HTP EFT-285, EFT-399, EFT-399LP Installation, Start-up, Maintenance, Parts, Warranty

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Installation

Start-Up

Maintenance

Parts

Warranty

Elite FT

Residential and

Commercial Models

EFT-285 / EFT-399* Models Manufactured On or After 10/30/17 with 10:1 Turndown Ratio

* “LP” Denotes Propane Gas Operation

“PU” Denotes Included Pump

Heat Exchanger Bears the ASME “H” Stamp

This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The manufacturer 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.

272 Duchaine Blvd. New Bedford, MA 02745 www.htproducts.com

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WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

• Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re department.

• Installation and service must be provided by a qualied installer, service agency or the gas supplier.

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this manual. Installation and service must be performed by a qualied installer, service agency, or gas supplier.

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The following dened terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious personal injury or death.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state, local government, or individual such as a re chief, re marshal, chief of a re prevention bureau, labor department or health department, building ocial or electrical inspector, or others having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding ocer or departmental ocial may be the AHJ.

NOTE: HTP reserves the right to modify product technical specications and components without prior notice.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in personal injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor personal injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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 in this system, and additional publications including the National Fuel Gas Code - ANSI Z223.1 (latest versions), 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.

For the Installer

This boiler must be installed by qualied and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and by 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, latest version.

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations, and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

In Canada - CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code, C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

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 undergoing tests specied in ANSI Z21.13

- latest edition.

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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.

IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, HTP has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases. These features include:

• A modulating combustion system that adjusts ring rate based on heat demand.

• Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor. The outdoor sensor is supplied by HTP with this boiler.

• This boiler does not include a standing pilot.

• This boiler is designed and shipped to assure the highest eciency operation possible. Such high eciency is achieved by limiting heating circuit water temperature to 140°F when there is no anticipated heat load, based upon the outdoor sensor and the Outdoor Reset Curve (sensor response curve) in the boiler software.

• This feature may be over-ridden as described below in specic installations:

• The boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems (for systems with total input of 300,000 BTU/hr or greater).

See statement below for an important notice on the use of the override.

IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for space heating.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

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 o 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. The temperature control system integrated into the 926 control provided with this heating appliance complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature dierence between the inlet and the outlet sensor, which is aected by boiler water ow. If this temperature dierence exceeds 55°F (typically because of low water ow or very low heat load), the control will reduce the maximum fan speed. If the temperature dierence exceeds 60°F, the control will eectively sense there is little or no water ow or heat load and shut the boiler down. The controller will restart automatically once the temperature dierence has dropped below 55°F and the minimum o time (anti-cycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 210°F, the boiler is put into a hard lockout and requires manual reset to restart.

Table of Contents

Part 1 - General Safety Information 5

A. Improper Combustion 6 B. Gas 6 C. When Servicing the Boiler 6 D. Boiler Water 6 E. Freeze Protection 6 F. High Elevation Installations 6

Part 2 - Before You Start 6

A. What’s in the Box 6 B. How the Boiler Operates 6 C. Optional Equipment 7

Part 3 - Prepare the Boiler 7

A. Locating the Boiler 8 B. Structure 8 C. Leveling 8 D. Clearances for Service Access 9 E. Wall Mounting Considerations 9 F. Wall Mounting Instructions 9

1. Mounting to a Wood Studded Wall 10

2. Mounting to a Metal Frame 10

G. Residential Garage and Closet Installations 10 H. Exhaust Vent and Intake Pipe 10

1. Direct Vent of Exhaust and Intake 11

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space 11

I. Carbon Monoxide Detectors 11 J. Prevent Combustion Air Contamination 11 K. Removing a Boiler from a Common Vent System 12 L. Water Chemistry Requirements* 12 M. Technical Specications 14

Part 4 - Piping 15

A. General Plumbing Information 15 B. Relief Valve 16 C. Backow Preventer 16 D. Potable Expansion Tank 16 E. Circulators 16 F. Hydronic Piping with Circulators, Zone Valves, and Multiple Boilers 16 G. Circulator Sizing 17 H. Check / Control Water Chemistry 19 I. Plumbing 19

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J. Fill and Purge Heating System 19 K. Glycol Antifreeze Solutions 19 L. Zoning with Zone Valves 20 M. Zoning with Circulators 20 N. Multiple Boilers 20 O. Applications* 21

Part 5 - Venting 26

A. General 26 B. Approved Materials for Exhaust Vent and Intake Pipe 27 C. Additional Requirements for Installation in Canada 27 D. Exhaust Vent and Intake Pipe Location 28 E. Exhaust Vent and Intake Pipe Sizing 29 F. Longer Vent Runs 29 G. Exhaust Vent and Intake Pipe Installation 29 H. Applications 30

1. Direct Vent Installation of Exhaust and Intake 30

2. Venting Through an Existing System 32

3. Power Venting, Indoor Combustion Air in Conned or Unconned Space 33

Part 6 - Condensate Removal 35 Part 7 - Wiring 37

A. Installation Must Comply With 37 B. Field Wiring Terminations 37 C. Field Wiring 37 D. Line Voltage Wiring for Standard Boiler 38 E. Alarm Connections 38 F. Low Voltage Connections for Standard Boiler 38 G. Thermostat 38 H. Outdoor Sensor 38 I. Indirect Sensor 38 J. Optional 0-10 Volt Building Control Signal 39 K. Optional UL353 Low Water Cut-O Interface Kit 39 L. Wiring of Cascade System Communication Bus 39 M. Cascade Master Pump and Sensor Wiring 40 N. Cascade Follower Pump and Sensor Wiring 40

