HTP EL-80, EL-220, EL-110, EL-299, EL-399 Installation Manual

Elite

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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.

INSTALLATION

START-UP

MAINTENANCE

PARTS

Elite Models*

EL-80 / 110 / 150 / 220 / 299 / 399

*A suffix of “LP” denotes propane gas

*A suffix of “N” denotes natural gas

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

LP- 293 REV. 3.29.12

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IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY

RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE

GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER

APPLIANCE.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.
 Do not touch any electrical switch.
 Do not use any phone in your building.
 Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
 If you cannot reach your gas supplier, call the fire department. Installation and service must be provided

by a qualified installer, service agency, or the gas supplier.

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

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

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

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

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided,

may result in property damage.

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.

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 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 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

This appliance 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.

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.

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.

Code for the installation of Heat Producing Appliances (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.

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TABLE OF CONTENTS

PART 1 – GENERAL SAFETY INFORMATION ....................................................................................................... 7

A. PRECAUTIONS ................................................................................................................................................................... 7

B. IMPROPER COMBUSTION ................................................................................................................................................ 8

C. GAS ..................................................................................................................................................................................... 8

D. WHEN SERVICING THE BOILER ...................................................................................................................................... 8

E. BOILER WATER ................................................................................................................................................................. 8

F. BOILER WATER CHEMISTRY* .......................................................................................................................................... 9

G. FREEZE PROTECTION FLUIDS ........................................................................................................................................ 9

PART 2 – BEFORE YOU START .............................................................................................................................. 9

A. WHAT’S IN THE BOX ......................................................................................................................................................... 9

B. HOW BOILER OPERATES ............................................................................................................................................... 10

C. OPTIONAL EQUIPMENT ................................................................ ................................ .................................................. 11

PART 3 – PREPARE BOILER LOCATION ............................................................................................................. 12

A. BEFORE LOCATING THE BOILER .................................................................................................................................. 12

B. LEVELING AND DIMENSIONS ......................................................................................................................................... 13

C. CLEARANCES FOR SERVICE ACCESS ......................................................................................................................... 14

D. RESIDENTIAL GARAGE INSTALLATION ........................................................................................................................ 16

E. EXHAUST VENT AND INTAKE AIR VENT ....................................................................................................................... 17

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F. PREVENT COMBUSTION AIR CONTAMINATION ........................................................................................................... 17

G. REMOVING A BOILER FROM A COMMON VENT SYSTEM .......................................................................................... 18

H. UNCRATING THE BOILER ............................................................................................................................................... 18

PART 4 – BOILER PIPING ...................................................................................................................................... 19

A. GENERAL PIPING INFORMATION .................................................................................................................................. 19

B. RELIEF VALVE ................................................................................................................................................................. 20

C. BACKFLOW PREVENTER ............................................................................................................................................... 20

D. SYSTEM WATER PIPING METHODS .............................................................................................................................. 20

E. CIRCULATORS ................................................................................................................................................................. 21

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS .............................................. 22

G. PIPING DETAILS* ............................................................................................................................................................. 22

H. PIPING INSTALLATION .................................................................................................................................................... 27

I. CIRCULATOR SIZING ........................................................................................................................................................ 28

J. CHECK/CONTROL WATER CHEMISTRY ........................................................................................................................ 29

K. FILL AND PURGE HEATING SYSTEM ............................................................................................................................ 31

L. GLYCOL ANTIFREEZE SOLUTIONS ............................................................................................................................... 31

M. ZONING WITH ZONE VALVES ........................................................................................................................................ 32

N. ZONING WITH CIRCULATORS........................................................................................................................................ 32

O. MULTIPLE BOILERS ........................................................................................................................................................ 32

PART 5 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL ........................................................ 33

A. GENERAL ......................................................................................................................................................................... 33

B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS ............................................................................. 34

C. REQUIREMENTS FOR INSTALLATION IN CANADA ...................................................................................................... 35

D. EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION .......................................................................................... 36

E. EXHAUST VENT AND INTAKE AIR VENT SIZING ................................ ................................ ................................ .......... 39

F. LONGER VENT RUNS ...................................................................................................................................................... 40

G. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION .............................................................................................. 40

H. SIDEWALL VENTING ....................................................................................................................................................... 42

I. VERTICAL VENTING ......................................................................................................................................................... 43

J. HORIZONTAL VENTING ................................................................................................................................................... 44

K. UNBALANCED FLUE / VERTICAL VENT ................................................................ ......................................................... 45

L. VENTING THROUGH AN EXISTING SYSTEM................................................................................................................. 46

1. CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM ......................................................................................................... 46

2. VENTING AS A CHASE ..................................................................................................................................................................... 48

M. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE............................................. 49

PART 6 – GAS PIPING ............................................................................................................................................ 51

A. GAS CONNECTION .......................................................................................................................................................... 51

B. GAS PIPING ...................................................................................................................................................................... 51

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C. CHECK INLET GAS PRESSURE ..................................................................................................................................... 52

D. BOILER GAS VALVE ........................................................................................................................................................ 54

PART 7 – FIELD WIRING ........................................................................................................................................ 55

A. INSTALLATION MUST COMPLY WITH: ........................................................................................................................... 55

B. FIELD WIRING TERMINATIONS ...................................................................................................................................... 55

C. FIELD WIRING .................................................................................................................................................................. 55

D. LINE VOLTAGE WIRING FOR STANDARD BOILER ....................................................................................................... 56

E. ALARM CONNECTIONS ................................................................................................................................................... 56

F. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER .......................................................................................... 56

G. THERMOSTAT ................................................................................................................................................................. 56

H. OUTDOOR SENSOR ........................................................................................................................................................ 57

I. INDIRECT SENSOR ........................................................................................................................................................... 57

J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL .................................................................................................... 57

K. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT ......................................................................................... 58

L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS ............................................................................................. 58

M. CASCADE MASTER PUMP AND SENSOR WIRING ...................................................................................................... 59

N. CASCADE FOLLOWER PUMP AND SENSOR WIRING .................................................................................................. 59

PART 8 – START-UP PREPARATION ................................................................................................................... 63

A. CHECK / CONTROL WATER CHEMISTRY ..................................................................................................................... 63

B. CHECK FOR GAS LEAKS ................................................................................................................................................ 64

C. FREEZE PROTECTION (WHEN USED) .......................................................................................................................... 64

D. FILL AND TEST WATER SYSTEM ................................................................................................................................... 64

E. PURGE AIR FROM WATER SYSTEM .............................................................................................................................. 65

F. CHECK THERMOSTAT CIRCUIT(S) ................................................................................................................................ 66

G. CONDENSATE REMOVAL ............................................................................................................................................... 66

H. FINAL CHECKS BEFORE STARTING BOILER ............................................................................................................... 67

I. CASCADE SYSTEM ........................................................................................................................................................... 67

J. LOCKOUT CONDITION ..................................................................................................................................................... 68

PART 9 – START-UP PROCEDURE ....................................................................................................................... 68

A. CONTROL OVERVIEW ..................................................................................................................................................... 68

B. NAVIGATION OF THE DISPLAY ...................................................................................................................................... 69

C. OPERATING INSTRUCTIONS ......................................................................................................................................... 69

D. PROGRAMMING BOILER SETTINGS ............................................................................................................................. 70

E. PROGRAMMING THE SYSTEM SETTING ...................................................................................................................... 71

F. SYSTEM SETTING PROGRAM NAVIGATION ................................................................................................................. 71

G. RESETTING THE MAINTENANCE SCHEDULE .............................................................................................................. 73

PART 10 – START-UP PROCEDURES FOR THE INSTALLER ............................................................................ 74

A. BOILER CONTROL STATUS MENU ................................................................................................................................ 74

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INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.

USER – This manual is for use only by a qualified heating installer/service technician. Have this boiler
serviced/inspected by a qualified service technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS BOILER
SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE
PERSONAL INJURY, OR DEATH.

B. BOILER TEST MODE ....................................................................................................................................................... 76

C. CASCADE MENU ............................................................................................................................................................. 76

D. TEST MODE ACCESS ...................................................................................................................................................... 77

PART 11 – TROUBLESHOOTING .......................................................................................................................... 77

A. BOILER ERROR CODE .................................................................................................................................................... 77

B. BOILER ERROR ............................................................................................................................................................... 78

C. BOILER FAULT ................................................................................................................................................................. 78

D. USER INTERFACE DISPLAY ........................................................................................................................................... 79

PART 12 – MAINTENANCE .................................................................................................................................... 84

A. MAINTENANCE PROCEDURES ..................................................................................................................... 84

B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER .............................................. 85

C. CLEANING WATER SIDE OF HEAT EXCHANGER ....................................................................................... 86

BOILER START-UP REPORT ................................................................................................................................. 91

MAINTENANCE REPORT ....................................................................................................................................... 92

MAINTENANCE NOTES .......................................................................................................................................... 96

HTP CUSTOMER INSTALLATION RECORD FORM ..................................................................................... 97

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and 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 appliance has been approved for closet
installation. Do not install this appliance directly on carpeting. For installation on combustible flooring. Category IV
vent systems only.

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

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NOTE: If the boiler is exposed to the following, do not operate until all corrective steps have been made by a
qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by
the consignee.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a
qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an
appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage
causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air.
Operating a previously submerged appliance could result in property damage, severe personal injury, or death.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under
product warranty.

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.

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.

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.

B. IMPROPER COMBUSTION

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 appliance.

D. WHEN SERVICING THE BOILER

 To avoid electric shock, disconnect electrical supply before performing maintenance.
 To avoid severe burns, allow boiler to cool.

E. BOILER WATER

 If you have an old system with cast iron radiators, thoroughly flush the system (without boiler connected)

to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to
sediment. HTP recommends a suction strainer in this type of system.

 Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the

system may be damaged, possibly resulting in substantial property damage.

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.

Consider boiler piping and installation when determining boiler location.

 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 make­up 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 exchanger. Such damage IS NOT covered by warranty.

F. BOILER WATER CHEMISTRY*

 Sodium less than 20mGL.
 Water pH between 6.0 and 8.0

o Maintain water pH between 6.0 and 8.0. Check with litmus paper or have it chemically analyzed

by water treatment company.

o If the pH differs from above, consult local water treatment company for treatment needed.

 Hardness less than 7 grains

o Consult local water treatment companies for unusually hard water areas (above 7 grains

hardness).

 Chlorine concentration less than 100 ppm

o Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm.
o Do not 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.

Hardness: 7 grains
Chloride levels: 100 ppm
pH levels: 6-8
TDS: 2000 ppm
Sodium: 20 mGL

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G. FREEZE PROTECTION FLUIDS

NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT
covered by warranty.

