set point temperature on its own supply sensor This code will reset automatically when repair is complete This code will not display if system setting function ERROR SYSTEM SENS is set to OFF 74 Fault Code TT Temperature Blocking TT Demand TEMPER BLOCKING PUMP ON TT This screen indicates a temporary hold on the burner There is a demand on the boiler the pump is powered on but the temperature of the water at the supply sensor is too high for the boiler to ign
109. ingly and only to the male threads Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the boiler WARNING Failure to apply pipe sealing compound as detailed above could result in substantial property damage severe personal injury or death CAUTION CSA UL listed flexible gas connections can be used when installing the boiler Flexible gas connections have different capacities and must be sized correctly for the connected boiler firing rates Consult with the flex line supplier to assure the line size is adequate for the job Follow local codes for proper installation and service requirements WARNING Never use an open flame match or lighter to check for gas leaks Use a soapy solution to test connection Failure to use a soapy solution test or check gas connection for leaks could result in substantial property damage severe personal injury or death CAUTION Use a two wrench method when tightening gas piping near the boiler and its piping connection One wrench to prevent the boiler gas line connection from turning the second to tighten the adjacent piping Failure to support the boiler gas piping connection could damage the boiler beyond repair Such damage IS NOT covered by warranty C CHECK INLET GAS PRESSURE The gas valve is equipped with an inlet gas pressure tap that can be used to measure the gas pressure
110. injury or death D BOILER GAS VALVE NOTE IF FOR ANY REASON THE THROTILE NEEDS TO BE ADJUSTED IT IF 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 THROTTLE ADJUSTER GAS OUTLET GAS OUTLET PRESSURE GAS VALVE OFFSET ADJUSTMENT CAUTION DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW WITHOUT A COMBUSTION ANALYZER GAS INLET_ Y PRESSURE TAP GAS INLET LP 387 U 09 19 11 Figure 29 Gas Valve Detail DA Do not a gas conversion this boiler without an officially approved conversion kit and instructions supplied by Failure to use conversion kit when converting the boiler to fire on Natural or LP gas will result in dangerous burner operation leading to fire explosion severe injury or death WARNING Strain on the gas valve and fittings may result in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death WARNING Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion an
111. intakes then a space of 36 to the next set of vents Note There must be a minimum of 35 spacing between every 2 kit grouping Figure 14 NOTE Drawing is meant to demonstrate system venting ONLY D EXHAUST VENT AND INTAKE PIPE LOCATION NOTE SEE ADDITIONAL REQUIREMENTS FOR MASSACHUSETTS IN THE BACK OF THIS MANUAL 1 Determine exhaust vent location e Total length of vent may not exceed the limits specified in Part 6 The vent piping for this boiler is approved for zero clearance to combustible construction See Venting Details within this section of clearances for location of exit terminals of direct vent venting systems Avoid terminating exhaust vents near shrubs air conditioners or other objects that will obstruct the exhaust stream The flue products coming from the exhaust vent will create a large plume when the boiler is in operation Avoid venting in areas that will affect neighboring buildings or be considered objectionable The boiler vent system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 m e Provide 6 feet of clearance from the inside corner of vertical walls chimneys etc as well as horizontal corners created by roof overhangs 2 Determine intake pipe location e Provide 1 foot of clearance from the bottom of the intake pipe and the level of maximum snow accumulation Snow removal may be necessary to maintain clearances e Do locate the intake pipe in a parking
112. iod a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified LP 172 REV 02 16 06 89 3 SIGNAGE metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS the following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 The equipment listed in Chapter 10 entitled Equipment Not Required to be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residenti
113. ion H OUTDOOR SENSOH NOTE RESISTOR PLUG INSTALLED HERE BOILER CONTROL e 0 10 INPUT E BUS ZONE CONTROL ONLY THER 3 SENSOR 0 10 gy ete SEN 2 DHW SENSOR sensor ALAR LOWLNOD AUC 5 DHW GND 2w Narr fg ow Hor Bower cmo BOLERY BOWLER neur X Pon rE GREEN GROUND WHITE NEUTRAL BLACK HUT LINE VOLTAGE IN 120 VAC ALTERNATE CONNECTION FOR PUMPS GREATER THAN 3 AMPS 120 ALTERNATE CONNECTION FOR PUMPS GREATER THAN 3 AMPS 120 PUMP MOTOR Figure 31 Boiler Control If the system requires a fixed operating temperature the outdoor sensor is not required and should not be installed There is no connection required if an outdoor sensor is not used in the installation 1 Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet 5 5 1 iL CAT 5 CONNECTION POINTS Q J4 FACTORY SET TO dnd 331108 13 did 23 PUMP MOTOR 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 55 NOTE For correct mounting procedures follow instructions provided with the sensor NO
114. ion plug is included in the CAT 3 CAT 5 Bus Connection Point labeled J3 in Figure 23 DO NOT REMOVE THIS PLUG Doing so will affect boiler operation and void warranty 1 Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V Neutral Ground shown in Figure 31 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 31 to the terminals marked 1 HOT 2 NEUT and 3 54 GND The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts If the pump requires more current or voltage than the 120 volts supplied an external motor starter or contactor will be required E ALARM CONNECTIONS The control includes a dry contact alarm output This is an SPDT circuit rated at 5 amps at 120 volts This contact can be used to activate an alarm light or bell or notify a building management system if the boiler goes into a lockout condition The circuit between the ALARM COM and NC terminals is closed during normal operation and the circuit between ALARM COM and NO is open during normal operation The connections depicted in Figure 31 show two 120 volt lights connected to the alarm terminals One light will be on when the boiler is in normal mode and the other light will be on when the boiler is in lockout mode
115. ior to turning the gas on all gas connections must be approved by the local gas supplier or utility in addition to the governing authority GAS LINE GAS LINE A gas conversion kit comes with the boiler Follow the included instructions VERY carefully Failure to follow gas conversion instructions could result in property damage serious injury or death SEDIMENT TRAP LJ NOTE SEDIMENT TRAP MUST BE INSTALLED AS SHOWN Figure 28 Gas Line WARNING Do not attempt to support the weight of gas piping with the boiler or its accessories The gas valve and blower will not support the weight of the piping Failure to follow this warning could result in substantial property damage severe personal injury or death The gas connection on the boiler is 3 4 It is mandatory that Gas Table this fitting is used for connection to a field fabricated drip leg as 2 Nominal shown in the illustration above per the National Fuel Gas Code iron Pipe Internal Length of Pipe Feet You must ensure that the entire gas line to the connection at Size Diameter the boiler is no smaller than the boiler supplied connection finches inches 10 20 30 4 5 6 70 3 4 824 278 190 152 130 115 105 596 BTU S Once all inspections have been performed the piping must be 1 1 049 520 350 285 245 215 195 180 PER leak tested If the leak te