Part 8 - Gas Connections 42

A. Gas Piping 42 B. Check Inlet Gas Pressure 43 C. Boiler Gas Valve 44

Part 9 - Start-Up Preparation 44

A. Check / Control Water Chemistry 44 B. Check for Gas Leaks 44 C. Freeze Protection (When Used) 44 D. Fill and Test Water System 45 E. Purge Air from Water System 45 F. Check Thermostat Circuit(s) 45 G. Condensate Removal 45 H. Final Checks Before Starting Boiler 45 I. Setting Up a Single Boiler 46 J. Setting Up a Cascaded System 46 K. Lockout Condition 46 L. Cascade System Programming 46

Part 10 - Start-Up Procedure 47

A. Control Overview 47 B. Navigation of the Display 47 C. Operating Instructions 47 D. Programming Boiler Settings 47 E. Programming the System Setting 48 F. System Setting Program Navigation 48 G. Resetting the Maintenance Schedule 50

Part 11 - Start-Up Procedures for the Installer 51

A. Boiler Control Status Menu 51 B. Cascade Menu 53 C. Boiler Test Mode 53

Part 12 - Troubleshooting 54

A. Boiler Error and Fault Codes 54 B. Boiler Error 54

C. Boiler Fault 54 D. User Interface Display 55

Part 13 - Maintenance 60

A. Procedures 60 B. Combustion Chamber Coil Cleaning Instructions 60 C. Cleaning Water Side of Heat Exchanger 61 D. Maintaining the Condensate System 61

Part 14 - Shutdown 62

A. Shutdown Procedure 62 B. Vacation Procedure 62 C. Failure to Operate 62 D. Important Notice 62

Part 15 - Installation Checklist 63 Part 16 - Maintenance Report 63 Part 17 - Replacement Parts 65

Limited Warranty 67 Maintenance Notes 69 Customer Installation Record Form 70

Part 1 - General Safety Information

This boiler is approved for indoor installations only and is not intended for use as a pool heater. Clearance to combustible materials: 6” top, bottom, sides, and 0” back. Left side has all boiler mechanical connections. Boiler must have room for service: 24” front is minimum recommended service clearance. (A combustible door or removable panel is acceptable front clearance.) This boiler has been approved for closet installation and installation on combustible ooring. Do not install directly on carpeting. Install the boiler in a location where temperature and pressure relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available, install the boiler over a drain pan. Use only Category IV vent systems.

Installer - Read all instructions in this manual before installing. Perform steps in the given order.

User - This manual is for use only by a qualied heating installer / service technician. Have this boiler serviced / inspected annually by a qualied service technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the boiler is exposed to the following, do not operate.

Immediately call a qualied service technician.

1. Fire

2. Damage

3. Water Failure to follow this information could result in property damage, severe personal injury, or death.

NOTE: Obey all local codes. Obtain all applicable permits before installing the boiler.

NOTE: Install all system components and piping in such a manner that does not reduce the performance of any re rated assembly.

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied 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 re 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 ood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Altering any HTP boiler with parts not manufactured by HTP WILL INSTANTLY VOID the boiler warranty and could result in property damage, personal injury, or death.

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exchanger. Such damage IS NOT covered by warranty.

Do not use this boiler for anything other than its intended purpose (as described in this manual). Doing so could result in property damage and WILL VOID product warranty.

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.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this boiler and related components near high heat sources.

A. Improper Combustion

Do not obstruct the ow of combustion and ventilating air. Adequate air is necessary for safe operation. Failure to keep the exhaust vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

E. Freeze Protection

NOTE: Consider piping and installation when determining boiler

location.

Failure of the boiler due to freeze related damage IS NOT covered by product warranty.

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (nonpotable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

F. High Elevation Installations

Natural gas at high elevation might contain less heating value than typical 1,000 BTU/cu ft and therefore can cause improper air / gas mix leading to improper combustion. For natural gas installations above 3,000 ft, call your gas provider to determine the heating value of the supplied natural gas.

Part 2 - Before You Start

B. Gas

Should overheating or gas supply fail to shut o, turn o the manual gas control valve to the boiler.

C. When Servicing the Boiler

Be sure to disconnect electrical power before opening boiler cabinet or performing service. Failure to do so could result in electrical shock, property damage, serious personal injury, or death.

To avoid electric shock, disconnect electrical supply before performing maintenance.

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.

To avoid severe burns, allow boiler and associated equipment to cool before servicing.

D. Boiler Water

• If you have an old system with cast iron radiators, thoroughly ush the system (without boiler connected) to remove sediment. The high-eciency heat exchanger can be damaged by build-up or corrosion due to sediment. HTP recommends a suction strainer in this type of system.

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”. Substantial property damage, damage to boiler, and/or serious personal injury may result.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen from make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once.

NOTE: DO NOT add cold make up water to the system when the boiler is hot. Thermal shock can potentially cause cracks in the heat

UNCRATING THE BOILER - Any claims for damage or shortage in shipment must be led immediately against the transportation company by the consignee.