PART 2 – BEFORE YOU START

A. WHAT’S IN THE BOX

Also included with the boiler:

 Temperature and Pressure Gauge (Part #7450-222)

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 Pressure Relief Valve (Part #7250P-219 for EL80/110/150, #7350P-065 for EL220/299/399)
 Indirect Sensor
 Outdoor Sensor
 Intake PVC Tee with Screens
 Exhaust PVC Coupling with Screens
 Outlet Combination Fitting (1” - Part #7450P-134 for EL80/110/150/220, 1.25” - #7450-135 for EL299,

1.5” - #7450-136 for EL399)

 Installation Manual
 Warranty
 CSD-1 Form
 H-3 Data Sheet
 NAT to LP Conversion Kit (Part #7450P-223) (Included with NAT models)
 LP to NAT Conversion Kit (Part #7450P-224) (Included with LP models)

B. HOW BOILER OPERATES

Elite® condensing technology intelligently 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 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.
All 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.

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Supply Water Temperature Sensor – This sensor monitors the boiler outlet water temperature (System Supply).
The control adjusts the boiler firing rate so the supply temperature will match the boiler set point.

Return Water Temperature Sensor – This sensor monitors the boiler return water temperature (System Return).
Flue Sensor – Monitors flue temperature and adjusts firing rate.
Temperature and Pressure Gauge – Allows the user to monitor system temperature and pressure.
Electrical field connections with terminal strips – The electrical cover allows easy access to the line voltage

and low voltage terminals strips which are clearly marked to facilitate wiring of the boiler.
Condensation Collection System – This boiler is a high efficiency appliance, therefore the boiler will produce

condensate. The collection system has a float switch 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 – Monitors outdoor temperature and adjusts unit set point to provide greater efficiency.
0-10 Volt Input – Allows Installer to connect a BMS (Building Management System) to control the boiler.
Condensate Flue 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 II System (Optional) – Allows the user to supply mixed temperatures in up to eight zones. The Vision

II system controls the temperature to each zone by employing three way mixing valves. The Vision II 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. These additional options may be purchased through
your HTP distributor:

 Wall Mount Bracket (Part # 7450P-211)
 System Sensor (Part # 7250P-324)
 Indirect Tank Sensor (Part # 7250P-325)
 3" PVC 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)
 U.L. 353 Compliant Low Water Cut-Off Interface Kit with Manual Reset (Part # 7450P-225)
 Manual Reset High Limit (Part # 7450P-217)
 Alarm System (Part # 7350P-602) (to monitor any failure)
 PC Connection Kit (Part # 7250P-320)
 Condensate Neutralizer (Part # 7450P-212 for EL-80/110/150/220/299, Part # 7350P-611 for EL-399)
 Flow Switch Kit (Part # 7450P-213 for EL-80/110/150/220, Part # 7450P-214 for EL-299, Part # 7450P-

215 for EL-399)

 Vision II (Part # 7250P-322)

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.

Incorrect ambient conditions can lead to damage to the heating system and 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.

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

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.

This boiler is certified for indoor installations only. Do not install the boiler outdoors. Failure to install this boiler
indoors could result in substantial property damage, severe personal injury, or death.

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.

PART 3 – PREPARE BOILER LOCATION

A. BEFORE LOCATING THE BOILER

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,

Part 3, Section F.

 Avoid continuously high levels of humidity
 Never close existing ventilation openings

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2. Check for nearby connections to:

 System water piping
 Venting connections
 Gas supply piping
 Electrical power
 Condensate drain

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

13

Do not mount the boiler to a hollow wall. Mount to the studs only. Failure to do so will result in substantial property
damage, and could result in severe personal injury or death.

Use extreme care not to drop the boiler or cause bodily injury while lifting or mounting the boiler onto the optional
wall mount bracket. Failure to do so will result in property damage, and could result in severe personal injury or
death.

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.

In order for the condensate to properly flow out of the
collection system, the area where you locate the boiler
must be level. The boiler comes equipped with
leveling feet. Should you find the floor beneath the
boiler is uneven, adjust the leveling feet with a wrench.

Figure 1 – Leveling

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 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.

B. LEVELING AND DIMENSIONS

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

Figure 2 – Recommended Service Clearances

C. CLEARANCES FOR SERVICE ACCESS

See Figure 2 for recommended service clearances.
If these minimum clearances are not provided, it
may not be possible to service the boiler without
removing it from the space.

MINIMUM CLEARANCES FROM COMBUSTIBLE
MATERIALS

 Hot water pipes – at least 1” from combustible materials.
 Exhaust vent pipe – at least 1” from combustible materials.

14

15

Figure 3

16

Figure 4

D. RESIDENTIAL GARAGE INSTALLATION

PRECAUTIONS

If the boiler is located in a residential garage, per ANSI Z223.1:

 Mount the bottom of the boiler a minimum of 18” above the floor of the garage, to ensure the burner and

ignition devices are well off the floor.

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

Vents must be properly supported. The boiler intake and exhaust 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.

Ensure that the intake air will not contain any of the contaminants below. 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.

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 Muriatic acid

Furniture refinishing areas and establishments

Cements 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

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).

E. EXHAUST VENT AND INTAKE AIR VENT

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 adaptor. The resultant installation is
categorized as direct vent (sealed combustion). NOTE: To prevent combustion air contamination, see Table 1 in
this section when considering exhaust vent and intake air vent termination.

Intake and exhaust vents must terminate near each other and may be vented vertically through the roof or out a
side wall. Intake and exhaust venting methods are detailed in the Venting Section. Do not attempt installation
using any other means. Be sure to locate the boiler so intake and exhaust vent piping can be routed through the
building and properly terminated. The air intake and exhaust vent piping lengths, routing and termination method
must all comply with methods and limits given in the venting section.

17

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.

Table 1

18

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

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

UNCRATING BOILER – Any claims for damage or shortage in shipment must be filed immediately against the
transportation company by the consignee.

Cold weather handling – If boiler has been stored in a very cold location (below 0oF) before installation, handle
with care until the plastic components come to room temperature.

Figure 5 - CO Warning Label

G. REMOVING A BOILER FROM A COMMON VENT SYSTEM

When removing an existing boiler, the following steps must be
followed.

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 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 appliances not
connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts, at
maximum speed. Do not operate a summer exhaust fan. Close all fireplace dampers.

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

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

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

7. Any improper operation of the common venting system should be corrected so the installation conforms 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.

H. UNCRATING THE BOILER

19

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

The National Standard Plumbing Code, the National Plumbing Code of Canada, and the Uniform Plumbing Code
limit heat transfer fluid pressure to less than the minimum working pressure of the potable water system up to 30
PSI maximum. In addition, the heat transfer fluid must be water or another non-toxic fluid 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.

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

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.

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.

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.

Remove all sides of the shipping crate to allow the boiler to be lifted into its installation location. The boiler is also
equipped with leveling feet that can be used to level the boiler properly on an uneven location surface. If surface
flooring is rough, take care when sliding boiler into position, as you could catch the leveling feet and damage the
boiler.

PART 4 – BOILER PIPING

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 an indirect water heater to supply domestic hot water. HTP
offers indirect water heaters in a wide range of gallon sizes in either stainless steel or glass-lined construction.

A. GENERAL PIPING INFORMATION

NOTE: The addition of a high temperature limiting device is important if the boiler is to be connected to a
domestic hot water system.

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 floor drain,

making discharge clearly visible.

 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 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.

 Test 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.

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

All piping methods shown in this manual use primary/secondary connection to the boiler loop. This is to avoid the
possibility of inadequate flow through the boiler. For other piping methods, consult your HTP representative or
refer to separate Piping Details, Section J, in this manual.

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.

B. RELIEF VALVE

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

20

C. BACKFLOW PREVENTER

Use a backflow preventer specifically designed for hydronic boiler installations. This valve should be installed on
the cold water fill supply line per local codes (see Piping Details, Section J).

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.

21

EXPANSION TANK SIZING

EL-80

1.4 Gallons

EL-110

1.7 Gallons

EL-150

2.0 Gallons

EL-220

2.6 Gallons

EL-299

3.1 Gallons

EL-399

3.7 Gallons

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.

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.

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.

Table 2

2. The expansion tank must be located as shown in Part 4, 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 suction side of the circulator.
Always install the system fill connection at the same point as the expansion tank connection to the system.

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

DIAPHRAGM (OR BLADDER) EXPANSION TANK

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

E. CIRCULATORS

Sizing Space Heat System Piping

1. See Piping Details in this manual, Section G. 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.

22

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

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS

This boiler is designed to function in a closed loop hydronic system. We have included a temperature and
pressure gauge that allows the user to monitor the 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 # 7450P-225). Check with local codes for 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 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 32oF to 180oF, while water expands 3% with the same temperature rise.

G. PIPING DETAILS*

*NOTE: Systems shown are primary/secondary piping systems. These recommended systems have a primary
(boiler) loop, and secondary circuits for heating. The primary loop and secondary circuits have separate
circulators. The use of other near boiler piping configurations could result in improper flow rates, leading to
inadvertent boiler high limit shutdowns and poor system performance.

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 appliance to prevent gravity circulation.

23

Figure 6 – LP-293-L NOTES:

1. This drawing is meant to show system piping concept only.

2. A mixing valve is recommended if the DHW temperature is set above 119oF.

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

4. Piping shown is Primary/Secondary.

5. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow
rate must be maintained above the minimum flow rates published on p. 28, this manual.

6. Installations must comply with all local codes.

7. In Massachusetts, a vacuum relief valve must be installed in the cold water line per 248 CMR.

24

Figure 7 – LP-293-Q
NOTES:

1. This drawing is meant to show system piping concept only.

2. A mixing valve is recommended if the DHW temperature is set above 119oF.

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

4. Piping shown is Primary/Secondary.

5. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be
maintained above the minimum flow rates published on p. 28, this manual.

6. Installations must comply with all local codes.

7. In Massachusetts, a vacuum relief valve must be installed in the cold water line per 248 CMR.

8. Reference Figure 10 to determine manifold pipe sizing.

25

Figure 8 – LP-293-O
NOTES:

1. This drawing is meant to show system piping concept only.

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

3. Piping shown is Primary/Secondary.

4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be
maintained above the minimum flow rates published on p. 28, this manual.

5. Installations must comply with all local codes.

26

Figure 9 – LP-293-P
NOTES:

1. This drawing is meant to show system piping concept only.

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

3. Piping shown is Primary/Secondary.

4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be
maintained above the minimum flow rates published on p. 28, this manual.

5. Installations must comply with all local codes.

27

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

H. PIPING INSTALLATION

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 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 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 4, 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 unit 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.