116. isting vent system is utilized for the combustion air source Two methods have been approved for such venting Concentric Venting and Venting as a Chase Do not install the boiler into a common existing vent with any other boiler This will cause flue gas spillage or boiler malfunction resulting in substantial property damage severe personal injury or death CAUTION Contractors must check state and local codes before installing through an existing vent opening State and local codes always take precedence over manufacturer s instructions Failure to check state and local codes before installing through an existing opening could result in property damage and add significantly to installation costs 1 CONCENTRIC VENTING Concentric venting must run vertically through the roof See Section E Venting Section for proper minimum vent sizing Use only the approved venting materials specified in Table 10 for piping the system All instructions listed in Part 6 Venting apply See Figures 24 1 and 24 2 for venting demonstrations DA R The upper and lower vent terminations as well all joints in the venting system must be properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system Failure to properly seal the venting system will result in property damage severe personal injury or death FLUE EXHAUST j FLUE EXHAUST COMBUSTION AIR I
117. ite This occurs because the water tempera ture measured by the supply sensor is higher than the boiler temperature ignition diff setting This error will clear itself when the water temperature measured by the supply sensor is less than the boiler temperature ignition diff setting Fault Code DHW Temperature Blocking DHW Demand TEMPER BLOCKING PUMP ON DHW This display indicates a temporary hold on the burner There is a demand on the boiler from the DHW circuit for heat the pump is powered on but the boiler supply sensor indicates that the water temperature is too high to ignite This is a temporary hold on the burner only and all other functions will remain functioning properly This error will clear itself when either the boiler supply temperature drops below the BOILER SUPPLY minus boiler supply differential 52 or DHW SETPOINT is satisfied and no longer calls for heat Fault Code PRO LOW WATER PRESS PUMP OFF PRO This display indicates that there is low water pressure in the boiler This code will reset automatically after the water pressure is high enough for the boiler to run safely The second line indicates the status of the pump Note that while the water pressure is low the pump will be off 1 Assure that the system pressure is above 10 psig 2 Check for leaks in the system piping Fault Code FLU HIGH FLUE PRESS FLU PUMP ON This display indicates that there is excessive flue pr
118. ive action is taken 6 If the refractory wall falls against the rectifier probe it may conduct the signal to ground giving a false reading Fault Code F13 FAN SPEED ERROR F13 PUMP ON The fan is not running at the speed that the con trol 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 sec onds The red light will display and the word LOCKOUT will flash This code indicates a serious safety issue and the boiler will not restart until the cause is determined by a technician and he pushes the RESET button on the display During this lockout fault the pump will be on as indicated on the second line 1 Check the combustion air fan wiring 2 Measure the DC voltage from the red fan wire to ground while it is connected to the fan It should be between 24 to 40 volts If it is lower than 24 volts check for excessive external loads connected to the boiler sensor terminals Disconnect the 5 pin plug from the fan and check the voltage on the red wire again If it is now between 24 40 volts replace the fan If it is still below 24 volts replace the boiler control board SCREEN DESCRIPTION POSSIBLE REMEDY Fault Code F20 CONDENSATE FULL F20 PUMP ON The condensate trap is full The red light will display and the word LOCKOUT will flash This code indicates a serious safety issue The boiler will not restart until the cause is dete
119. ll be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a SuperStor indirect water heater is 1 5 The minimum pipe size for connecting an EFT 55 80 110 1 EFT 155 199 285 1 25 EFT 399 1 5 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Piping shown is Primary Secondary System flow secondary loop must be greater than the boiler s primary loop flow 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 VERY IMPORTANT Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling 29 H PIPING INSTALLATION CAUTION This boiler should not be operated as a potable hot water heater It should not be used as a direct hot water heating device Basic steps are listed below that will guide you through the installation of the boiler 1 Connect the system return marked Boiler Return 2 Connect the system supply marked Boiler Supply 3 Install a purge and balance valve or shut off valve and drain on the system return to purge air out of each zone 4 Install a back flow preventer on the cold feed make up water line 5 Install a pressure reduci
120. lligently delivers hydronic heating while maximizing efficiency Outlined below are the features of the system and how they operate Stainless Steel Heat Exchanger The highly efficient stainless steel heat exchanger is designed to extract all available heat from the supply line before it is exhausted Modulating Combustion System The combustion system will modulate the output of the burner during operation to match the system demand and achieve the control set point while in operation The set point can change by internal or external signals which enhance the overall performance of the system Control The integrated control system monitors the system and regulates fan speed to control boiler output This allows the boiler to deliver only the amount of heat energy required and nothing more The control can be set up to monitor outdoor temperature through an outdoor sensor to regulate boiler set point The system can be further enhanced by installing an indirect water heater to provide domestic hot water The control can regulate the output of multiple boilers through its cascade system function The cascade system is capable of connecting up to eight boilers together in such a way that they function as one boiler system This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize efficiency The cascade system works by establishing one boiler as the master
121. llower boiler you are working on c Enter the system settings following instructions in Part 11 of this manual 64 d Set the Cascade Address parameter 15 to 1 for the first follower 2 for the second follower etc depending on which boiler you are programming e Change CASCADE parameter to 926 BOILER This makes the boiler a follower and enables all data to be transferred between boilers as needed for the system to function to full capability f Exit the system menu NOTE For the system to operate properly the temperature set point of the follower must match that of the master boiler J LOCKOUT CONDITION If any boilers including the master boiler in the cascade system are in a lockout condition the master control will recognize the lockout condition and skip over the boiler in the firing sequence Each boiler in the cascade system is responsible for its own safety functions So if any individual boiler control senses an unsafe condition it will extinguish the burner and if necessary go to a lockout condition In this way every boiler in the system has its individual safety controls intact and operational even if the firing of the boiler is under control of the master boiler PART 10 START UP PROCEDURE WARNING 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
122. low CAUTION If using a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage CAUTION It is very important that the condensate piping be no smaller than To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched 74 per foot to allow for proper drainage CAUTION The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condensate can exit from the tee resulting in potential water damage to property 39 EXHAUST PIPING AROUND OBSTRUCTIONS SUGGESTED SETUP FOR PIPING AROUND BEAMS IN ORDER TO ELIMINATE CONDENSATION PIPING llb M M BUILDING STRUCTURE PIPING LENGTH DETERMINED BY DISTANCE NEEDED TO CLEAR BEAM I TUBING MUST FORM A LOOP 6 IN DIAMETER 3 4 CLEAR FLEXIBLE TUBING 1 x 3 4 PVC PIPE 3 4 HOSE REDUCER BARB 3 4 PVC PIPE SWEAT CONNECTIONS 11 4 11 THROUGHOUT 7 TO t HORIZONTAL LINES PIPING SUPPORTS MUST BE INSTALLED WITH A PITCH OF 1 4 PER FOOT N1100 CONDENSATE NEUTRALIZER Figure 17 Piping Exhaust around Obstructions Suggeste