Remove all sides of the shipping crate of the boiler.

A. What’s in the Box

Components (and Part #) included with the boiler:

• Temperature and Pressure Gauge (7500P-098)

• Pressure Relief Valve (7350P-066)

• Wall Mount Bracket (285 Model - 7600P-121, 399 Model 7600P-221)

• Indirect Sensor (7250P-325)

• Outdoor Sensor (7250P-319)

• Intake PVC Tee with Screens

• Exhaust PVC Coupling with Screens

• Installation Manual and Warranty

• CSD-1 Form

• H-2 Data Sheet

B. How the Boiler Operates

Elite FT® condensing technology intelligently delivers hydronic heating while maximizing eciency. Outlined below are the features of the system and how they operate:

Stainless Steel Heat Exchanger

The highly ecient 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 modulates the output of the burner during operation to match system demand and achieve the control set point while in operation. The set point can change by internal or external signals to 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 to monitor outdoor temperature through an outdoor sensor to regulate boiler set point. The system can be

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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 eciency. The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating input from the connected boilers. Each cascaded boiler will have its own pump to provide maximum ow and control heat exchanger ow 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 ow only if powered and combustion air is owing.

All Metal Integrated Venturi

Controls air and gas ow into the burner.

Burner

The high grade stainless steel burner uses premixed air and gas to provide a wide range of ring rates.

Spark Ignition

The burner is ignited by applying high voltage through the system spark electrode. The spark from the electrode ignites mixed gas o of the burner.

Supply Water Temperature Sensor

This sensor monitors the boiler outlet water temperature (System Supply). The control adjusts boiler ring rate so the supply temperature will match the boiler set point.

Return Water Temperature Sensor

This sensor monitors boiler return water temperature (System Return).

Flue Sensor

Monitors ue temperature and adjusts ring rate.

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Electrical eld connections with terminal strips

The electrical cover allows easy access to the clearly marked line voltage and low voltage terminal strips to facilitate wiring the boiler.

Condensate Collection System

This boiler is a high eciency appliance and will produce condensate. The condensate collection system has a oat switch which monitors condensate level and prevents condensate from backing up into the combustion system. Inside the collection system 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

Monitors outdoor temperature and adjusts unit set point to provide greater eciency.

0-10 Volt Input

Allows the installer to connect a BMS (Building Management System) to control the boiler.

Condensate Flue Check System

The check system prevents heat exchanger exhaust from backing up into the cabinet.

Pump Service Mode

Allows manual operation of pumps to commission system and check pump operation.

C. Optional Equipment

Optional equipment available from HTP (and Part #):

• System Sensor (7250P-324)

• 3” PVC Concentric Vent Kit (KGAVT0601CVT)

• 3” Stainless Steel Vent Termination Kit (V1000)

• 4” Stainless Steel Vent Termination Kit (V2000)

• 6” Stainless Steel Vent Termination Kit (V3000)

• 3” Polypro Vent Kit (8400P-001)

• 3” Polypro Pipe

(33’ length # 8400P-002, 49.5’ length # 8400P-003)

• UL 353 Compliant Low Water Cut-O Interface Kit with Manual Reset (7600P-990)

• Manual Reset High Limit (7450P-217)

• Alarm System (to monitor any failure) (7350P-602)

• PC Connection Kit (7250P-320)

• Condensate Neutralizer (285 Model - 7450P-212, 399 Model 7350P-611)

• Condensate Removal Pump (554200)

• Flow Switch Kit (7450P-213)

• Fuel Conversion Kit (285 Model - LP to NG - 7600P-890, NG to LP 7600P-891)

• Fuel Conversion Kit (399 Model - LP to NG - 7600P-892, NG to LP 7600P-893)

NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system eciency.

Part 3 - Prepare the Boiler

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 axed to the skid (Figure 1 and 2). Remove the mounting bracket from the crate (Figure 1). Take care to place the boiler in a safe location prior to installation to prevent damage to the mechanical connections.

COLD WEATHER HANDLING - If the boiler has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the components come to room temperature. Failure to do so could result in damage to the boiler.

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.

Figure 1 - Pallet with Axed Mounting Bracket

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Figure 2 - Boiler Mounted to Mounting Bracket on Pallet

A. Locating the Boiler

This boiler is certied for indoor use only. DO NOT INSTALL OUTDOORS. Outdoor installations ARE NOT covered by warranty. Failure to install the boiler indoors could result in property damage, severe personal injury, or death.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death. Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32oF / 0oC and lower than 104oF / 40oC

• Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual

• Avoid continuously high levels of humidity

• Never close existing ventilation openings

• Ensure a minimum 1” clearance around hot water and exhaust vent pipes

• NOTE: To prevent condensing in the fan, it is recommended to avoid prolonged exposure to temperatures below 45oF

This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32oF. Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions. Failure to take precautions could result in property damage, severe personal injury, or death.

2. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

3. Check area around boiler. Remove any combustible materials, gasoline, and other ammable liquids.

This boiler must be installed upright in the vertical position as described in this manual. DO NOT attempt to install this boiler in any other orientation. Doing so will result in improper boiler operation and property damage, and could result in serious personal injury or death.

Failure of the boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

High heat sources (generating heat 100oF / 37oC or greater, such as boiler ue pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations, and ordinances when installing this boiler and related components near high heat sources.