HEAT EXCHANGER PRESSURE DROP CHART

Model

Flow Rate Δ P’

Flow Rate

2

GPM 3 GPM 4 GPM 5 GPM 6 GPM 7 GPM 8 GPM 9 GPM

10

GPM

11

GPM

12

GPM

13

GPM

14

GPM

15

GPM

16

GPM

17

GPM

18

GPM

19

GPM

20

GPM

EL-80

2.5’

3’

4’

7’

10’

14’

17’

21’

26’ * * * * * * * * * *

EL-110

*

3’

4’

7’

9’

12’

15’

17’

22’

25’

33’ * * * * * * * *

EL-150

* * 3’

4’

5’

6’

9’

10’

12’

15’

17’

19’

22’

27’ * * * * * EL-220

* * * * *

2’

2’

3’

4’

5’

5.5’

6’

12’

8’

10’

11.5’

13’

15’

16.5’

EL-299

* * * * * * 3’

3.5’

4’

4.5’

5’

6’

7’

8’

8.75’

9.25’

10.25

11’

13’

EL-399

* * * * * * * * * * *

3.8’

4’

5’

6’

6.6’

7’

7.8’

8.3’

Flow Rate

21

GPM

22

GPM

23

GPM

24

GPM

25

GPM

26

GPM

27

GPM

28

GPM

29

GPM

30

GPM

31

GPM

32

GPM

33

GPM

34

GPM

35

GPM

36

GPM

37

GPM

38

GPM

39

GPM

EL-80

* * * * * * * * * * * * * * * * * * *

EL-110

* * * * * * * * * * * * * * * * * * *

EL-150

* * * * * * * * * * * * * * * * * * *

EL-220

17’

19’

21’

23’

24’ * * * * * * * * * * * * * *

EL-299

14’

15’

16.5’

18’

20’

22’

24’

26’

29’

33’

36’ * * * * * * * *

EL-399

9.2’

9.7’

10.3’

11.1’

12’

12.9’

13.6’

14’

15.7’

17’

18’

19.4’

21’

22.5’

26’

28’

31’

34’

39’

Table 3 – NOTE: *Do not operate boiler at these flow settings as it will damage the heat exchanger or related components.

SYSTEM TEMPERATURE RISE CHART

Model

20°Δt

25°Δt

30°Δt

35°Δt

40°Δt

Ft / Friction

Flow Rate

Ft / Friction

Flow Rate

Ft / Friction

Flow Rate

Ft / Friction

Flow Rate

Ft / Friction

Flow Rate

EL-80

17’

8 GPM

10’

6.6 GPM

7’

5.3 GPM

7’

4.6 GPM

4’

4 GPM

EL-110

25’

11 GPM

17’

9.1 GPM

12’

7.3 GPM

9’

6.4 GPM

8.2’

5.5 GPM

EL-150

27’

15 GPM

17’

12.5 GPM

12’

10 GPM

10’

8.8 GPM

8.8’

7.5 GPM

EL-220

19’

22 GPM

13’

18.3 GPM

12’

14.6 GPM

6’

12.8 GPM

5’

11 GPM

EL-299

29’

29 GPM

18’

24.5 GPM

13’

20 GPM

9.5’

17.3 GPM

8’

14.5 GPM

EL-399

39’

39 GPM

19’

32.5 GPM

13’

26 GPM

10’

22.8 GPM

8’

19.5 GPM

Table 4

I. CIRCULATOR SIZING

The heat exchanger has a pressure drop that must be considered in your system design. Refer to Table 3 for
pressure drop through the heat exchanger.

28

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.

The chart on the following page 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) EL-220 Boilers® with a design of 20°Δt degree temperature rise with each boiler having an
individual flow rate of 22 GPM. To correctly size the manifold feeding these (5) boilers you would need a pipe size
of 4”.

MULTIPLE BOILER MANIFOLD PIPING

Flow Rate (GPM)

16

22

24

30

32

33

40

44

45

48

50

55

60

66

75

80

85

88

90

100

110

Pipe Dia. (Inches)

2 2 2 2 2

2½

2½

2½

2½

2½

2½

2½

2½

2½ 3 3 3 3 3 3

4

MULTIPLE BOILER MANIFOLD PIPING

Flow Rate

(GPM)

120

132

150

160

170

179

200

210

239

240

250

255

300

340

350

400

425

510

595

680

Pipe Dia. (In.)

4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 6 6

6

0

1

2

3

4

5

6

0 50 100 150 200 250

Pipe Diameter Size (Inches)

Combined Boiler Water Flow (GPM)

Multiple Boiler Manifold Piping

Table 5

29

Figure 10

Table 6

J. CHECK/CONTROL WATER CHEMISTRY

NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY.
Sodium less than 20 mGL
Water pH between 6.0 and 8.0

1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water
treatment company.

2. If pH differs from above, consult local water treatment company for treatment needed.

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.

30

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.

Hardness: 7 grains
Chloride levels: 100 ppm
pH levels: 6-8
TDS: 2000 ppm
Sodium: 20 mGL

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 12 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 Table 5 and Table 6.
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. Failure 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 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 specifications. Storage tank may require
additional relief valves depending on local codes.

MINIMUM PIPE SIZES

EL 80, EL 110, EL 150, EL 220

1” NPT or Copper

EL 299

1 ¼” NPT or Copper

EL 399

1 ½” NPT or Copper

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.

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%.

Table 7

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 purged.

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

31

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

 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.

 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
coefficients.

M. ZONING WITH ZONE VALVES

1. When zoning with zone valves, connect the boiler to the system as shown in Piping Details, Part 4, 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 4, Section G.
NOTE: The boiler circulator cannot be used for a zone. It must only supply the boiler loop.

2. Install a separate circulator for each zone.

3. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Piping Details.

32

O. MULTIPLE BOILERS

1. Connect multiple boilers as shown in Piping Details, Part 4, 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.

The boiler must be vented as detailed in this Venting Section. Ensure exhaust and intake piping complies with
these instructions regarding vent system. Inspect finished combustion air intake and exhaust 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.

This boiler is certified as a “Category IV” appliance, and requires a special venting system. The vent system will
operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent
materials and rules outlined in these instructions. Do not connect vent connectors serving appliances vented by
natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting
instructions below carefully. Failure to do so will result in substantial property damage, severe personal injury, or
death.

Exhaust and intake air pipes are to be piped separately. This boiler cannot share a common exhaust or intake
with multiple appliances. Failure to follow this instruction will result in substantial property damage, severe
personal injury, or death.

Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the
exhaust vent pipe 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.

Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust and
intake air 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 the necessary precautions to avoid these risks.

PART 5 – VENTING, COMBUSTION AIR, AND CONDENSATE
REMOVAL

A. GENERAL

33

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 and approved for Category IV
boilers.

NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to
the outdoors.

APPROVED EXHAUST VENTING AND AIR INLET MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or air inlet

pipe and fittings

PVC schedule 40/80

ANSI/ASTM D1785

PP, CPVC, and PVC

venting must be ULC-S636

Certified. IPEX is an

approved manufacturer in

Canada, supplying vent

material listed to ULC-S636.

PVC-DWV

ANSI/ASTM D2665

CPVC schedule 40/80

ANSI/ASTM F441

Polypropylene

ULCS636

Stainless Steel AL29-4C

Certified for Category IV and
direct vent appliance venting

Certified for Category IV and
direct vent appliance venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements

& Primers

CPVC

ANSI/ASTM F493

 The air inlet and exhaust components installed with this boiler must be used for near boiler piping

BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed
components. Doing so WILL VOID appliance warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable. CPVC pipe is rated

for higher temperature applications, and is more expensive than PVC. To save installation cost, it is
recommended to use CPVC for high temperature applications ONLY.

 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 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.

Failure to follow these directions will result in substantial property damage, severe personal injury, or death.

DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue
products into the living space. Use only the approved pipe and fitting materials, and primer and cement
specifically designed for the material used, as listed in Table 9. Failure to do so could result in property damage,
severe personal injury, or death.

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 a minimum of ¼” per

foot back to the appliance 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.

B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS

34

Table 8 - NOTES:

1. Air inlet piping does not require high temperature pipe material. Check applicable local codes for acceptable materials.

2. UL S636 PVC is approved for flue gas temperatures up to 149oF (65oC) and must only be used for low temperature
applications. High temperature applications requiring appliance supply water temperatures greater than 140oF (60oC) must use
ULC S636 CPVC, PP, or AL29-4C stainless steel.

NOTE: The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold
climates to prevent the condensation of airborne moisture in the incoming combustion air.

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.

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 appliance 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.
NOTE: The use of double-wall vent or insulated material for the air inlet is recommended in cold climates to

prevent the condensation of airborne moisture in the incoming combustion air.

Figure 11 - NOTE: Drawing is meant to demonstrate system venting ONLY.

36

You must insert the provided intake and exhaust screen at your vent termination to prevent blockage caused by
debris or birds.

The building owner is responsible for keeping the exhaust and air intake terminations free of snow, ice, or other
potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear
and properly maintain the boiler could result in property damage, severe personal injury, or death.

For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area
outside the bedrooms, as well as in the room that houses the boiler. 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.

D. EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION

NOTE: SEE ADDITIONAL REQUIREMENTS FOR MASSACHUSETTS IN THE BACK OF THIS MANUAL.

1. Determine exhaust vent location:

 Total length of vent may not exceed the limits specified in Part 5 Section E.
 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). NOTE: This does not apply to the combustion air intake of a direct-vent appliance.

 Provide a minimum of 1 foot distance from any door, operable window, or gravity intake into any building.
 Provide a minimum of 1 foot clearance from the bottom of the exhaust above the expected snow

accumulation level. Snow removal may be necessary to maintain clearance.

 Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment,

exhaust fans and inlets. In no case shall the exit terminal be above or below the aforementioned
equipment unless the 4 foot horizontal distance is maintained.

 Do not locate the boiler exhaust over public walkways where condensate could drip and/or freeze and

create a nuisance or hazard.

 When adjacent to a public walkway, locate exit terminals at least 7 feet above grade.
 To prevent icicles from forming, do not locate the exhaust directly under roof overhangs.
 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 air intake vent location:

 Provide 1 foot of clearance from the bottom of the intake vent and the level of maximum snow

accumulation. Snow removal may be necessary to maintain clearances.

 Do not locate the intake air vent in a parking area where machinery may damage the vent.
 Follow required minimum clearances located in Figure 11.

NOTE: 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.

37

3. Determine location of condensate piping:

This boiler is a high efficiency appliance, and therefore produces condensate: a by-product of the combustion
process. A condensate collection system with an internal float switch monitors the condensate level to prevent it
from backing up into the combustion system. There is a ¾” socket connection provided to connect the outlet of
the collection system to a drain or condensate pump.

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 for EL-80/110/150/220/299, Part # 7350P-611 for EL-399). 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 ½” to avoid blockage in condensate piping (refer to
Figure 12 for piping of the condensate neutralizer.)

38

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 flow.

NOTE: To clean out condensate collector, blow water into collector to remove any foreign matter that may block

the condensate line.

Figure 12 – Condensate Piping

When servicing is complete, you must make sure this cap is replaced securely. Failure to do so will cause venting
issues that will result in serious injury or death.

When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The
pump should have an overflow switch to prevent property damage from condensate spillage.