123. manifold feeding these 5 boilers you would need a pipe size of 2 MULTIPLE BOILER MANIFOLD PIPING Maximum Flow Rate GPM at 3 feet per second 8 14 19 31 5 45 69 93 120 150 188 271 Schedule 40 Pipe Diameter Inches 1 1 1 2 2h 3 35 4 4 5 6 Table 7 J CHECK CONTROL WATER CHEMISTRY NOTE BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY Sodium less than 20 mGL Water pH between 6 and 8 1 Maintain boiler water pH between 6 and 8 Check with litmus paper or have chemically analyzed by water treatment company 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 100 ppm 1 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm 2 Do not use the boiler to directly heat swimming pool or spa water 3 Do not fill boiler or operate with water containing chlorine in excess of 100 ppm 31 ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS cm at 25 C CHLORIDE Less than 100 ppm IRON Less than 0 5 mg L COPPER Less than 0 1 mg L SODIUM Less than 20 mg L HARDNESS Less than 7 Grains Table 8 Water Quality Requirements Clean system to remove sediment 1 Y
124. ng valve on the cold feed make up water line 15 psi nominal on the system return This boiler has a maximum working pressure of 160 psi You may order a higher pressure relief valve kit from the factory Check temperature and pressure gauge when operating It should read a minimum pressure of 12 psi 6 Install a circulator as shown in piping details this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the system supply see Part 5 Section D for water volume Consult the expansion tank manufacturer s instructions for specific information relating to expansion tank installation Size the expansion tank for the required system volume and capacity 8 Install an air elimination device on the system supply 9 Install a drain valve at the lowest point of the system NOTE The boiler cannot be drained completely of water without purging the boiler with an air pressure of 15 psi 10 The relief valve and temperature and pressure gauge are included in the boiler accessory kit A pipe discharge line should be installed 6 above the drain in the event of pressure relief The pipe size must be the same size as the relief valve outlet NEVER BLOCK THE OUTLET OF THE SAFETY RELIEF VALVE I CIRCULATOR SIZING The heat exchanger has a pressure drop that must be considered in your system design Refer to Table 4 for pressure drop through the heat exchanger EFT Pressure Drop Curves
125. nt termination is less than seven 7 feet above finished grade in the area of the venting including but not limited decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the respohsibility of the property owner to secure the service of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day per
126. ntent DO NOT exceed a 50 50 ratio of antifreeze to water 2 NOTE Local codes may require back flow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level D FILL AND TEST WATER SYSTEM WARNING Ensure the boiler is full of water before firing the burner Failure to do so will damage the boiler Such damage IS NOT covered by warranty and could result in property damage severe personal injury or death 1 Fill the system only after ensuring water chemistry meets the requirements listed in this manual 2 Close the manual and automatic air vents and boiler drain valve 3 Fill to the correct system pressure Correct pressure will vary with each application a Typical cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Operating pressure of the system should never exceed 25 psi and must never exceed the relief valve pressure setting 4 At initial fill and during boiler startup and testing check system thoroughly for leaks Repair all leaks before proceeding further WARNING Eliminate all system leaks Continual fresh make up water will reduce boiler life Minerals can build u
127. o 185 F 119 F DHW DIFF SET POINT Function Adjusts the indirect tank differential set point Default 7 F Range 1 F to 30 F 7 F TEMP DISPLAY C ORF Function Adjusts the temperature measurement F Fahrenheit to C Celsius Default is Fahrenheit Table 17 Boiler Setting Screen Descriptions Clock Settings NOTE The clock will reset if the boiler is powered off for more than a week SCREEN DESCRIPTION CLOCK MODE 12 24 Function Changes the clock from 12 hour mode 8 45 PM to 24 hour mode 20 45 To change to 24 hour mode 28 2 Fr 9 42A 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 08 28 2009 r9 will disappear Press the ENTER key to save the new setting CLOCK HOUR Function Allows the user to adjust the hour setting 08 28 2009 Fr 10 01A CLOCK MINUTE Function Adjusts the minute setting 08 28 2009 Fr 10 01A CLOCK DAY OF WEEK Function Adjusts the day of week 08 28 2009 Fr 10 01A CLOCK DATE MODE Function Allows the user to switch to European date format 2009 08 28 from US format 08 28 2009 08 28 2009 Fr 10 01A CLOCK YEAR Function Adjusts the year setting 08 28 2009 Fr 10 01A CLOCK MONTH Function Adjusts the month setting 08 28 2009 Fr 10 01A CLOCK DATE The clock is set 08 28 2009 Fr 10 01A Table 18 Clock Setting Screens
128. ombustion 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 Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sufficient combustion air based on the boiler input Never obstruct the supply of combustion air to the boiler If the boiler is installed in areas where indoor air is contaminated see Table 3 it is imperative that the boiler be installed as direct vent so that all combustion air is taken directly from the outdoors into the boiler intake connection Unconfined space is space with volume not less than 50 cubic f i h DO NOT PLACE feet per 1 000 Btu hour 4 8 cubic meters per kW of the tota DRYER IN PROXIMITY input rating of all fuel burning boilers installed in that space TO WATER HEATER Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space is space with volume less than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning boilers installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space When drawing combustion air from inside a con
129. 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 FLUE 95 F ON in place of the temperature The second line displays the current flue temperature of the boiler Press the V key once FLAME 0 0uA FAN SPEED 3497 RPM This screen displays the boiler flame current on the top line The second line displays the fan speed in the boiler Press the V key once 0 10 V 0 0 V 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 Press the V key once 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 multiple coiler configuration is the Master Boiler and other boilers are connected to the communication bus and powered this screen will show the address of each boiler connected to the bus Press the V key once POWER ON OH The top line of this display indicates the amount of hours the boiler has had power applied to it over its life The CH ON OH second line indicates how many hours the burner has been on for central heat demand over its life Press the V key once DHW ON The top line of this displ
130. onsignee CAUTION Due to the low water content of the boiler improper sizing of the boiler with regard to heating system load will result in excessive cycling and accelerated component failure HTP DOES NOT warrant failures caused by improperly sized boiler applications DO NOT oversize the boiler to the system Modular boiler installations greatly reduce the likelihood of boiler oversizing B IMPROPER COMBUSTION WARNING Do not obstruct the flow of combustion and ventilating air Adequate air must be provided for safe operation Failure to keep the vent and combustion air intake clear of ice snow or other debris could result in property damage serious personal injury or death C GAS Should overheating or gas supply fail to shut off do not turn off or disconnect electrical supply to the circulator Instead shut off the gas supply at a location external to the boiler D WHEN SERVICING THE BOILER e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool E BOILER SYSTEM e Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment HTP recommends a suction strainer in all systems e Do not use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged possibly resultin
131. ou must thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 For zoned systems flush each zone separately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system 3 Flush system until water runs clean and you are sure piping is free of sediment NOTE It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section Part 14 of this manual Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer instructions Piping components Heating system piping Water boiler system piping MUST be sized per technical pipe requirements listed in Tables 4 through 7 Reducing pipe size can restrict flow rate through the water boiler causing inadvertent short cycling and poor system performance Check valves Field supplied Check valves are recommended for installation as shown in Piping Details Water boiler isolation valves Field supplied Full port ball valves are required F