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 inuenced 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 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.

4. Gas control system components must be protected from dripping water during operation and service.

5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as:

• System leaks

• Location that could cause the system and boiler to freeze and leak

• Incorrectly sized expansion tank

6. Clean and ush 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.

NOTE: A combustible door or removable panel is acceptable front clearance.

B. Structure

Assure that the structure of the installation location is sucient to support the full installed weight of the boiler, including water content of the heat exchanger and related piping. Failure to ensure the structure of the installation location is structurally sound before installation of the boiler can result in structural failure, substantial property damage, severe personal injury, or death.

C. Leveling

In order for the condensate to properly ow out of the collection system, the area where you locate the boiler must be level. Location must also fully support the weight of the lled boiler.

Failure to keep the boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

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D. Clearances for Service Access

NOTE: If you do not provide the minimum clearances shown in

Figure 3 it might not be possible to service the boiler without removing it from the space.

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Figure 3 - Recommended Service Clearances

Minimum Clearances from Combustible Materials

• Hot water pipes - at least 1” from combustible materials

• Exhaust vent pipe - at least 1” from combustible materials

Do not mount the boiler to a hollow wall. Mount to the studs only. Use extreme care not to drop the boiler or cause bodily injury

while lifting or mounting the boiler onto the wall mount bracket.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.

All boilers eventually leak. Locate the boiler where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower oors of the building. Any boiler should be installed in such a manner that if it should leak the resulting ow of water will not cause damage to the area in which it is installed. If the boiler is installed in a location where a leak could cause damage, it is required to provide containment measures. Such measures include but are not limited to: a properly sized drain pan installed beneath the boiler and piped to an open drain line, or installing the boiler on a concrete oor pitched to a free owing drain. Failure to provide containment measures is the sole responsibility of the owner and/ or installer. Leakage damages ARE NOT covered by warranty. In addition, water leak detection devices and automatic water shuto valves are readily available at plumbing supply houses. IT IS HIGHLY RECOMMENDED BY THE MANUFACTURER TO INSTALL WATER LEAK DETECTION DEVICES AND AUTOMATIC SHUTOFF VALVES IN ANY BOILER INSTALLATION WHERE A LEAKAGE OF WATER COULD RESULT IN PROPERTY DAMAGES.

The space must be provided with combustion / ventilation air openings correctly sized for all other appliances located in the same space as the boiler. The boiler cover must be securely fastened to prevent the boiler from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

E. 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 300 lbs (136 kg) for the 285 model, and 500 lbs (227 kg) for the 399 model. If ooding is possible, elevate the boiler to prevent oodwater from reaching the boiler. Ensure the boiler is installed in a location that minimizes the risk of water damage due to leaking valves, pumps, unions, etc.

The mounting location must be capable of carrying the weight of the boiler and its related components. If the mounting location cannot support the minimum weight of the mounted lled boiler, 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.

F. Wall Mounting Instructions

This boiler is too heavy for one person to lift. It is highly recommended to install the boiler with two people. Use caution as to not drop the boiler, which could damage the boiler and cause property damage and/or severe personal injury. Verify that the boiler is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

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Figure 4 - Wall Mounting Bracket - NOTE: Drawing for Demonstration Purposes Only

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

DO NOT use the bolts included in shipping for wall mounting the boiler. Doing so may result in property damage, serious injury, or death.

1. Mounting to a Wood Studded Wall

a. The building frame (studs) must be 2 X 4 minimum and 16” on center (24” on the 399 model). If not, you must use ½” minimum plywood 24” x 48” with at least fourteen (14) #12 x 3” (3/16” x 3”) round head tapping screws to the frame of the building to provide proper support for the boiler. No alternate methods of mounting or fastening (ex. Toggle bolts, hollow wall anchors, or any other fastener) may be used. b. The provided mounting bracket must be mounted directly to the center of at least 2 studs using standard steel or stainless steel ¼” x 2 ½” lag bolts for all models. Be sure the bracket is level and mark the hole location of the bracket height and horizontal stud location. Ensure the marked holes are located in the center of the building frame (studs). c. For all models, 2 ½” is the minimum lag bolt length if the bracket is directly on stud. Increase lag bolt length for any materials covering the studs. d. Predrill pilot holes on the marked stud locations. The pilot holes for bare studs should be 2” deep for all 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 insucient support or out of level boiler. See Figure 4. NOTE: Bolt must embed into the wood structure a minimum of 2”. e. 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.

If the boiler is not installed upright, vertically plumb, and level, improper and unsatisfactory operation may occur, causing excessive condensation build-up, nuisance fault codes, and unnecessary maintenance.