It is very important that the condensate piping be no smaller than ¾”. You must use a tee at the condensate

connection with a branch vertically up and open to the atmosphere, so as not to cause a vacuum that could
obstruct the flow of condensate from the boiler. To prevent sagging and maintain pitch, condensate piping should
be supported with pipe supports.

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.

FRICTION LOSS EQUIVALENT FOR STAINLESS OR PLASTIC PIPING AND FITTINGS

FITTING DESCRIPTION

3”

4”

6”

90o elbow short radius

5’

5’

3’

90o elbow long radius

4’

4’

3’

45o elbow

3’

3’

2’

Coupling

0’

0’

0’

Tee (intake only)

0’

0’

0’

V Series Vent Kit

1’

1’

1’

AL20 4C Vent Terminal

1’

1’

1’

Pipe (All Materials)

1’

1’

1’

Figure 13

NOTE: To allow for proper drainage on larger horizontal condensate runs, tubing size may need to increase to 1

inch and a second line vent may be required.

39

E. EXHAUST VENT AND INTAKE AIR VENT SIZING

1. The exhaust vent and intake air vent pipes are 3” for the Elite EL-80/110/155/220 and 4” for the EL-299/399.

2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 200 feet.
a. The equivalent length of friction loss in elbows, tees, and other fittings are listed in Table 9.

Table 9 *Friction loss for long radius elbow is 1’ less. NOTE: Consult Polypropylene venting instructions for friction
loss and pressure drop equivalents.

b. For example: If the exhaust vent is 3” in diameter,
and has two short 90o elbows and 10 feet of PVC pipe
we will calculate: Exhaust Vent Pipe Equivalent Length
= (2x5) + 10 = 20 feet.

Further, if the 3” intake air vent pipe has two short 90o
elbows, one 45o elbow, and 10 feet of PVC pipe, the
following calculation applies: Intake Air Equivalent
Length = (2x5) + 3 + 10 = 23 feet.

Therefore, the total equivalent length equals 43 feet.

40

VENT TRANSITION FITTING

SIZE

REDUCING COUPLING

FINAL VENT SIZE

3” Venting

4” x 3”

4”

4” Venting

6” x 4”

6”

6” Venting

8” x 6”

8”

Do not exceed the maximum lengths for increased diameter vent pipes. Excessive length could result in appliance
shutdown and property damage.

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into
living space. Failure to do so could result in carbon monoxide leakage, property damage, severe personal injury,
or death.

c. You should keep a minimum combined equivalent length between the intake air vent pipe and the
exhaust vent. The minimum combined equivalent length is 32 combined equivalent feet.

d. The size of venting can also be reduced in order to accommodate existing vent sizes. When reducing

down to a 2” vent from a 3” vent, or a 3” vent from a 4” vent, the combined length shall not exceed 100

equivalent feet. Vent reduction must begin at the boiler.

F. LONGER VENT RUNS

The maximum combined equivalent length can be extended by equally increasing the diameter of both the
exhaust and intake air vent pipes. However, transitions should begin a minimum of 32 combined equivalent feet
from the boiler equally on both the intake and exhaust.

The maximum equivalent length for increased diameter vent pipes is 275 feet, which includes the combined 32
feet from the boiler, 16 ft. (inlet) + 16 ft. (exhaust) = 32 ft. combined with transition total of 243 ft. upsize piping for
longer vent runs.

Table 10

G. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION

1. Use only solid PVC or CPVC pipe, 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.

41

DESCRIPTION

STOCK CODE

3” PVC CONCENTRIC VENT TERMINATION 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

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 and 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 appliance not less than ¼" 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 appliance to support any piping.

14. A screened straight coupling is provided with the appliance for use as an outside exhaust termination.

15. A screened inlet air tee is provided with the appliance to be used as an outside intake termination.

The following information on Table 11 lists optional intake air/exhaust vent terminations available from HTP:

Table 11

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back
to the boiler to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must
be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.

Figure 14 – Sidewall Venting with Tee (Intake) and Coupling (Exhaust) – LP-293-E

H. SIDEWALL VENTING

42

NOTE: Vent piping should be 12” over anticipated maximum snow level.
NOTE: Drawing is meant to demonstrate system venting ONLY.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back

to the boiler to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must
be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.

I. VERTICAL VENTING

43

Figure 15 – Vertical Venting - LP-293-F

NOTE: Vent piping should be 12” over anticipated maximum snow level.
NOTE: Drawing is meant to demonstrate system venting ONLY.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back
to the boiler to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must
be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.

J. HORIZONTAL VENTING

44

Figure 16 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY.
NOTES:

A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building
structure and not two adjacent walls [corner of building]).

B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake.
C. Maintain 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.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back
to the boiler to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must
be within 1 foot of the boiler and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.

An unbalanced vent system can be installed ONLY when the exhaust is in a vertical position.

K. UNBALANCED FLUE / VERTICAL VENT

45

Figure 17 – LP-293-T – Unbalanced Flue/Vertical Vent - NOTE: Drawing is meant to demonstrate system venting

ONLY.

46

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

Contractors must check state and local codes before installing through an existing vent opening. State and local

codes always take precedence over manufacturer’s instructions. Failure to check state and local codes before

installing through an existing opening could result in property damage and add significantly to installation costs.

The upper and lower vent terminations as well as 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.

L. VENTING THROUGH AN EXISTING SYSTEM

This boiler may be vented through an existing unused vent system. The inner diameter of the existing vent system
is utilized for the combustion air source. Two methods have been approved for such venting: Concentric Venting
Through an Existing System and Venting as a Chase.

1. CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM

NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with

HTP’s concentric vent kits (2” Part # KGVAT0501CVT, 3" Part # KGAVT0601CVT). Refer to Concentric Vent Kit

installation manual (Part # LP-166) for further concentric venting information and instructions.
Concentric venting through an existing system must run vertically through the roof. See Table 11 for proper

minimum vent sizing. Use only the approved venting materials specified in Table 10 for piping the system. All
instructions listed in Part 5 - Venting, Sections A – G apply. See Figures 18-1 and 18-2 for venting
demonstrations.

47

If an existing venting system is converted for use with this boiler, the installer must ensure that the existing
venting system is clean and free from particulate contamination that could damage the boiler. Failure to do so
could result in property damage and boiler failure. Such failure IS NOT covered under warranty.

VENT / AIR INLET SIZE

MINIMUM EXISTING VENT / CHASE SIZE

2”

4”

3”

5”

4”

7”

Figure 18 – 1, 18 – 2 Concentric 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. Maintain 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.
F. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater).

Table 12 – Minimum Vent / Chase Sizing

Figure 19 – Venting as a Chase

2. VENTING AS A CHASE

When venting as a chase, follow all instructions
included in Part 5 – Venting, Sections A – G of
this manual, as well as the previous Concentric
Venting section. See Figure 19 for chase venting
demonstration.

NOTES:

A. For every 1” of overhang, the exhaust vent must be
located 1” vertical below overhang (overhang means

top of building structure and not two adjacent walls
[corner of building]).

B. Typical installations require 12” minimum

separation between bottom of exhaust outlet and top
of air intake.

C. Maintain 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.

F. Maintain 12” minimum clearance above highest

anticipated snow level or grade (whichever is greater).

48

Figure 20 – LP-387-Z

M. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE

NOTE: This installation is intended for commercial
applications. For residential applications, it is
recommended to pipe intake combustion air from
the outdoors.

This boiler requires fresh, uncontaminated air for
safe operation and must be installed in a
mechanical room where there is adequate
combustion and ventilating air. NOTE: To prevent

combustion air contamination, see Table 3.

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 feet per 1,000 Btu/hour (4.8 cubic
meters per kW) of the total input rating of all fuel­burning boilers installed in that space. 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 conventionally 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 per 1,000 Btu/hr (22cm2/kW) of the total input of all boilers in the space, but not less than 100 square inches
(645cm2).

When drawing combustion air from inside a conventionally constructed building to a confined space located on
different stories, such spaces should be considered as communicating spaces when connected with one or more
permanent openings in doors or floors having a total minimum free area of two square inches per 1,000 Btu/hr
(22cm2/kW) of the total input of all boilers in the space, but not less than 200 square inches (645cm2).

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.

49

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.

50

Figure 21 – 1, 21 - 2 NOTE: These drawings are meant to demonstrate system venting only. The installer is

responsible for all equipment and detailing required by local codes.

FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS
SECTION COULD RESULT IN FIRE, EXPLOSION, OR
DEATH!

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 “NAT” for natural or city gas. You must not do a gas conversion without an approved

gas conversion kit. Prior to turning the gas on, all gas connections must be approved by the local gas supplier or
utility, in addition to the governing authority.

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.

The gas valve and blower will not support the weight of gas piping. Do not attempt to support the weight of piping
with the boiler or its accessories. Failure to follow this warning could result in gas leakage, substantial property
damage, severe personal injury, or death.

Figure 22

Table 13 – Gas Pipe Sizing / BTU’s per Hour

PART 6 – GAS PIPING

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.

51

The gas connection on the boiler is 3/4” for the
EL-80/110/150 and 1” for the EL-220/299/399. It
is mandatory that this fitting is used for
connection to a field fabricated drip leg as shown
in the illustration above per the National Fuel
Gas Code. You must ensure that the entire gas
line to the connection at the boiler is no smaller
than the unit supplied connection.

Once all inspections have been performed, the
piping must be leak tested. If the leak test
requirement is a higher test pressure than the
maximum inlet pressure, you must isolate the
boiler from the gas line. In order to do this, shut
the gas off using factory and field-installed gas
cocks. This will prevent high pressure. Failure to do so may damage the gas valve. In the event the gas valve is
exposed to a pressure greater than ½ PSI, 14" w.c., or 3.5 kPa, the gas valve must be replaced. Never use an
open flame (match, lighter, etc.) to check gas connections.

B. GAS PIPING

1. Run the gas supply line in accordance with all applicable codes.

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Failure to apply pipe sealing compound as detailed above could result in substantial property damage, severe
personal injury, or death.

Never use an open flame (match or lighter) to check for gas leaks. Use a soapy solution to test connection.
Failure to use a soapy solution test or check gas connection for leaks can result in substantial property damage,
severe personal injury, or death.

Use two wrenches when tightening gas piping at the boiler: One to prevent the boiler gas line from turning. Failure
to prevent the boiler gas connection from turning could result in damage to the gas line components, substantial
property damage, severe personal injury, or death.

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.

Figure 23 – LP-205-W

2. Locate and install manual shutoff valves in accordance with state and local requirements.

3. In Canada, the Manual Shutoff must be identified by the installing contractor.

4. It is important to support gas piping as the unit is not designed to structurally support a large amount of weight.

5. Purge all gas lines thoroughly to avoid start up issues with air in the lines.

6. Sealing compound must be approved for gas connections. Care must be taken when applying compound to

prevent blockage or obstruction of gas flow which may affect the operation of the unit.