132. p in the heat exchanger reducing heat transfer overheating the heat exchanger causing heat exchanger failure and possibly resulting in property damage severe personal injury or death 62 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 CAUTION It is important to purge the system of air to avoid damage to the boiler E PURGE AIR FROM WATER SYSTEM CAUTION IMPORTANT While commissioning the system the air vent on top of the boiler must remain fully open to allow the boiler to properly fill Failure to keep the air vent open could lead to improper boiler and system operation To purge air from the system a Connect a hose to the purge valve and route hose to an area where water can drain and be seen b Close the boiler or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water make up line e Open purge valve f Open the isolation valves one zone at a time Allow water to run through the zone pushing out the air Run water until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remo
133. perty damage and or severe personal injury Verify that the boiler is properly and securely mounted before leaving unsupervised Failure to comply with the above and properly mount the boiler could result in substantial property damage severe personal injury or death LEVEL LINE Sie 88 AR BRACKET MUST BE MOUNTED ON AT LEAST 2 STUCS Figure 6 Wall Mounting Bracket NOTE Drawing for Demonstration Purposes ONLY WARNING This wall mounting system is not seismic rated and should not be applied as such Failure to comply with the above and properly mount the boiler could result in substantial property damage severe personal injury or death WARNING DO NOT use the bolts included in shipping for wall mounting the boiler Doing so may result in property damage serious injury or death 1 MOUNTING TO A WOOD STUDDED WALL The building frame studs must be 2 X 4 minimum and 16 on center 24 on the EFT 399 If not you must use minimum plywood 24 x 48 with at least fourteen 14 12 x 3 3 16 x 3 round head tapping screws to the frame of the building to provide proper support for the boiler No alternate methods of mounting or fastening ex Toggle bolts hollow wall anchors or any other fastener may be used 18 b The provided mounting bracket must be mounted directly to the center of at least 2 studs using standard steel or stainless steel 74 x 2 V lag bol
134. piping to a safe disposal location following the guidelines on the following page WARNING To avoid water damage or scalding due to relief valve operation e Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge e Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length e Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible e Discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater e Do not pipe discharge to any location where freezing could occur No shutoff valve may be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line e the operation of the relief valve after filling and pressurizing the system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve Test relief valve at least once annually to ensure the waterway is clear If valve does not operate turn the boiler off and call a plumber immediately care whenever operating relief valve to avoid scalding injury o
135. pliance or equipment at the completion of the installation LP 172 REV 02 16 06 MAINTENANCE NOTES 90 91 HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim After reading the important notes at the bottom of the page please also sign this document Customer s Name Installation Address Date of Installation Installers Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installers Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please contact your HTP Sales Hepresentative Distributor Dealer Please insert contact details LP 387 REV 5 23 13
136. r such as the tank thermostat is turned off so the boiler will remain idle to allow programming SCREEN DESCRIPTION ENTER MENU CODE To access the boiler setting program press and hold the ENTER Key for 4 seconds until the display shows the screen 000 at left ENTER MENU CODE Using the arrow keys log in the Boiler Menu Access Code 600 To confirm the code press ENTER to access 600 Boiler Setting Program navigation menu Table 16 Programming Screens Boiler Setting Program Navigation Once the code is confirmed the user can now start to set the Boiler Settings Use the arrow keys on the display to navigate through the Boiler Setting Program A blinking setting indicates it can be changed To change a setting press the ENTER Key Boiler settings can be increased by pressing the UP ARROW A and decreased by pressing the DOWN ARROW Y on the display When done press ENTER Setting will stop blinking and you can move on to next setting Press RESET to exit programming and store settings Listed below are the boiler settings that can be programmed into the control 66 SCREEN DESCRIPTION CENTRAL HEAT Function Adjusts the boiler set point Default 180 F Range 50 F to 190 F 180 CENTRAL DIFF SET Function Adjusts the boiler differential set point Default 30 F Range 5 F to 30 F 30 F DHW SET POINT Function Adjusts the indirect tank set point Default 119 F Range 70 F t
137. r 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 87 the boiler Installer must also inform the owner that the lack of proper care and maintenance of the boiler may result in a hazardous condition INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING 1 YEAR 2 YEAR 3 YEAR 4 YEAR Near boiler piping Check boiler and system piping for any sign of leakage Continual fresh make up water will reduce boiler life Leaking pipes could cause property damage Make sure all piping is properly supported Vent Check condition of all vent pipes and joints Ensure all vent piping is properly supported Check for obstructions at exhaust and intake termination points Gas Check Gas piping test for leaks and signs of aging Make sure all pipes are properly supported SYSTEM Visual Do a full visual inspection of all system components Functional Test all functions of the system Heat Safeties Temperatures Verify safe settings on boiler or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see
138. r drainage on long horizontal runs a second line vent may be required and tubing size may need to increase to 1 Failure to add a second vacuum break could result in condensate backup improper boiler operation and nuisance shutdowns NOTE See Part 14 this manual for instructions on how to maintain the condensate trap 4 Condensate neutralization Condensate from the boiler is slightly acidic with a pH of 3 2 4 5 To avoid long term damage to the drainage system and to meet local code requirements HTP recommends neutralizing the condensate with a Condensate Neutralizer Kit Part 7450P 212 The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the water vapor The neutralizer kit should be checked annually and the limestone chips replenished if necessary When replacing the limestone chips take care to ensure chips are no smaller than 72 to avoid blockage in condensate piping for piping details refer to condensate neutralizer installation instruction 38 CONDENSATE PIPING CONDENSATE PIPING WITH PUMP SUGGESTED SETUP FOR SUGGESTED SETUP FOR CONDENSATE CONDENSATE REMOVAL REMOVAL TO OUTSIDE SOURCE TO FLOOR DRAIN TO OUTSIDE SOURCE PIPE HANGERS MUST BE USED TO SUPPORT VERTICAL OR HORIZONTAL PIPING RIGID PVC V PIPING 3 4 HOSE BARB PIPE HANGERS
139. r property damage e For boilers installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA4 4 FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH C BACKFLOW PREVENTER Use a backflow preventer specifically designed for hydronic installations This valve should be installed on the cold water fill supply line per local codes see Piping Details Part 5 Section G 20 D SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE UP WATER 1 Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature For sizing information refer to expansion tank manufacturer s sizing guidelines or the latest ASHRAE expansion tank sizing standards WARNING Expansion tanks must be sized according to total system volume This includes all length of pipe all fixtures boilers etc Failure to properly size system expansion could result in wasted time money and possible property damage personal injury or death ADDED VOLUME TO SYSTEM BY ELITE FT BOILER MODEL GALLONS EFT 55 EFT 80 22 110 2 6 155 6 2 199 6 1 285 6 1