Required Amount of Bolts for Wall-Mounting the Boiler

Model Amount of Bolts

285 4

399 6

Pilot Hole Size by Wood Type

Type Drill Bit Size

Soft 3/32”

Hard 3/16”

Table 1 - Bolts Required and Pilot Hole Size for Wall-Mounting the Boiler

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 at least 18 gauge studs. Be sure the bracket is level and mark the hole location of the top bracket height and horizontal stud location. Ensure the marked holes are located in the center of the building frame (studs). b. 2” is the minimum toggle bolt length if the bracket is directly on stud. Increase length for any materials covering the studs. c. Predrill holes on the marked stud locations. The predrilled holes should be ½” in diameter for 3/16” bolts, and ¾” in diameter for 3/8” bolts, to allow for the collapsed wings of the toggle to slide through. Ensure that the predrilled holes are straight and square to the wall. Failure to do so could lead to insucient support of out of level boiler. See Figure 4. d. Using the predrilled holes, mount the hanger bracket to the building frame (studs) with the toggle bolts. Ensure that the bolt toggles are through the stud and expanded catching the inside of the stud. Tighten the toggle bolt until the mounting bracket is secure. Hang boiler on the now wall mounted bracket. Be certain that the bracket is engaged before letting the boiler hang free. Slowly release the weight of the boiler while ensuring the bracket is properly secure. Verify that the boiler is securely mounted before leaving it unsupervised.

G. Residential Garage and Closet Installations

Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage or closet. 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, per ANSI Z223.1:

• Install the boiler burner and ignition devices a minimum of 18” above the oor of the garage. This will ensure the burner and ignition devices are well o the oor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the boiler. For power venting installations using room air for combustion, refer to the boiler venting section, this manual, for descriptions of conned and unconned spaces. 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.

H. Exhaust Vent and Intake Pipe

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.

NOTE: The venting options described here (and further detailed in the Venting section, this manual) are the lone venting options approved for this boiler. Failure to vent the boiler in accordance with the provided venting instructions will void the warranty.

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Failure to vent the boiler properly will result in serious personal injury or death.

but not less than 100 square inches (645cm2). If the conned 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.

Do not attempt to vent this boiler by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Vents must be properly supported. 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. Boiler must be readily accessible for visual inspection for rst 3’ from the boiler. Failure to properly support vents could result in property damage, severe personal injury, or death.

The exhaust discharged by this boiler may be very hot. Avoid touching or other direct contact with the exhaust gases of the vent termination assembly. Doing so could result in severe personal injury or death.

1. Direct Vent of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake and exhaust must terminate outdoors. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3. Unbalanced Venting. Be sure to locate the boiler such that the exhaust vent and intake piping can be routed through the building and properly terminated. Dierent vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in Venting Section). The exhaust vent and intake piping lengths, routing, and termination methods must all comply with the methods and limits given in the Venting Section, this manual. When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent

combustion air contamination, see Table 2.

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space

This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 2. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sucient 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 2) 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. Unconned space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details. Conned space is space with volume less than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. When drawing combustion air from inside a conventionally constructed building to a conned space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space oor. Each opening should have a free area of one square inch per 1,000 BTU/hr (22cm2/kW) of the total input of all appliances in the space,

When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.

Failure to provide an adequate supply of fresh combustion air can cause poisonous ue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 2.

I. Carbon Monoxide Detectors

In the Commonwealth of Massachusetts and As Required by State and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation or replacement of the vented gas fueled appliance, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas appliance is installed, unless the appliance is located in a detached, uninhabitable structure separate from the dwelling, building, or structure used in whole or in part for residential purposes. In addition, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on each additional level of the dwelling, building, or structure served by the vented gas appliance. It shall be the responsibility of the property owner to secure the service of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent oor level. b. In the event that these requirements 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 period, a battery operated carbon monoxide detector with an alarm shall be installed.

Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Approved Carbon Monoxide Detectors: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certied.

J. Prevent Combustion Air Contamination

Install intake air piping for the boiler as described in the Venting Section, this manual. Do not terminate exhaust in locations that can allow contamination of intake air.

Ensure that the intake air will not contain any of the contaminants in Table 2. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool or laundry facilities. These areas always contain contaminants.

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Figure 5 - CO Warning Label

K. Removing a Boiler from a Common Vent System

Do not install the boiler into a common vent with any other appliance. This will cause ue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

When removing an existing boiler, follow the steps below.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion, or other deciencies that could cause an unsafe condition.

3. If practical, close all building doors, windows, and doors between the space in which the boiler remains connected to the common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all replace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, replace dampers, and any other gas burning appliances to their previous condition of use.

7. Any improper operation of the common venting system should be corrected to conform to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the system should approach the minimum size as determined using the appropriate tables in Appendix G of ANSI Z223.1.

Products to Avoid

Spray cans containing uorocarbons

Permanent wave solutions Swimming pools

Chlorinated waxes / cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Adhesives used to fasten building products

Table 2 - Products and Areas Likely to Have Contaminants

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.)

Areas Likely to Have

Contaminants

Dry cleaning / laundry areas and establishments

Beauty shops

Refrigeration repair shops

Photo processing plants

Furniture renishing areas and establishments

Remodeling areas

Garages and workshops

L. Water Chemistry Requirements*

Chemical imbalance of the water supply may aect eciency and cause severe damage to the appliance and associated equipment. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the appliance. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality. Adverse water quality will aect the reliability of the system. In addition, operating temperatures above 135oF will accelerate the build-up of lime scale and possibly shorten appliance service life. Failure of an appliance due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

Closed loop water must be free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger.

If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

• Water pH between 6.5 and 8.5

• pH levels below 6.5 can cause an increase in the rate of

corrosion. pH of 8.5 or higher can potentially cause lime scale build-up

• Maintain water pH between 6.5 and 8.5. Check with litmus

paper or have it chemically analyzed by a local water treatment company.