C. CHECK INLET GAS PRESSURE

The gas valve is equipped with an inlet gas pressure tap that can be
used to measure the gas pressure to the unit. To check gas pressure,
perform the steps listed below:

1. IMPORTANT! Before you connect to the inlet pressure, shut off the

gas and electrical power to unit.

2. Loosen the pressure tap with a small screwdriver. Refer to Figure 24

for location.

3. Each unit is equipped with a needle valve that will accept a 5/16 ID

hose to connect to a digital manometer or liquid gauge designed to
measure incoming pressure from 0-35” w.c. See Figure 24.

4. Turn on the gas and power up the unit.

5. Put the unit into manual test mode (details on test mode are in Part

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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.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet
pressure and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet
pressure could result in damage to the valve and cause substantial property damage, severe personal injury, or
death.

Ensure that the high gas pressure regulator is as least 6 – 10 feet upstream of the appliance. Failure to do so
could result in substantial property damage, severe personal injury, or death.

10 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 unit. 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.

The gas 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 regulator is used, it must be a minimum of 10 feet from the boiler. It is very important that the
gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines, or improper
line sizing, will result in ignition failure. This problem is especially noticeable in NEW LP installations and

empty tank situations. This situation can also occur when a utility company shuts off service to an area to provide
maintenance to their lines. This gas valve must not be replaced with a conventional gas valve under any
circumstances.

Do not do a gas conversion on this boiler without an officially approved conversion kit and instructions supplied by
HTP. Failure to use a conversion kit when converting the boiler to fire on Natural or LP gas will result in extremely
dangerous burner operation, leading to fire, explosion, severe injury or death.

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.

Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated
combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in fire,
explosion, property damage, severe personal injury, or death.

D. BOILER GAS VALVE

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Figure 24 – LP-293-V

ELECTRICAL SHOCK HAZARD - For your safety, 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.

Wiring must be N.E.C. Class 1. If original wiring supplied with the boiler must be replaced, use only UL Listed
TEW 105o C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code
ANSI/NFPA 70 – Latest Edition.

To ease future service and maintenance, label all wires. Wiring errors can cause improper and dangerous
operation, and result in substantial property damage, severe personal injury, or death.

To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit.
Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions
could result in component or product failure, serious injury, or death. Such product failure IS NOT covered by
warranty.

Figure 25 – Knockout Locations

PART 7 – FIELD WIRING

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A. INSTALLATION MUST COMPLY WITH:

1. National Electrical Code and any other national, state,

provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and

any local codes.

B. FIELD WIRING TERMINATIONS

All connections made to the boiler in the field are done inside
the electrical junction box located on the left side of the unit.
Multiple knockout locations are available to route field wires
into and out of the electrical junction box.

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 unit, each pump can
provide a maximum of 3 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 CAT3 or CAT5 patch cables.

Figure 26 – LP-293-NN Elite Boiler Control

D. LINE VOLTAGE WIRING FOR
STANDARD BOILER

1. Connect 120V / 60Hz / 15 AMP incoming

power wiring to the line voltage terminal strip
in the electrical junction box at terminals
120V, Neutral, Ground (shown in Figure 26).

2. A line voltage fused disconnect or service

switch may be required, externally mounted
and connected according to local codes that
may apply.

3. Connect the boiler pump as shown in

Figure 26 to the terminals marked 4 –
(HOT), 5 – (NEUT), and 6 – (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.

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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 26 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.

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 25.

2. Connect all low voltage field devices to the low voltage terminal strip located in the electrical junction box.

G. THERMOSTAT

1. Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box (see Figure

26). 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.

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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.

Caution should be used to ensure neither of these 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 .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
information.

H. OUTDOOR SENSOR

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.

2. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an area that will

not be affected by direct sunlight and will be exposed to varying weather conditions. NOTE: For correct mounting
procedures, follow instructions provided with the sensor.

NOTE: For correct mounting procedures, follow instructions provided with the sensor.
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.

I. INDIRECT SENSOR

There is no connection required if an indirect water heater is not used in the installation.

1. The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the

indirect tank or an HTP 7250P-325 tank sensor. 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 26) in the

electrical junction box.

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.

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

58

building control system can be used to control the set point temperature of the boiler. The control interprets the 0­10 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 10 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 26). 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 26) from A to B.

4. See Part 9, Section D, Function 17 to program the 0-10 volt signal.

NOTE: When a 0-10 volt building management system is installed, the return sensor temperature cannot be
monitored through the appliance display.

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.

L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS

1. Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each

of the boilers. These cables are readily available at any office supply, computer, electronic, department or
discount home supply store in varying lengths. If you possess the skills you can also construct custom length
cables.

2. It is recommended to use the shortest length cable that will reach between the boilers and create a neat

installation. Do not run unprotected cables across the floor 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.

3. Route the communication cables through one of the knockouts in the cabinet.

4. Connect the boilers in a daisy chain configuration as shown below. It is best to wire the boilers using the

shortest wire runs rather than trying to wire them in the order that they are addressed. The communication bus
jacks on the customer connection panel are interchangeable so you can use either one or both in any order to
connect the cable. If you have connected the boilers to each other properly, two of the boilers will have one open
connection port on them.

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Figure 27

M. CASCADE MASTER PUMP AND SENSOR WIRING

1. Connect the system pump hot wire to the terminal marked 8.

2. Connect the system pump neutral to the 2 terminal and the pump ground wire to the 3 terminal.

3. Connect a jumper wire from the 120 VOLT terminal to the 9 terminal.

4. Connect the boiler pump to the terminals marked 4 (HOT), 5 (NEUT) and 6 (GND).

5. Connect the system pipe sensor to the terminals marked 10 and 11.

N. CASCADE FOLLOWER PUMP AND SENSOR WIRING

1. Connect the boiler pump to the terminals labeled 4 (HOT), 5 (NEUT), and 6 (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.

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Figure 28 – Cascade Master and Follower

Note that in a cascade system the alarm output of the boiler addressed as #1 will also be active if the master
boiler has a lockout condition. The alarm output of boilers addressed as 2-7 will only activate an alarm if a lockout
condition occurs on that specific boiler.

61

Figure 29

62

Figure 30

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.

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 water 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.

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.

PART 8 – START-UP PREPARATION

A. CHECK / CONTROL WATER CHEMISTRY

To assure good extended service life, it is recommended that you test your water quality prior to installation.
Listed below are some guidelines.

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Sodium less than 20 mGL
Water pH between 6.0 and 8.0

1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water

treatment company.

2. If pH differs from above, consult local water treatment company for treatment needed.

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.

Hardness: 7 grains
Chloride levels: 100 ppm
pH levels: 6-8
TDS: 2000 ppm
Sodium: 20 mGL

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.

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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.

PROPANE BOILERS ONLY – Your propane supplier mixes an odorant with the propane to make its presence
detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup
(and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

NEVER use automotive or standard glycol antifreeze. Do not use ethylene glycol made for hydronic systems. 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.

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.

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 12 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.

NOTE: BOILER FAILURE DUE TO IMPROPER WATER CHEMISTRY IS NOT COVERED BY WARRANTY.

B. CHECK FOR GAS LEAKS

C. FREEZE PROTECTION (WHEN 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 content.

2. Local codes may require back flow preventer or actual disconnect from city water supply.

3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze

protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze
protection level.

D. FILL AND TEST WATER SYSTEM

Eliminate all system leaks. Continual fresh make-up water will reduce boiler life. Minerals can build up in the heat
exchanger, reducing heat transfer, overheating the heat exchanger and causing heat exchanger failure.

It is important to purge the system of air to avoid damage to the boiler.

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 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.

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.

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E. PURGE AIR FROM WATER SYSTEM

1. 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 remove the hose. Open all isolation valves. Watch
the system pressure rise to correct cold-fill pressure. It is recommended that you put the pumps into
manual operation to assist in purging the circuits.
h. Disconnect the wires that are connected to the THERMOSTAT terminals of the customer connection
board. Apply power to the boiler. The display will show the temperature of the water in the boiler. Press
the ▼ and ENTER keys simultaneously and hold for 1 second. The display will read:

The central heating pump will come on. If you then press the ▲ 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 ▲ key
again, the DHW pump will shut off. The display will read:

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The system pump will come on. Use the ▲ and ▼ 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 ▲ and ▼
together at any time will return the boiler to normal operation.
i. After the system has operated for awhile, 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.
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.)

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 REMOVAL

1. The boiler is a high efficiency condensing boiler. Therefore, the unit has a condensate drain. Condensate fluid

is nothing more than water vapor, derived from combustion products, similar to that produced by an automobile
when it is initially started.

Condensation 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, can be made up of lime crystals, limestone or phosphate
chips that will neutralize the condensate. This may be done by the installer or you may purchase a condensate
neutralizer from HTP (7450-212).

2. The boiler is equipped with a ¾ female socket weld fitting connection that must be piped to a local drain. It is

very important that the condensate line is sloped downward away from the boiler to a suitable inside drain. If the
condensate outlet on the appliance is lower than the drain, you must use a condensate removal pump, available
from HTP (554200). This 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.

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H. FINAL CHECKS BEFORE STARTING BOILER

1. Read Start-Up Procedure, Part 9 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 intake and exhaust piping for signs of deterioration from corrosion, physical damage, or sagging. Verify

intake and exhaust piping are intact and correctly installed per Venting Section (Part 5) and local codes.

I. 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 10 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 follower boiler you are working on.
c. Enter the system settings following instructions in Part 10 of this manual.

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 MODE” 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.

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FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This boiler does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do
not try to light the burner by hand.

2. BEFORE OPERATING: smell all around the boiler area for gas. 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.

If you discover any evidence of a gas leak, shut down the boiler at once. Find the leak source with a bubble test
and repair immediately. Do not start the boiler again until the leak is repaired. Failure to comply could result in
substantial property damage, severe personal injury, or death.

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 9 – START-UP PROCEDURE

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.

ENTER MENU CODE
000

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.

RESET – The RESET button has two functions.

– Resets any lockout error code
– 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 ▲▼ arrow keys to change the blinking digit to the correct value. Use
the   arrow keys to select the next digit to change and again use the ▼▲ keys to change the value. Repeat
until the correct code is entered. Press the ENTER key to accept the code entered. 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 ▼▲ 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 displays if they are enabled. The   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 – ▼▲ 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 ▼▲ keys are used to adjust the
function upward or downward to the desired value.

69

C. OPERATING INSTRUCTIONS

Before operating the unit, 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.

70

SCREEN

DESCRIPTION

ENTER MENU CODE
000

To access the boiler setting program, press and hold the ENTER Key for 4 seconds, until the display shows
the screen at left.

ENTER MENU CODE
600

Using the arrow keys, log in the Boiler Menu Access Code “600”. To confirm the code, press ENTER to
access Boiler Setting Program navigation menu.