140. r soon 73 B BOILER ERROR When an error condition occurs the controller will display a description and code on the display readout These error messages and their recommended corrective actions are described in Section D C BOILER FAULT 1 When a fault condition occurs the controller will illuminate the red FAULT indication light and display a fault message in the screen The alarm output will also activate Most fault conditions cause the CH pump to run in an attempt to cool the boiler 2 Note the fault message displayed and refer to Part D in this section for an explanation of the message along with several suggestions for corrective actions 3 Press the reset key to clear the fault and resume operation Be sure to observe the operation of the boiler for a period of time to assure correct operation and no reoccurrence of fault message WARNING When servicing or replacing any components of this boiler be certain that e The gas is off e electrical power is disconnected When servicing or replacing components that are in direct contact with boiler water be certain that e There is no pressure in the boiler Pull the release on the relief valve Do not depend on the pressure gauge reading e boiler water is not hot e electrical power is disconnected WARNING DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician
141. rate with water containing chlorine in excess of 100 ppm ACIDITY 6 to 8 pH CONDUCTIVITY Less than 400 uS cm at 25 C CHLORIDE Less than 100 ppm IRON Less than 0 5 mg L COPPER Less than 0 1 mg L SODIUM Less than 20 mg L HARDNESS Less than 7 Grains Table 15 Clean system to remove sediment 1 You must thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment 2 For zoned systems flush each zone separately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system 3 Flush system until water runs clean and you are sure piping is free of sediment NOTE It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section Part 14 of this manual 61 Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer instructions NOTE BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY B CHECK FOR GAS LEAKS
142. re through the stud and expanded catching the inside of the stud Tighten the toggle bolt until the mounting bracket is secure Hang boiler on the now wall mounted bracket Be certain that the bracket is engaged before letting the boiler hang free Slowly release the weight of the boiler while ensuring the bracket is properly secure Verify that the boiler is securely mounted before leaving it unsupervised CAUTION If the boiler is not installed upright and level improper and unsatisfactory operation may occur causing excessive condensation build up nuisance fault codes and unnecessary maintenance PART 5 BOILER PIPING WARNING Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage serious injury or death 19 CAUTION Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler Failure to follow this instruction can lead to premature failure of the boiler system Such failures ARE NOT covered by warranty Plumbing of this product should only be done by a qualified licensed plumber in accordance with all local plumbing codes The boiler may be connected to a storage tank to supply domestic hot water HTP offers 60 80 119 175 gallon size storage tanks in either stainless steel or glass lined construction These storage tanks can be directly connected to the boiler supply and retu
143. return sensor temperature cannot be monitored through the boiler display NOTE Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct Reversed polarity could lead to erratic and or no response from the boiler controller K OPTIONAL UL353 LOW WATER CUT OFF INTERFACE KIT If an optional UL 353 Low Water Cut Off LWCO Interface Kit is used the control box of the kit should be mounted to the left side of the boiler cabinet near the low water cut off probe which is located on the outlet nipple of the boiler Follow the complete instructions included in the kit for proper installation NOTE The control system senses system water temperatures entering and exiting the heat exchanger to provide protection against low water conditions Where local codes or jurisdictions do not accept a pressure device for low water protection the jurisdictions may accept these control functions as a means of providing low water protection L WIRING OF CASCADE SYSTEM COMMUNICATION BUS 1 A Cascade Bus Termination Plug has been installed on the customer connection board of this boiler The purpose of this plug is to stabilize communication between multiple boilers and reduce electrical noise See Figures 30 32 and 33 for Cascade Bus Termination Plug installation detail 56 2 Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers Th
144. rmined by a technician and he pushes the RESET button on the display During this lockout fault the pump will be off as indicated on the second line of the display 1 Check condensate lines for obstructions 2 Check wiring from condensate reservoir to 926 control Verify the leads are green and red Repair as necessary 77 Fault Code F31 PROGRAM ERROR F31 There was an error while programming the con trol and the memory is corrupt The boiler control will not function in this state and the pump will be off as indicated on the bottom line This error only occurs if a technician is programming the control and the programming function fails The only way to recover from this error is to repro gram the control If this error occurs at any time other than when a technician is servicing the boiler the control has failed and must be replaced by a qualified technician The control must be re programmed If programming does not solve problem the control must be replaced Fault Code PP CONTROL PROGRAMED PP The control has been programmed by a technician or the factory After programming the control is left in a locked out mode Press the RESET key for at least 1 second to begin use of the control The following blocki ng codes will block operation until the cont rol determines the situation safe for boiler operation Blocking Code E07 FLUE TEMP HIGH E07 PUMP OFF TIME This display in
145. rn connection CAUTION The National Standard Plumbing Code the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum The heat transfer fluid must be water or other non toxic fluid having a toxicity of Class 1 as listed in Clinical Toxicology of Commercial Products 5 Edition A GENERAL PIPING INFORMATION CAUTION The building piping system must meet or exceed the piping requirements in this manual CAUTION Use two wrenches when tightening water piping at the boiler Use one wrench to prevent the boiler return or supply line from turning Failure to prevent piping connections from turning could cause damage to boiler components CAUTION The control module uses temperature sensors to provide both high limit protection and modulating temperature control The control module may also provide low water protection through the addition of an optional kit by sensing the water level in the heat exchanger An optional flow switch may be installed on the supply of the system to activate the boiler when there is enough flow Some codes jurisdictions may require additional external controls NOTE The addition of a high temperature limiting device is important if the boiler is to be connected to a domestic hot water system B RELIEF VALVE Connect discharge
146. rnational 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 e Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website e Wear long sleeved loose fitting clothing gloves and eye protection e Apply enough water to the combustion chamber lining to prevent dust e Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air B COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER Before beginning this procedure you must have on hand the following items e anylon brush e NOTE Do not use a metal brush on the heat exchanger Doing so could scratch the heat exchanger and lead to early boiler failure Such failure IS NOT covered by warranty anFDA approved liquid lime scale remover for use with stainless steel or water in a spray bottle e gloves and eye protection 1 S