• If the pH is not between 6.5 and 8.5, consult a local water

treatment company for solutions.

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• Hardness less than 7 grains (120 mg/L) (Water temperatures of 140oF and greater)

• Hardness levels above the required amounts can lead to

lime scale build-up throughout the system. Water below 5 grains/gallon (85 mg/L) may be over softened.

• Consult local water treatment companies for unusually

hard water areas (above the required amounts) or for other treatment solutions if water is being over softened (below 5 grains/gallon [85 mg/L]).

• Chloride concentration less than 100 ppm (mg/L)

• Do not ll appliance or operate with water containing

chlorides in excess of 100 ppm (mg/L).

• Using chlorinated fresh water should be acceptable as

levels are typically less than 5 ppm (mg/L).

• Do not connect the appliance to directly heat swimming

pool or spa water.

• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)

• Total dissolved solids are minerals, salts, metals, and

charged particles that are dissolved in water.

• The greater the amounts of TDS present, the higher the

corrosion potential due to increased conductivity in the water.

• If using softened water to ll the appliance, it is still

possible to have high TDS. This water can be corrosive. Consult local water treatment companies for other treatment solutions to reduce this eect.

*NOTE: It is recommended to clean the heat exchanger at least once a year to prevent lime scale buildup. To clean the heat exchanger, follow the maintenance procedure in this manual.

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M. Technical Specications

Model 285 399

Installation Indoor, Wall Hung, Fully Condensing

Minimum / Maximum Input (Btu/Hr) 28,500 / 285,000 39,900 / 399,000

Heating Capacity (MBH) 262 367*

Flue System Category IV, Sealed Combustion Direct Vent, Power Vent

Minimum Combined Vent Run 16 feet

Maximum Combined Vent Run 3” (150 feet) 4” (200 feet)

Approved Exhaust Vent Materials PVC, CPVC, PP, Stainless Steel

Shipping Weight (lbs) 203 298

Gas Supply Pressure

Manifold Pressure Min / Max NG/LP: -0.01” WC

Power Supply 120V 60 Hz, 6.3A

General Operating Conditions

Ignition System Direct Electronic Spark Ignition / Flame Rectication

Burner System Premixed Fuel Modulation / Stainless Steel Metal Fiber Burner

Gas Valve System Air Ratio Valve

Dimensions

(in Inches)

Boiler Water Content (Gallons) 6.1 7.9

Minimum Flow Rate @ 30oF ∆T (GPM) 17.9 25.0

Boiler Setpoint Temperature Range 50 – 190oF / 32 - 190oF (with Outdoor Reset Curve)

DHW Indirect Setpoint Temperature Range 70 – 180oF

Water Pressure (PSI)

Control Panel / Main Controller LCD Display with LED Indicators / 926 SIT Control

Connection Sizes

Materials

Safety Devices

Table 3 - Technical Specications

Heat Exchanger MAWP 80

Ambient Temperature Range: 33 – 104oF (0.6 – 40oC)

Product Approvals and Requirements: ANSI Z21.13 / CSA 4.9

W 20 25.5

H 32.6 36.4

D 20.6 23.6

Pressure Relief Valve 80

Supply / Return 1 1/4” Copper SWT 1 1/2” Copper SWT

Gas Inlet 1” NPTF

Cabinet Powder Coated Galvaneal Steel

Heat Exchanger S43932 Stainless Steel Fire Tube

Flame Rectier Probe, Dual Water Supply Temperature Sensor (199oF), Water Pressure Switch (Min. 10 PSI), Freeze Protection, Blocked Condensate Pressure Switch, Condensate Trap with Float, Flue Temperature High Limit Sensor (210oF), Blocked Vent Pressure Switch, Optional UL353 Low Water Cut-O

3.5” to 14” WC

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Figure 6 - Boiler Dimensions - NOTE: All Dimensions Are Approximate

Part 4 - Piping

Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, severe personal injury, or death.

The National Standard Plumbing Code, the National Plumbing Code of Canada, and the Uniform Plumbing Code limit heat transfer uid pressure to less than the minimum working pressure of the potable water system up to 30 PSI maximum. In addition, the heat transfer uid must be water or another non-toxic uid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th Edition. Failure to follow this warning could result in property damage, severe personal injury, or death.

Dielectric unions or galvanized steel ttings must not be used in a system with this boiler. Doing so WILL VOID the warranty. Use only copper, brass, or stainless steel ttings. Teon thread sealant must be used on all connections.

Plumbing of this product should only be done by a qualied, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to an indirect water heater to supply domestic hot water. HTP oers indirect water heaters in a wide range of gallon sizes in either stainless steel or glass-lined construction.

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 ow switch may be installed on the supply of the system to activate the boiler when there is enough ow. 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.

A. General Plumbing Information

The building piping system must meet or exceed the the piping requirements in this manual.

Use two wrenches when tightening water piping at 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.

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B. Relief Valve

Connect discharge piping to a safe disposal location following the guidelines below.

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the oor drain, making discharge clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375oF or greater.

• Do not pipe discharge to any location where freezing could occur.

• No valve may be installed between the relief valve and boiler or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Test the operation of the relief valve after lling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, immediately replace with a new properly rated relief valve.

• Test T&P valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the boiler “o” and call a plumber immediately.

• Take care whenever operating relief valve to avoid scalding injury or property damage.