SCREEN

DESCRIPTION

CENTRAL HEAT
180 oF

Function: Adjusts the boiler set point. Default: 180oF (Range: 50oF to 190oF).

CENTRAL DIFF SET
30 oF

Function: Adjusts the boiler differential set point. Default: 30oF (Range: 5oF to 30oF).

DHW SET POINT
119 oF

Function: Adjusts the indirect tank set point. Default: 119oF (Range: 70oF to 185oF).

DHW DIFF SET POINT
7 oF

Function: Adjusts the indirect tank differential set point. Default: 7oF (Range: 1oF to 30oF).

TEMP DISPLAY C OR F
oF

Function: Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit).

SCREEN

DESCRIPTION

CLOCK MODE (12/24)
08/28/2009 Fr 9:42A

Function: Changes the clock from 12 hour mode (8:45 PM) to 24 hour mode (20:45). To change to 24
hour mode, press the ENTER key. The letter (A or P) after the time will blink. Press the up or down arrow
key once and the letter will disappear. Press the ENTER key to save the new setting.

CLOCK HOUR
08/28/2009 Fr 10:01A

Function: Allows the user to adjust the hour setting.

CLOCK MINUTE
08/28/2009 Fr 10:01A

Function: Adjusts the minute setting.

CLOCK DAY OF WEEK
08/28/2009 Fr 10:01A

Function: Adjusts the day of week.

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 boiler, such as the tank thermostat, is turned off, so the boiler will remain idle to allow
programming.

Table 14 – 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 ▲ 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.

Table 15 – Boiler Setting Screen Descriptions

Clock Settings

(NOTE: The clock will reset if the boiler is powered off for more than a week.)

CLOCK DATE MODE
08/28/2009 Fr 10:01A

Function: Allows the user to switch to European date format (2009/08/28) from US format (08/28/2009).

CLOCK YEAR
08/28/2009 Fr 10:01A

Function: Adjusts the year setting.

CLOCK MONTH
08/28/2009 Fr 10:01A

Function: Adjusts the month setting.

CLOCK DATE
08/28/2009 Fr 10:01A

The clock is set.

SCREEN

DESCRIPTION

ENTER MENU CODE
000

To access the boiler setting program, press and hold the ENTER Key for 4 seconds, until the display shows
the screen at left.

ENTER MENU CODE
925

Using the arrow keys on the display, log in your System Menu Access Code “925”. To confirm code, press

ENTER to access system setting program navigation menu.

SCREEN

DESCRIPTION

Function 1

Factory Program Mode

MODE
INDIRECT 1

This screen indicates that the control is configured correctly. Do not change this setting.

Function 3

DHW Tank Max Temp

DHW TANK MAX TEMP
180 oF 3

This is the maximum temperature that can be selected for the DHW indirect tank set point in the boiler menu.
Default: 180oF (Range: 95oF to 180oF).

Function 6

DHW Post Pump Time

DHW POST PUMP TIME
0 MINUTES 6

The indirect pump has the ability to post purge energy from the boiler to run the pump after the set point has
been achieved. Please note that running the pump for a time greater than 5 minutes may cause tank energy
to be released back to the boiler heat exchanger. Default: 0 Minutes (Range: 0 – 10 minutes).

Function 7

Warm Weather Shutoff

WARM WEATHER OFF
68 oF 7

When used with an outdoor sensor, warm weather shut down will disable the boiler if the programmed
outdoor temperature is exceeded. Default: 68oF (Range: 41oF to 122oF).

Function 8

Min Outdoor Temp

MIN OUTDOOR TEMP
5 oF 8

Sets the minimum outdoor design temperature for the system. Default: 5oF (Range: -49oF to 32oF).

Table 16 – Clock Setting Screens

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.

71

Table 17 – 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
  arrow keys on the display to navigate through the system setting program. To change a setting, press

ENTER. System settings can be increased by 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.

72

Function 9

Max Supply Temp

MAX SUPPLY TEMP
190 oF 9

Sets the maximum design supply temperature based on the minimum outdoor design temperature. Default:
190oF (Range: 77oF to 190oF).

Function 10

Max Outdoor Temp

MAX OUTDOOR TEMP
68 oF 10

Sets the maximum outdoor design temperature for the system design. Default: 68oF (Range 32oF to 190oF).

Function 11

Min Supply Temp

MIN SUPPLY TEMP
95 oF 11

Sets the design supply water temperature based on the maximum outdoor design temperature. Default: 95oF
(Range: 32oF to 190oF).

Function 12

Min Boiler Temp

MIN BOILER TEMP
68 oF 12

Sets the design minimum heat curve temperature for central heat. Default: 68oF (Range: 32oF to 190oF).

Function 13

CH Post Pump Time

CH POST PUMP TIME
0 MINUTES 13

Allows the user to set the boiler pump post purge time once the thermostat is satisfied. Default: 0 minutes
(Range: 0 – 10 minutes).

Function 14

DHW Priority

DHW PRIORITY
30 MINUTES 14

Allows the user to set the maximum run time for the indirect fired water heater and the minimum run time for
central heating. Default: 30 minutes (Range: 0 – 60 minutes).

Function 15

Cascade Address

CASCADE ADDRESS
0 15

Bus addressing boilers (maximum boilers allowed 8 in a cascade system). Master Boiler address is 0 and
Following Boilers are addressed 1 thru 7. Default: 0 (Range: 0 – 8). NOTE: DO NOT USE ADDRESS 8.

Function 16

Optional Inputs

OPTIONAL INPUT
RETURN SEN 16

Allows the user to select from optional inputs to control or monitor the system. Default: RETURN (Range:
Off / Booster 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 Speed).

Function 18

Step Modulation Mode

STEP MODULATE MODE
ON 18

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: OFF or ON).

Function 19

Boiler DHW Temp

BOILER SUPPLY DHW

180oF 19

Allows the user to program the boiler supply water temperature to the indirect heat exchanger during a
demand cycle. Default: 180oF (Range: 119oF to 190oF).

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%)

Function 23

Cascade Mode

CASCADE MODE
VISION 3 23

Allows the user to select cascade mode. Factory Default: Vision 3 (Range: 926 Boilers / Vision 3).

Function 24

Cascade Rotation

CASCADE ROTATION
48 HOURS 24

Sets the amount of hours before the first boiler in the cascade firing rotation will be changed. NOTE: If this
parameter is set to 0, the firing order of the boilers will not rotate. Default: 48 hours (Range: 0 – 240 hours).

Function 25

Cascade DHW Mode

NOT USED
NOT USED 25

Not used on this product.

Function 26

System Freeze Protect

SYS FREEZE PROT
PROTECT OFF 26

NOTE: This parameter is only present if the boiler is a cascade master. Allows the user to set the freeze
protection when a system pump is used. Factory Default: OFF. Selection of temperature activates freeze
protection. (Range: OFF, -40oF – 104oF).

Function 27

Error System Sensor

ERROR SYSTEM SENS
ON 27

Allows the user to set the control to display an error message if the system sensor is open or shorted. NOTE:
This error does not stop the boiler (or boilers) from running. Factory Default: ON (Range: ON / OFF).

Function 28

Freeze Protection

FREEZE PROTECTION
ON 28

Allows the user to set freeze protection on the boiler. Factory Default: ON (Range: ON / OFF).

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 short 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

OFF 30

Allows for a non HTP boiler to be controlled when the cascade output has risen above the percent of the
cascade firing rate set in this parameter. Factory Default: Off (Range: 50% - 100%).

Function 31

System Sensor Mode

SYSTEM SENSOR MODE
OFF 31

Suppresses the ‘NO FOLLOWER’ message on the display if the boiler is used as a cascade master boiler
with no follower boilers connected. Factory Default: OFF (Range: ON / OFF).

Function 32

Service Schedule

SERVICE SCHEDULE
OFF 32

Allows the user to select a service date or time based on the boiler run hours to program the boiler
maintenance schedule. Factory Default: OFF (Range: Date or Run Hours). NOTE: Without setting this
function, Functions 33/34/35/36 will not display.

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
10000’s 000000h 33

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 000000 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
10000’s 000000 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 18 – 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 ▲ or down ▼ arrows to change the
digit. Use the   arrow keys to switch between digits. When you’ve made your selection, press ENTER again.

73

Table 19 – Maintenance Reminder Function Screens

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 key  scroll to the selection
of year or hours. Select enter to reset the mode you are in. Use the up ▲ or down ▼ arrow key for each
adjustment then select ENTER when reset is complete.

SCREEN

DESCRIPTION

SUPPLY SEN 180oF
RETURN SEN 150oF

This screen is displayed after pressing the  key as described above. This shows the actual
temperature that the supply and return sensors are measuring. NOTE: If the boiler is configured to
use a 0 – 10 volt input, the return sensor is disabled and the second line of the display will be blank.

Press the ▼ key once.

CH SET 180oF
SUPPLY 122oF

The screen displays the current central heating temperature set point on the top line. NOTE: This
temperature set point may vary from what was set in the boiler settings if an outdoor sensor is used.
The actual temperature measured by the supply sensor is displayed on the bottom line.

Press the ▼ key once.

CH DEMAND OFF
BOILER

This screen displays the central heat demand set for the cascade system.

Press the ▼ key once.

0-10 SIGNL ON
*

Shows if 0 – 10 volt is enabled.

Press the ▼ key once.

CAS SET 190 oF
SYSTEM 112 oF

NOTE: This screen will appear only when set in Master Boiler mode.
This screen displays the cascade set point (maximum 190oF) 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.

Press the ▼ key once.

PART 10 – START-UP PROCEDURES FOR THE INSTALLER

74

Table 20 – NOTE: It is important to note that the user can adjust the heat curve down by lowering the central heating temperature.

A. BOILER CONTROL STATUS MENU

The boiler control also has the ability to review the status of the system. To access the status screens, simply
press the right arrow . Once the first value is displayed, press the up arrow ▲ or down arrow ▼ to access
additional information. At any point you may press the RESET button to exit the status screen. Listed below are
the status screens.

75

DHW SET 119 oF
DHW 117 oF

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 ▼ key once.

OUTDOOR 11 oF
FLUE 95 oF

The current outdoor temperature is displayed on the top line. If there is no outdoor sensor connected
to the boiler, this line will display ‘OFF’ in place of the temperature. If the outdoor sensor is shorted,

this line will display ‘ON’ in place of the temperature. The second line displays the current flue

temperature of the boiler.

Press the ▼ key once.

FLAME 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 ▼ 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 ▼ 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 a 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 ▼ key once.

POWER ON 0H
CH ON 0H

The top line of this display indicates the amount of hours the boiler has had power applied to it over
its life. The second line indicates how many hours the burner has been on for central heat demand
over its life.

Press the ▼ key once.

DHW ON 0H
GOOD IGNIT 1X

The top line of this display indicates the amount of hours the burner has been on for domestic hot
water demand in the life of the boiler. The second line indicates how many times the burner has
successfully ignited in the life of the boiler.