147. rred in the boiler controller The top line will 08 28 2009 Fr 519A alternate between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the fault occurred 71 Press the V key once This screen displays the ninth oldest lockout fault that occurred in the boiler controller The top line will alternate FAULT HISTORY 9 between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the 08 28 2009 Fr 5 19 fault Press the V key once FAULT HISTORY 10 This screen displays the tenth oldest lockout fault that occurred in the boiler controller The top line will alternate 08 28 2009 Fr 5 19A between the words FAULT HISTORY and the fault encountered The bottom line displays the date and time the fault occurred Table 24 Fault History Screens B CASCADE MENU This menu is accessed by pressing the 4 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 This screen will alternate with the default screen every 5 seconds or it can be accessed by pressing the 4 key from the default screen CAS
148. s NOTE To avoid contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors gure that condensate trapped in a section of vent pipe and therefore reduce the open cross sectonal area of the vent Broathing carbon monoxide can cause brain damage death Always read and understand Instruction manual A DANGER Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death WARNING Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent is properly beveled and seated before insertion into the flue adapter Failure to do so could result in property damage severe personal injury or death DA Due to the extreme flammability of most glues cements solvents primers used to join plastic exhaust and intake pipes explosive solvent vapors must be cleared from all vent piping before start up Avoid using excess cement or primer as this may pool in the vent pipes Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance Failure to follow these instructions will result in substantial property damage severe personal injury or death It is the installers responsibility to understand the hazards associated with explosive solvents and take
149. s door of the boiler NOTE The switch temperature must be less than 90 F to reset Press the reset button on the display Run the boiler and check the flue temperature by using both an external thermometer in the flue pipe and the flue temperature display in the status screens If the flue temperature is within specs and the switch trips replace the switch If the flue temperature is excessive check and adjust combustion controls on the boiler If the problem persists inspect the target wall in the combustion chamber and replace it if cracked or damaged 75 Fault Code F02 SUPPLY SENSOR F02 PUMP ON Indicates that the supply temperature sensor of the boiler has failed This is a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display This situation is indicated by the red light on the display and the flashing word LOCKOUT During this lockout fault the pump will be on as indicated on the second line of the display 1 Check the electrical connection to the thermistor on the outlet manifold Verify 5 VDC by checking in Molex connector If there is no 5 VDC check the harness If harness is OK replace control NOTE The boiler will reset automatically Verify thermistor values by referencing chart in this manual 2 Replace thermistor if necessary Fault Code F03 RETURN SENSOR PUMP ON This display indicates that the
150. s piping must be sized for the proper flow and length of pipe to avoid pressure drop The gas meter and regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 w c 87 kPa the meter regulator or gas line may be undersized or in need of service You can attach a manometer to the incoming gas drip leg after removing the cap The gas pressure must remain between 3 5 87 kPa and 14 3 5 kPa during stand by static mode and while in operating dynamic mode If an in line high gas pressure regulator is used it must be installed a minimum of 10 feet from the boiler It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition failure This problem is especially noticeable in NEW LP installations and empty tank situations This situation can also occur when a utility company shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with a conventional gas valve under any circumstances 52 WARNING 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
151. s recommended if the DHW temperature is set above the factory setting of 119 F 8 Piping shown is Standard VERY IMPORTANT Minimum flow rates outlined in the manual must be maintained to minimize short cycling 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators Elite FT Standard Piping with Pumps amp DHW Priority Single Temp EFT 50 amp EFT 80 Only MUERE ELE EVER LEER AH EE DUE LEE UE make up water purging valves anti scald mixing valve Super Stor Ultra indirect DHW Tank Figure 10 Standard Piping with Pumps and DHW Priority NOTES 1 This drawing is meant to show system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a SuperStor indirect water heater is 1 5 The minimum pipe size for connecting an EFT 55 or 80 1 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with circulator flanges as an alternative 7 A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Piping shown is Standard 9 Install a minimum of 12 diamet
152. st requirement is a higher test pres 11 4 1 380 1 050 730 590 500 440 400 370 HOUR sure than the maximum inlet pressure you must isolate the 11 2 1610 1 600 1 100 890 760 6 0 610 560 1 000 boiler from the gas line In order to do this shut the gas off Nominal using factory and field installed gas cocks This will prevent Iron Pipe Internal Length of Pipe Feet high pressure Failure to do so may damage the gas valve inches 80 56 100 125 150 175 200 3 4 824 90 84 79 72 64 59 55 8 In the event the gas valve is exposed to a pressure greater 1 049 170 160 150 130 120 110 100 PER than PSI 14 w c 3 5 kPa the gas valve must be 11 4 1 380 350 320 305 275 250 225 210 HOUR replaced Never use an open flame match lighter etc to 11 2 1 610 530 490 460 410 380 350 320 4 x1 000 check gas connections B GAS PIPING Table 14 Gas Pipe Sizing BTU s per Hour 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 51 4 It is important to support gas piping as the boiler is not designed to structurally support a large amount of weight 5 Purge all gas lines thoroughly to avoid start up issues with air in the lines 6 Sealing compound pipe dope must be used and approved for gas connections Apply spar
153. tailing required by BOILER local codes ROOM OPENING LP 387 X 09 29 11 EXHAUST VENT OUTDOOR COMBUSTION AIR SINGLE PIPE NOTE This drawing is meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes BOILER LP 387 Y 09 29 11 LOWER AIR DUCT Figure 27 1 27 2 NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes 50 PART 7 GAS PIPING WARNING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE EXPLOSION OR DEATH GAS LINE CONNECTION 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 FRONT OF BOILER NOTE Maximum inlet gas pressure must not exceed 14 w c 3 5 kPa NOTE Installer must supply trap to meet local code requirements It is very important that you are connected to the type of gas noted on the rating plate LP for liquefied petroleum propane gas or for natural or city gas You must not do a gas conversion without an approved gas conversion kit Pr
154. tallations 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 e 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 WARNING 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 the boiler is to replace an existing boiler check for and correct any existing system problems such as System leaks Location that could cause the system and boiler to freeze and leak Incorrectly sized expansion tank 6 Clean and flush system when reinstalling a boiler NOTE When installing in a zero clearance location it may not be possible to read or view some product labeling It is recommended to make note of the boiler model and serial number WARNING Gas conversion should be performed BEFORE the boiler is installed Carefully follow the gas conversion instructions when performing the conversion Failure to do so could result in property damage severe personal injury or death CAUTION Consi