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.

Do not thread a cap or plug into the relief valve or relief valve line under any circumstances! Explosion and property damage, serious injury, or death may result.

RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a licensed plumbing contractor or qualied service

technician to ensure that the product has not been aected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occuring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected. Do not attempt to conduct an inspection on your own. Contact your plumbing contractor for a re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILD-UP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

C. Backow Preventer

Use a backow preventer specically designed for hydronic boiler installations. This valve should be installed on the cold water ll supply line per local codes.

D. Potable Expansion Tank

Expansion Tank and Make-Up Water

1. Ensure that the expansion tank is sized to correctly handle boiler and system water volume and temperature.

Expansion tanks must be sized according to total system volume. This includes all length of pipe, all xtures, boilers, etc. Failure to properly size for system expansion could result in wasted time, money, possible property damage, serious injury, or death.

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.

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.

Expansion Tank Sizing

Model Heat Exchanger Volume (Gallons)

285 6.1

399 7.9

Table 4 - Expansion Tank Sizing

2. The expansion tank must be located as shown in Applications, this manual, 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 suction side of the circulator. Always install the system ll connection at the same point as the expansion tank connection to the system.

4. Most chilled water systems are piped using a closed type expansion tank.

DIAPHRAGM (OR BLADDER) EXPANSION TANK

Always install an automatic air vent on top of the air separator to remove residual air from the system.

E. Circulators

DO NOT use the boiler circulator in any location other than

the ones shown in this manual. The boiler circulator location is selected to ensure adequate ow through the boiler. Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insucient ow.

Sizing Space Heat System Piping

1. See Applications in this manual. In all 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.

F. Hydronic Piping with Circulators, Zone Valves, and Multiple Boilers

This boiler is designed to function in a closed loop hydronic system. It is recommended to install a temperature and pressure gauge (not included with the boiler) to allow the user to monitor system pressure and outlet temperature from the boiler. It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators. Unless the system has a closed type expansion tank, each boiler installation must have

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Page 17

an air elimination device that will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) Allow clearance for basic service of boiler circulator, valves and other components. Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials. On a boiler installed above radiation level, some states and local codes require a low water cut o device, which is an optional part available through HTP (Part # 7600P-990). Check with local codes for additional requirements. If the boiler supplies hot water to heating coils in air handler units, ow 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 specically formulated for this purpose. Antifreeze must include inhibitors that will prevent the glycol from attacking the metallic system components. Make certain that the system uid 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 32oF to 180oF, while water expands 3% with the same temperature rise.

G. Circulator Sizing

In addition, the heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator. M inimum ow rates are listed in the table below.

Minimum Boiler Flow Rates

Model Minimum Flow (GPM)

285 17.9

399 25

Table 5 - Minimum Flow Rates

The heat exchanger has a pressure drop that must be considered in your system design. Refer to Figure 7 for pressure drop through the heat exchanger.

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Page 18

Figure 7 - Boiler Pressure Drop

The chart below represents various system design temperature rise through the boiler along with respective ows and friction loss. This is provided to aid in circulator selection.

System Temperature Rise Chart

20°Δt 25°Δt 30°Δt

Model Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM)

285 7’ 26.8 4.7’ 21.4 3.5’ 17.9

399 9.5’ 37.5 7.1’ 30 5.7’ 25

Table 6 - Temperature Rise, Friction Ft and Flow Rate

The chart below represents the combined ow 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 ow rates for the system design temperature. Example: (5) 285 Model boilers with a design of 20°Δt degree temperature rise with each boiler having an individual ow rate of 26.8 GPM. To correctly size the manifold feeding these (5) boilers you would need a pipe size of 4 1/2”.

Multiple Boiler Manifold Piping

Maximum Flow Rate

(GPM at 3 Feet per Second)

19 31.5 45 69 93 120 150 188 271

Schedule 40 Pipe Dia. (In.) 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6

Table 7 - Multiple Boiler Manifold Piping

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H. Check / Control Water Chemistry

NOTE: Boiler failure due to improper water chemistry is not covered by warranty.

• Water pH between 6.5 and 8.5

• Hardness less than 7 grains (120 mg/L) (Water temperatures of 140oF and greater)

• Chloride concentration less than 100 ppm (mg/L)

• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)

*NOTE: It is recommended to clean the heat exchanger at least once a

year to prevent lime scale buildup. To clean the heat exchanger, follow the maintenance procedure in this manual.

Clean system to remove sediment*

1. You must thoroughly ush the system (without boiler connected) to remove sediment. The high-eciency heat exchanger can be damaged by buildup or corrosion due to sediment.

2. For zoned systems, ush 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.

Test/replace freeze protection uid

1. For systems using freeze protection uids, follow uid manufacturer’s instructions to verify inhibitor level and that other uid characteristics are satisfactory.

2. Freeze protection uid must be replaced periodically due to degradation of inhibitors over time. Follow all uid manufacturer instructions.

Piping Components Heating System Piping

System piping MUST be sized per technical pipe requirements listed in Tables 7 and 8. Reducing pipe size can restrict ow rate through the boiler, causing inadvertent short cycling and poor system performance.

Model Minimum Pipe Sizes

285 1 1/4” NPT

399 1 1/2” NPT

Table 8 - Minimum Pipe Sizes

Check Valves

Field supplied. Check valves are recommended for installation as shown in Applications.