Press the ▼ key once.

SYS CH ON 0h
SYS DWH ON 0h

This screen displays how many hours the boiler has run to meet central heat and DWH demand.

SCREEN

DESCRIPTION

Press the ▼ key once.

FAULT HISTORY 1
07/27/2009 Mo 5:19A

This screen displays the last lockout fault the boiler controller had. The top line will alternate between

the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line displays the date and

time the fault occurred.

Press the ▼ key once.

FAULT HISTORY 2
08/28/2009 Fr 5:19A

This screen displays the second oldest lockout fault that occurred in the boiler controller. The top line

will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom

line will display the date and time that the fault occurred.

Press the ▼ key once.

FAULT HISTORY 3
08/28/2009 Fr 5:19A

This screen displays the third oldest lockout fault that occurred in the boiler controller. The top line

will alternate between the 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 ▼ key once.

FAULT HISTORY 4
08/28/2009 Fr 5:19A

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 fault occurred.

Press the ▼ key once.

FAULT HISTORY 5
08/28/2009 Fr 5:19A

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 fault occurred.

Press the ▼ key once.

FAULT HISTORY 6
08/28/2009 Fr 5:19A

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 fault occurred.

Table 21 – 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 ▼ key.

76

Press the ▼ key once.

FAULT HISTORY 7
08/28/2009 Fr 5:19A

This screen displays the seventh 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 fault occurred.

Press the ▼ key once.

FAULT HISTORY 8
08/28/2009 Fr 5:19A

This screen displays the eighth 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 fault occurred.

Press the ▼ key once.

FAULT HISTORY 9
08/28/2009 Fr 5:19A

This screen displays the ninth 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 fault occurred.

Press the ▼ key once.

FAULT HISTORY 10
08/28/2009 Fr 5:19A

This screen displays the tenth 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 fault occurred.

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  key from the default screen.

CASCADE 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  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 in 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  key from the default screen.

CASCADE TT 0123 567
SYS PUMP ON 12:47P

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 the 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 above, 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 ▼ key once.

CASCADE PWR 100%
PRESENT 01234567

This screen shows the overall cascade power output. The range of this value is the number of boilers
communicating with the Master x 100. For example, if 8 boilers are connected and communicating,
the maximum cascade power is 800%. The second line shows which boiler addresses are
communicating with the Master.

Table 22 – Fault History Screens

B. BOILER TEST MODE

This function is intended to simplify the gas adjustment. Listed in Table 24 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 ▲ and ENTER keys simultaneously. To exit, press ▲ and ▼
simultaneously.

NOTE: The boiler will automatically exit test mode after 20 minutes of operation.

C. CASCADE MENU

This menu is accessed by pressing the  key from the default menu or the  key from the status menu.

Press the ▼ key once.

CASCADE SYST 118oF
CASCADE SET 190oF

This screen shows the current system temperature sensor reading on the top line and the cascade
system temperature setting on the bottom.

Press the ▼ key once.

BOILER 0 100%
BOILER 1 56%

This screen shows the current cascade power demand output on a per connected boiler basis for
boilers 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 ▼ key once.

BOILER 2 0%
BOILER 3 0%

This screen shows the current cascade power demand output on a per connected boiler basis for
boilers addressed as 2 and 3.

Press the ▼ key once.

BOILER 4 0%
BOILER 5 0%

This screen shows the current cascade power demand output on a per connected boiler basis for
boilers addressed as 4 and 5.

Press the ▼ key once.

BOILER 6 0%
BOILER 7 0%

This screen shows the current cascade power demand output on a per connected boiler basis for
boilers addressed as 6 and 7.

COMBUSTION SETTINGS ON ALL MODELS

NATURAL GAS

PROPANE LP

Low

High

Low

High

CARBON MONOXIDE (CO%)

0 – 20 ppm

70 – 135 ppm

0 – 20 ppm

80 – 150 ppm

CARBON DIOXIDE (CO2%)

8 ½% - 9 ½%

8 ½% - 9 ½%

9 ½% - 10 ½%

9 ½% - 10 ½%

ELITE FAN SPEEDS

MODEL

IGNITION

MIN

MAX

80

3000

1700

4600

110

3800

1700

4950

150

3800

1700

5200

220

3000

1450

4900

299

3000

1450

5000

399

3000

1600

6650

SERVICE RUN 3400 RPM
PUMP ON 4:49P

Table 23 – Cascade Menu Screens

Table 24

77

Table 25

D. TEST MODE ACCESS

To activate the test mode, be sure the appropriate pumps are running, then press the ▲ and ENTER keys
together for 1 second. The boiler will go through the ignition sequence. Then the user can adjust the fan speed by
pressing ▲ to increase or ▼ to decrease fan speed.

To leave service mode, press the ▲ and ▼ keys simultaneously.

PART 11 – TROUBLESHOOTING

A. BOILER ERROR CODE

If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the
boiler, the display may show an error message and error code. This 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.

78

When servicing or replacing any components of this boiler, be certain that:

 The gas is off.
 All electrical power is disconnected.

When servicing or replacing components that are in direct contact with boiler water, be certain that:

 There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure

gauge reading.

 The boiler water is not hot.
 The electrical power is disconnected.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a
qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an
appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage
causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air.
Operating a previously submerged appliance could result in property damage, severe personal injury, or death.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under
product warranty.

This appliance has wire function labels on all internal wiring. Observe the position of each wire before removing it.
Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.

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 occur soon.

B. BOILER ERROR

When an error condition occurs, the controller will display a description and code on the display readout. These
error messages and their recommended corrective actions are described in Section D.

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 Section D in this part 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 unit for a

period of time to assure correct operation and no reoccurrence of fault message.

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.

SCREEN

DESCRIPTION

POSSIBLE REMEDY

Fault Code EO3
System Sensor Failure

SYS SUPPLY SENSOR
PUMP OFF E03

This screen shows that there is a problem with the
system sensor circuit. The circuit 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.

Disconnect the system sensor from the wiring and
measure the resistance of it. Compare the measured
resistance to the table in this 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.

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 ignite. This occurs
because the water temperature 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 (5oF) 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
pressure. This code resets automatically after the
high pressure condition is resolved. The second 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.

D. USER INTERFACE DISPLAY

Cascade Control FAULT Codes

79

80

Fault Code LOU

24 VOLT LOW LOU
PUMP ON

This display indicates that the 24 volt power supply
on the control is damaged or overloaded. This code
resets automatically if it is the result of an overload
and that overload condition is removed. The second
line indicates the status of the pump. Note that while
24 volt power is low, the pump output will be on.

1. Check line voltage. It must be between 100 and
128 volts.

2. 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 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 shorts to ground.

4. If a message only occurs when the burner tries to
light, check the gas valve for excessive 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 repair if
necessary. If the wiring is ok and this code is still
present and the water is not excessively hot, replace
the ECO sensor.

Fault Code F01

FLUE TEMP/WAT LV F01
PUMP ON

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
UL353 LWCO is installed). This code indicates a
serious safety issue. The boiler will not restart until
the flue cools down sufficiently or the water level is
restored. A technician 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 UL353 LWCO, check if the red
LED on the LWCO control box is illuminated. If so,
correct the low water condition and press the reset
button on the LWCO control box to reset the LWCO.
The LED should change to green. Press the reset
button on the front panel of the boiler to reset the
boiler control.

2. Check the flue for obstructions or any sign of
damage, especially signs of excessive heat. Repair
as necessary. Push the red reset button on the flue
temperature switch located on the flue inside the rear
access 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.

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.

81

Fault Code F03

RETURN SENSOR F03
PUMP ON

This display indicates that the return temperature
sensor of the boiler has failed. This code indicates a
serious safety issue and the boiler will not restart
until the sensor is replaced by a technician and he
pushes the RESET button on the display. This
situation is indicated by the red light on the display
and the word LOCKOUT flashing on the display.
During this lockout fault, the pump will be on as
indicated on the second line of the display.

1. 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 F02.

Fault Code F04

FLUE SENSOR F04
PUMP ON

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
indicated by the red light and the flashing word
LOCKOUT on the display. During this lockout fault,
the pump will be on as indicated on the second line
of the display.

Inspect the flue sensor for physical damage or
corrosion and replace it if necessary. Check the
electrical connection to the flue sensor and repair as
necessary. Measure the resistance of the sensor and
refer to the chart in Table 17 of this manual. The
temperature on the chart should be close to the same
as the temperature in the flue. If not, replace the flue
sensor.

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 230oF and a serious safety
issue exists. The boiler will not restart until the cause
of 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 210oF. The message will
clear automatically when the temperature drops
below 194oF. 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

F02.

Fault Code F06

RETURN TEMP HIGH F06
PUMP ON

This display indicates that the return temperature of
the boiler is excessive. If accompanied by the red
FAULT light and LOCKOUT flashing on the display,
the return sensor temperature has exceeded 230oF
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 temperature of the boiler is at or above 210oF.
The message will clear automatically when the
temperature drops below 194o 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 on boiler circulator. (See
Piping Details in this manual.)

4. Troubleshoot thermistor by following steps in F02.

82

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.

1. Watch the igniter through the observation window
provided.

2. If there is no spark, check the spark electrode for
the proper .196” (5.0 mm ± 1mm) gap.

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.

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 microampere, clean
the flame rectifier and spark probe.

6. If the problem persists and the ‘FLAME” signal is
still less than 1.0, replace the flame probe and spark
igniter probe.

7. The flame signal should be steady after the boiler
has been firing for 1 minute and is normally at 5.0 to

9.0. If the flame signal is not steady, disassemble the
burner door and check the burner and its sealing
gaskets.

Fault Code F11

FALSE FLAME SIG 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 corrective
action is taken.

6. If the refractory wall falls against the rectifier probe,
it may conduct the signal to ground, giving a false
reading.

Figure 31

83

Fault Code F13

FAN SPEED ERROR
F13
PUMP ON

The fan is not running at the speed that the control
has commanded it to run at. The fan speed had
been more than 30% faster or slower than the
commanded speed for more than 10 seconds. 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.

Fault Code F20

CONDENSATE FULL F20
PUMP ON

The condensate trap is full. The red light will display
and the word LOCKOUT will flash. This code
indicates a serious safety issue. The boiler will not
restart until the cause is determined by a technician
and he pushes the RESET button on the display.
During this lockout fault, the pump will be off as
indicated on the second line of the display.

1. Check condensate lines for obstructions.

2. Check float switch in condensate reservoir.

3. Check wiring from condensate reservoir to 926
control and repair as necessary.

Fault Code F31

PROGRAM ERROR
F31

There was an error while programming the control
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 reprogram 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 blocking codes will block operation until the control determines the situation safe for boiler operation.

Blocking Code E07

FLUE TEMP HIGH E07
PUMP OFF TIME

This display indicates that the flue sensor tem­perature is excessive and above 210oF. When this
code is displayed, the boiler will not respond to a
demand for heat. When the flue temperature
decreases below 194oF, 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 frequency
is out of range. This could happen if the boiler is
being powered from a small gasoline powered
generator that is not functioning correctly or
overloaded.