155. ted material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air C REQUIREMENTS FOR INSTALLATION IN CANADA 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe from the boiler flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings Cellular foam core piping may be used on air inlet piping only 35 You must not use B vent in an exhaust application B vent is for intake applications ONLY Using B vent in an exhaust application will result in serious injury or death Location of exit terminals of mechanical draft and direct vent venting systems Reference National Fuel Gas Code ANSI 2223 1 54 2002 In Canada refer to CAN CSA B149 1 for vent terminal location DIRECT VENT IF A IS LESS THAN TERMINATION 10 FT THEN IS TO BE 3 FT MINIMUM FORCED AIR INLET 12 MIN Multiple Vents 10 to 6 10 to 6ft Multiple Vent Spacing Note Exhaust must extend out 1 foot There should be no more than 2 vents and 2
156. tely Do not start the boiler again until the leak is repaired Failure to comply could result in substantial property damage severe personal injury or death A CONTROL OVERVIEW The control is one of the primary safety devices of the boiler It monitors the safety sensors of the boiler to assure safe and efficient operation The control has many features associated with system design This section addresses programming features including Boiler Settings System Settings Maintenance Settings and System Diagnostics to help in customizing your control It is important to fully understand control capabilities before customization as its factory defaults may already fit your system design and not require any adjustment at all B NAVIGATION OF THE DISPLAY The display includes a two line backlit LCD readout to provide informative messages about the operation of the boiler Many operating parameters can be viewed and adjusted by using the six buttons on the display The function of each button is described below 65 RESET The RESET button has two functions ENTER MENU CODE Resets any lockout error code 000 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 One of the zeroes will be blinking Use the A V arrow keys to change the blinking digit to th
157. tes an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE is used to address practices not related to personal injury FOREWORD This manual is intended to be used in conjunction with other literature provided with the boiler This includes all related control information It is important that this manual all other documents included with this system and additional publications including the National Fuel Gas Code ANSI Z223 1 2002 be reviewed in their entirety before beginning any work Installation should be made in accordance with the regulations of the Authority Having Jurisdiction local code authorities and utility companies which pertain to this type of water heating equipment Authority Having Jurisdiction AHJ The Authority Having Jurisdiction may be a federal state local government or individual such as a fire chief fire marshal chief of a fire prevention bureau labor department or health department building official
158. that the circuit breaker is clearly labeled Exercise circuit breaker Switch and Plug Verify ON OFF switch and convenience plug are both functional CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Replace any gaskets that show signs of damage Spark Electrode Clean Set gap at 156 See Figure 36 Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate trap and hose Ensure the condensate trap is filled with water Disconnect condensate hose Clean out dirt Fill with water to level of outlet and re install NOTE Verify the flow of condensate making sure that the hose is properly connected during final inspection GAS Pressure Measure incoming gas pressure 3 5 to 14 W C Pressure Drop Measure drop in pressure on light off no more than 1 W C Check gas pipe for leaks Check piping for leaks Verify that all are properly supported COMBUSTION 2 Levels Check CO and 2 levels in Exhaust See Start up Procedures for ranges Record at high and low fire SAFETIES ECO Energy Cut Check continuity on Flue and Water ECO Replace if Out corroded Thermistors Check wiring V
159. the first bracket must be within 1 of the boiler and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler WARNING An unbalanced vent system can be installed ONLY when the exhaust is installed in a vertical position J DIAGRAM FOR VERTICAL VENTING 45 ROOF VENT WITH TEE INTAKE AND COUPLING EXHAUST EXHAUST VENT STRAIGHT COUPLING INTAKE AIR VENT TEE SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING RIGHT SIDE VIEW Figure 23 LP 293 F NOTE Vent piping should be 12 over anticipated maximum snow level NOTE Drawing is meant to demonstrate system venting ONLY r 24 MIN ES 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS GREATER 1 387 5 EXTERIOR WALL 09 19 11 WARNING vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the boiler to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler 46 K VENTING THROUGH AN EXISTING SYSTEM This boiler may be vented through an existing unused vent system The inner diameter of the ex
160. the necessary precautions to avoid these risks 34 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Standards for Installation in ftem United States Canada PVC schedule 40 80 ANSI ASTM D1785 PP CPVC and PVC venting PVC DWV ANSI ASTM D2665 must be ULC S636 Certified CPVC schedule 40 80 ANSI ASTM F441 IPEX is an approved Exhaust vent or Intake pipe manufacturer in Canada and fittings Polypropylene ULCS636 supplying vent material listed to ULC S636 Stainless Steel AL29 4C Certified for Category IV and Certified for Category IV and direct vent appliance venting direct vent appliance venting ANSI ASTM D2564 IPEX System 636 Cements amp pipe cement primer CPVC ANSI ASTM F493 primers Table 10 DA R e exhaust and intake components installed with this boiler must be used for near boiler piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID boiler warranty PVC CPVC pipe and fittings of the same diameter are considered interchangeable Do NOT use Foam Core Pipe in any portion of the exhaust piping from this boiler DO NOT connect PVC CPVC to PP without an approved vent connector When installing AL29 4C vent piping install a PVC to stainless adapter at the boiler vent connection and at the termination when using an
161. ting Section Part 6 and local codes CASCADE SYSTEM 1 If a single boiler is installed skip this section 2 Programming the Master Boiler a Make sure there is no demand for heat being supplied to the boiler b Apply power to the boiler c Enter the system setting program navigation following instructions in Part 11 of this manual d Verify that the cascade address function 15 is set to 0 This sets the Master Boiler s address as 0 NOTE The Master Boiler MUST be addressed as 0 e Change cascade mode function 23 to 926 Boiler This makes it a Master Boiler f Exit the installer menu NOTE In order for the system to operate properly the temperature set point of the master must match the follower boiler set point NOTE READ THE NOTES BELOW BEFORE PROGRAMMING FOLLOWER BOILERS The boiler addressed as 1 will share its alarm output with the master boiler If one of the follower boilers has an indirect fired water heater connected to it the address of this boiler must be 2 or greater It is recommended but not necessary to address boilers in the order that they are wired No two boilers can have the same address It is not required to use all consecutive address numbers Example In a 2 boiler system with an indirect connected to the follower the follower address would be 2 address 1 is not used 3 Programming Follower Boilers a Make sure there is no demand for heat being supplied to the master boiler b Apply power to the fo
162. to the ground repairing as necessary If the message is still present and the boiler is so equipped disconnect the UL 353 low water cut off to see if the message clears Replace the faulty part Check the low voltage wire harness in boiler for 4 If a message only occurs when the burner tries to light check the gas valve for exces sive current draw 5 If a message is present with the low voltage harness disconnected from the 926 control board replace the 926 control board Fault Code F00 WATER HIGH TEMP F00 PUMP ON This display indicates if the water in the boiler has overheated This code indicates a serious safety issue and the boiler will not restart until it cools sufficiently and a technician repairs the cause of overheating and pushes the RESET button on the display This is a serious situation and is indicated by the red light on the display illuminating and the word LOCKOUT flashing on the display During this lockout fault the pump will be on as indicated on the second line in an effort to cool the boiler down 1 Check circulator pump operation 2 If the circulator pump is running be sure that there is water in the system and that the water is moving through the system as intended Be sure that all correct ball valves and or zone valves are open or closed as intended 3 Observe the temperature pressure gauge If the water is not too hot and this message is displayed check the wiring to the water ECO sensor and