Isolation Valves

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ow rate through the boiler.

Anti-Scald Mixing Valve

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

Unions

Field supplied. Recommended for unit 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 specications. Storage tank may require additional relief valves depending on local codes.

I. Plumbing

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 o valve and drain on the system return to purge air out of each zone.

4. Install a back ow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line (15 psi nominal on the system return). This boiler has a maximum working pressure of 160 psi. You may order a higher pressure relief valve kit from the factory. Check temperature and pressure gauge when operating. It should read a minimum pressure of 12 psi.

6. Install a circulator as shown in Applications (this manual). Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the expansion tank manufacturer’s instruction manual (see Part 4, Section D for water volume) for specic 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 unit with an air pressure of 15 PSI.

10. The relief valve and temperature and pressure gauge are included in the accessory kit. A discharge line should be installed 6” above the drain in the event of a pressure relief. The pipe size must be the same size as the relief valve outlet. NEVER BLOCK THE OUTLET OF THE

SAFETY RELIEF VALVE.

J. 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 o valve after the drain.

3. Open the rst zone balance and purge or drain valve to let water ow 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 ll 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 owing. Disconnect the hose and connect it to next zone to be purged.

5. Repeat this procedure for additional zones (one at a time).

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 ows 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 ll valve and zone valves are in automatic positions. You must also assure the purge and shut o valves are in open positions.

K. Glycol Antifreeze Solutions

This boiler should not be operated as a potable hot water heater. It should not be used as a direct hot water heating device.

NOTE: Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials. Basic steps are listed below, with illustration that will guide you through the installation of the boiler.

Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Glycol mixtures should not exceed 50%. Failure to do so could result in property damage, severe personal injury, or death due to scalds.

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• Glycol in hydronic applications should include inhibitors that prevent the glycol from attacking metallic system components. Make certain that the system uid is checked for the correct glycol concentration and inhibitor level.

• The glycol solution should be tested at least once a year or as recommended by the glycol manufacturer.

• Anti-freeze solutions expand more than water. For example: A 50% by volume solution expands 4.8% in volume for a temperature increase from 32oF to 180oF, while water expands 3% over the same temperature rise. Allowances must be made in system design for expansion.

• A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head against the system circulator.

• A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head against the system circulator.

It is highly recommended that you carefully follow the glycol manufacturer’s recommended concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.) You must carefully calculate the additional friction loss in the system as well as the reduction in heat transfer coecients.

L. Zoning with Zone Valves

1. When zoning with zone valves, connect the boiler to the system

as shown in Applications. The primary/secondary piping shown ensures the boiler loop will have sucient ow. 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 Applications.

M. Zoning with Circulators

1. When using circulator zoning, connect the boiler to the system as

shown in Applications. NOTE: The boiler circulator cannot be used for a zone. It must only supply the boiler loop.

2. Install a separate circulator for each zone.

3. Connect DHW (domestic hot water) piping to indirect storage

water heater as shown in Applications.

N. Multiple Boilers

1. Connect multiple boilers as shown in Applications.

2. All piping shown is reverse return to assure balanced ow

throughout the connected boilers.

3. Each connected boiler must have its own circulator pump to

assure adequate ow.

4. Connect DHW (domestic hot water) piping to indirect storage

water heater as shown in Applications.

5. The system ow (secondary loop) must be greater than the boiler’s

primary loop ow.

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O. Applications*

Mixing valves are required for the protection of low temperature loops.

Figure 8 - 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.

NOTE: In piping applications utilizing a single zone, it is recommended that the installer use ow / check valves with weighted seats at or near

the appliance to prevent gravity circulation.

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Figure 9 - Piping Symbol Legend

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Figure 10 - Primary / Secondary Piping with Zone Valves and Indirect 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 an indirect water heater is 1”

5. The minimum pipe size for connecting a 285 – 1.25”, 399 – 1.5”.

6. Circulators are shown with isolation anges. The alternative is standard anges with full port ball valves. Purge valves can be used with circulator anges as an alternative.

7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119oF.

8. Piping shown is Primary/Secondary. System ow (secondary loop) must be greater than the boiler’s primary loop ow.

9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

10. VERY IMPORTANT – Minimum ow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.

The piping will not support the weight of the circulators. Refer to the circulator manufacturer’s instruc tions to properly support the circulator. Failure to comply with these instructions could result in property damage, severe personal injury, or death.

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Figure 11 - Primary / Secondary Piping with Pumps and Indirect 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 an indirect water heater is 1”

5. The minimum pipe size for connecting a 285 – 1.25”, 399 – 1.5”.

6. Circulators are shown with isolation anges. The alternative is standard anges with full port ball valves. Purge valves can be used with

circulator anges as an alternative.

7. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119oF.

8. Piping shown is Primary/Secondary. System ow (secondary loop) must be greater than the boiler’s primary loop ow.

9. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

10. VERY IMPORTANT – Minimum ow rates outlined in this manual must be maintained through the heat exchanger to minimize short

cycling.

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If boiler supply temperature for DHW is set higher than central heating, the heating circuit must be protected by a thermostatic mixing

thermostatic mixing valve.

Figure 12 - Multiple Boilers - Primary / Secondary Piping with Pumps and Indirect Priority