163. tors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure Follow the venting instructions below carefully Failure to do so will result in substantial property damage severe personal injury or death 1 Installation should be made in accordance with the regulations of the Authority Having Jurisdiction local code authorities and utility companies which pertain to this type of water heating equipment 2 Install the venting system in accordance with these instructions and with the National Fuel Gas Code ANSI Z223 1 NFPA 54 CAN CGA B149 and or applicable provisions of local building codes 3 This boiler must be vented with materials components and systems listed Do not operate heater flood damaged i Install vont rdance with and approved for Category IV boilers insta de d Tp n Cx lance installation in Do not air intake or exhaust Support all vent piping per manufacturers 4 amp DANGER installation ir Exhaust vent and intake pipes are to be piped separately This boiler Do not place chemical vapor emitting cannot share a common exhaust or intake with multiple appliances Failure products near unit ie j to follow this instruction will result in substantial property damage severe 19 NERA 729 carbon monoida personal injury or death sleeping aren Never Tor the heater uniess it i
164. ts and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Adhesives used to fasten building products Table 2 16 WARNING You must ensure that intake air will not contain any of the contaminants listed in Table 2 For example do not pipe intake vent near a swimming pool Avoid areas subject to exhaust fumes from laundry facilities These areas always contain contaminants Contaminated air will damage the boiler resulting in possible substantial property damage severe personal injury or death NOTE DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY Refer to the limited warranty for complete terms and conditions G REMOVING AN BOILER FROM A COMMON VENT SYSTEM Do not operate heater If flood damaged Install vert system in accordance with local codes and manufacturers 4 DANGER Do nct hes dir tld d Aa ar Thu exhaust 5 rt all vent Do not install the boiler into a common vent with any other boiler This will erre apad piping par cause flue gas spillage or boiler malfunction resulting in possible Do not place chemical vapor emitting substantial property damage severe personal injury or death products nepr umi According to NFPA 720 car
165. ts for all models Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location Ensure the marked holes are located in the center of the building frame studs C For all EFT models 2 72 is the minimum lag bolt length if the bracket is directly on stud Increase lag bolt length for any materials covering the studs d Predrill pilot holes on the marked stud locations The pilot holes for bare studs should be 2 deep for all EFT models See table below for pilot hole diameter by wood type Increase length for any material covering the stud Ensure that the predrilled holes are straight and square to the wall Failure to do so could lead to insufficient support or out of level boiler See Figure 6 NOTE Bolt must embed into the wood structure a minimum of 2 d Using the predrilled holes mount the hanger bracket to the building frame studs using the appropriately sized standard steel or stainless lag bolt Hang boiler on the wall mounted bracket Be sure that the bracket is engaged before letting the boiler hang free Slowly release the weight of the boiler while ensuring that the bracket is properly secured Verify that the boiler is securely mounted before leaving the boiler unsupervised REQUIRED AMOUNT OF BOLTS FOR WALL MOUNTING THE EFT BOILER MODEL AMOUNT OF BOLTS EFT 55 EFT 110 2 EFT 155 EFT 285 4 EFT 399 6 PILOT HOLE SIZE BY WOOD TYPE TYPE DRILL BI
166. ty damage MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS e Hot water pipes at least 1 from combustible materials e Exhaust vent pipe at least 1 from combustible materials 14 SPECIFICATIONS AND DIMENSIONS 3 HEATING MBH MBH 55 ET80 80 17 emio 110 22 SHIPPING WT LBS LP 387 K 11 16 12 HEATING CAP MBH M N o P iss ewm 32 5 8 20 5 8 11 1 8 6 7 8 3 7 8 2 1 4 15 1 4 11 1 8 7 3 4 6 7 8 2 1 4 13 3 8 16 5 8 20 ms sse er ve rave ev vare e sre pe wire s SHIPPING WT LBS 195 LP 387 K2 Figure 2 LP 387 K 15 D RESIDENTIAL GARAGE CLOSET AND ALCOVE INSTALLATIONS CAUTION Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage closet or alcove Please read the entire manual before attempting installation Failure to properly take factors such as boiler venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury PRECAUTIONS If the boiler is located in a residential garage it should be installed per the latest edition of the National Fuel Gas Code ANSI Z223 1 and CGA B149 Installation Code in Canada e Mount the bottom of the
167. ve 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 V and keys simultaneously and hold for 1 second The display will read The central heating pump will come on If you then press the A key the central heating pump will shut off The display will read The DHW pump will come on If the boiler is set up as the cascade master and you press the A key again the DHW pump will shut off The display will read The system pump will come on Use the A and V keys to toggle between running each pump in the system as required to help bleed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet Pressing A and V together at any time will return the boiler to normal operation i After the system has operated for some time eliminate any residual air by using the manual air vents located throughout the System j If purge valves are not installed in the system open manual air vents in the system one at a time beginning with the lowest floor Close vent when water squirts out Repeat with remaining vents
168. ventionally constructed building to a confined space located on the same story such space should be provided with two permanent openings one located 6 15 cm below the space ceiling the other 6 15cm above the space floor Each opening should have a free area of one square inch 1 000 Btu hr 22cm kW of the total input of all boilers in the space but not less than 100 square Figue26 P 367 Z 20 098812 inches 645cm When drawing combustion air from inside conventionally constructed building to confined space located on different stories such spaces should be considered as communicating spaces when connected with or more permanent openings in doors or floors having a total minimum free area of two square inches per 1 000 Btu hr 22cm of the total input of all boilers in the space but not less than 200 square inches 645 If the confined space is within a building of tight construction air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual NOTE It is always recommended to isolate the boiler installation room from the rest of the building and bring uncontaminated air in from the outside for combustion and ventilation 49 EXHAUST VENT INDOOR COMBUSTION AIR SINGLE PIPE ROOM OPENING NOTE This drawing 15 meant to demonstrate system venting only The installer is responsible for equipment and de
169. y scroll to the selection of year or hours Select enter to reset the mode you are in Use the up A or down arrow key for each adjustment then select ENTER when reset is complete PART 11 START UP PROCEDURES FOR INSTALLER CENTRAL HEATING CURVE CENTRAL HEATING CURVE Factory Default Plot your Curve X DEFAULT RESET CURVE FUNCTION 11 SUPPLY OUTLET TEMPERATURE F E lt a H gt a NETIQN 1 5 OUTSIDE TEMPERATURE OUTSIDE TEMPERATURE Table 22 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 gt Once the first value is displayed press the up arrow or down arrow to access additional information At any point you may press the RESET button to exit the status screen Listed below are the status screens SCREEN DESCRIPTION SUPPLY SEN 180 F This screen is displayed after pressing the gt key as described above This shows the actual temperature that RETURN SEN 150 the supply and return sensors 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 V key once CH SET 180 F Th

HTP EFT-399PU Instructions / Assembly

Contents

Download Pdf Manuals

Related Search

Related Contents