Inspect power wiring to boiler and repair as nec­essary. If connected to line voltage, notify the 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 26 – Fault and Blocking Code Screens

84

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.

Table 27

PART 12 – MAINTENANCE

A. MAINTENANCE PROCEDURES

Periodic maintenance should be performed once a year by a qualified service technician to assure that all the
equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified
heating contractor for periodic maintenance of the boiler. The installer must also inform the owner that a lack of
proper care and maintenance of the boiler may result in a hazardous condition.

The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be
converted to cristobalite in very high temperature applications. The International Agency for Research on

Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from
occupational sources is carcinogenic to humans (Group 1).”

 Avoid breathing dust and contact with skin and eyes.
 Use NIOSH certified dust respirator (N95). 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.

 Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
 Apply enough water to the combustion chamber lining to prevent dust.
 Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

 Eye: Irrigate immediately.
 Breathing: Fresh air.

B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER

*Before beginning this procedure, you must have on hand the following items:

 a nylon, stainless steel or brass brush (not steel)
 an FDA approved liquid lime scale remover, in a spray bottle
 gloves and eye protection

1. Shut down the Boiler by using the following steps:
a. Shut down the appliance. Close the gas valve. Wait for the appliance to be cool to the touch.
b. Disconnect the condensate piping from the outside connection, (not from the Boiler side), so flow from
condensate reservoir can be observed.
c. Remove the front panel of the boiler by firmly pulling the panel toward you until it releases.
d. Open the control door by turning the hand tightened nut counter-clockwise.
e. Disconnect electrical connections from the gas valve, spark electrode, flame rectification probe and
combustion blower.
f. Remove the (4) screws on the aluminum ¾” NPT connector on the right side of the gas valve.
g. Disconnect the wiring connected to the combustion blower motor.
h. Remove the (6) 10MM nuts from the burner plate assembly.

85

Figure 32

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.

i. Pull the entire burner plate assembly with blower still attached towards you. Remove or push aside any
wiring to allow the removal of the assembly.

2. Using a spray bottle filled with the FDA approved lime scale remover, spray liberally on the coils, making sure

the solution penetrates and funnels down through the condensate system. If the condensate system is blocked,
let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon, stainless steel or brass brush (do not use steel) and scrub coils to remove any buildup. Then

vacuum the debris from the coils.

4. Spray the coils with clear water, making sure to confine the spray to the area being cleaned (Try to avoid

getting the back ceramic wall of the appliance wet). Flush the combustion chamber with fresh water until it runs
clear from the condensate. At this point, the boiler should be ready to be re-assembled.

a. Inspect gaskets.
b. Re-install the burner assembly
c. Replace and tighten the (6) 10MM nuts to the burner plate using staggered tightening sequence. (See
detail)
d. Re-connect all wiring connections
e. Inspect the gas valve to assure the O-ring is in place.
f. Replace the (4) screws on the aluminum connector on the gas valve. Turn the gas back on.
(IMPORTANT: CHECK FOR GAS LEAKS!)
g. Re-secure the control door.
h. Replace the boiler front panel by aligning the four panel pins with the four jacket holes. Push firmly until
the panel is secure.
i. Turn the Boiler power back on and create a demand on the boiler. When boiler is lit, observe
condensate flow from the boiler. Be sure the boiler is operating properly.
j. Re-connect the condensate piping to the outside condensate connection.

86

C. CLEANING WATER SIDE OF HEAT EXCHANGER

1. Make sure power is turned off to the boiler. Run water through the hot water system to assure it is below room

temperature.

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 unit back in service.

87

Figure 33

88

Figure 34

89

Figure 35 – LP-293-A

NOTE: Parts listed on the following page.

90

ITEM#

EL-80

EL-110

EL-150

EL-220

EL-299

EL-399

DESCRIPTION

1

7450P-039

7450P-039

7450P-039

7450P-039

7450P-065

7450P-065

JACKET - REAR

2

7450P-055

7450P-055

7450P-056

7450P-038

7450P-064

7450P-068

JACKET - BOTTOM

3

7450P-121

7450P-121

7450P-121

7450P-121

7450P-121

7450P-121

LEVELING FEET

4

7450P-057

7450P-059

7450P-060

7450P-036

7450P-061

7450P-066

JACKET - LEFT SIDE

5

7450P-058

7450P-123

7450P-062

7450P-037

7450P-063

7450P-067

JACKET - RIGHT SIDE

6

7450P-080

7450P-080

7450P-080

7450P-080

7450P-080

7450P-080

10-32 X 5/16 PAN HEAD SCREW - JACKET

7

7450P-081

7450P-081

7450P-081

7450P-081

7450P-081

7450P-081

6-32 X 1/4 PAN HEAD SCREW - ACCESSORIES

8

7450P-074

7450P-074

7450P-074

7450P-074

7450P-075

7450P-075

AIR/EXHAUST SUPPORT PLATE

9

7500P-115

7500P-115

7500P-115

7500P-115

7500P-115

7500P-115

6-32 X 1/4 PAN HEAD SCREW - ELECTRONIC
BOARDS

10

7450P-178

7450P-178

7450P-178

7450P-178

N/A

N/A

FIELD CONNECTION BOARD PLATE

11

7450P-088

7450P-088

7450P-088

7450P-088

7450P-088

7450P-088

8-32 FLANGED NUT - AIR EXHAUST PLATE

12

7450P-030

7450P-030

7450P-030

7450P-030

7450P-031

7450P-031

AIR INLET ADAPTER

13

7450P-032

7450P-032

7450P-032

7450P-032

7450P-033

7450P-033

AIR INLET CONNECTOR NUT

14

7450P-201

7450P-201

7450P-201

7450P-201

7450P-202

7450P-202

EXHAUST ADAPTER

15

7250P-739

7250P-739

7250P-739

7250P-739

7250P-739

7250P-739

ECO FLUE SWITCH - 160 DEGREES

16

7250P-154

7250P-154

7250P-154

7250P-154

7250P-154

7250P-154

S.S. BARBED FITTING - 1/4 HOSE X 10-32

17

7450P-026

7450P-026

7450P-026

7450P-026

7450P-026

7450P-026

FLUE THERMISTOR

18

7250P-152

7250P-152

7250P-152

7250P-152

7250P-152

7250P-152

SILICONE O-RING 2-007 - BARBED FITTING

19

7450P-079

7450P-079

7450P-079

7450P-079

7450P-079

7450P-079

HINGE BRACKET

20

7450P-091

7450P-091

7450P-091

7450P-091

7450P-091

7450P-091

HINGE

21

7450P-132

7450P-132

7450P-132

7450P-132

7450P-132

7450P-132

CONTROL BOARD DOOR W/HINGE

22

7450P-122

7450P-122

7450P-122

7450P-122

7450P-122

7450P-122

926 CONTROL BOARD

23

7350P-070

7350P-070

7350P-070

7350P-070

7350P-070

7350P-070

FIELD CONNECTION BOARD

24

7450P-040

7450P-040

7450P-041

7450P-042

7450P-043

7450P-044

JACKET - TOP COVER FRONT

25

7450P-072

7450P-072

7450P-099

7450P-099

7450P-073

7450P-073

JACKET - TOP COVER BACK

26

7450P-021

7450P-021

7450P-021

7450P-021

7450P-021

7450P-021

MEMBRANE TOUCHPAD

27

7000P-805

7000P-805

7000P-805

7000P-805

7000P-805

7000P-805

PLASTIC TUBING - 3/16 OD - BLOCKED VENT
PRESSURE SWITCH

28

7250P-150

7250P-150

7250P-150

7250P-150

7250P-150

7250P-150

BLOCKED VENT PRESSURE SWITCH

29

7450P-142

7450P-142

7450P-142

7450P-142

7450P-142

7450P-142

6-32 FLANGED NUT - BLOCKED VENT
PRESSURE SWITCH

30

7450P-046

7450P-046

7450P-046

7450P-046

7450P-051

7450P-051

JACKET - FRONT COVER ASSY

31

7450P-045

7450P-045

7450P-045

7450P-045

7450P-045

7450P-045

JACKET - TOP COVER INSERT

32

7500P-087

7500P-087

7500P-087

7500P-087

7500P-087

7500P-087

POWER SWITCH

33

7450P-092

7450P-092

7450P-092

7450P-092

7450P-092

7450P-092

6-32 FLAT HEAD SCREW - ACCESSORIES

34

7450P-028

7450P-028

7450P-028

7450P-028

7450P-028

7450P-028

DISPLAY BOARD

35

7450P-018

7450P-018

7450P-018

7450P-018

7450P-018

7450P-018

MEMBRANE SWITCH BRACKET

36

7250P-378

7250P-378

7250P-378

7250P-378

7250P-378

7250P-378

FUSE - CONTROL BOARD - 6.3 AMPS

37

7350P-129

7350P-129

7350P-129

7350P-129

7350P-129

7350P-129

FUSE - CONNECTION BOARD - 3.15 AMPS

38

7450P-160

7450P-160

7450P-160

7450P-160

7450P-160

7450P-160

FIELD CONNECTION BOARD COVER

39

N/A

N/A

N/A

7450P-061

N/A

N/A

BOILER ACCESS COVER

40

7450P-076

7450P-076

7450P-076

7450P-076

7450P-077

7450P-077

(2)

MODULE HOLD-DOWN STRAP

41

N/A

N/A

N/A

7450P-221

7450P-221

7450P-221

TRANSFORMER ASSEMBLY

42

7450P-204

7450P-204

7450P-204

7450P-208

7450P-209

7450P-210

120V WIRING HARNESS (NOT SHOWN)

43

7450P-203

7450P-203

7450P-203

7450P-205

7450P-206

7450P-207

LOW VOLTAGE WIRING HARNESS (NOT
SHOWN)

44

7450P-226

7450P-226

7450P-226

7450P-226

7450P-226

7450P-226

7/8 HOLE PLUG

45

7450P-282

7450P-282

7450P-282

7450P-282

7450P-157

7450P-157

CLAMP ALL - EXHAUST VENT ADAPTER

LIGHT OFF ACTIVITIES

DATE COMPLETED ________________

1) Fill the
heating
system

Check all piping and gas connections,
verify all are tight

Pressurize system (12 – 15 psi)

____ PSI

Add water to prime condensate cup

Percentage of glycol in system (0 –
50%)

____ %

Verify near boiler piping is properly
supported

2) Check
gas pipe

Leak test using locally approved
methods (consult jurisdictional code
book)

Check incoming gas pressure (3.5” to

14” W.C.)

____ in w.c.

Static

What is the “drop” on light off (No more
than 1” W.C.)?

____ in w.c.

Dynamic

3) Check
combustion

Check and adjust (if necessary) carbon
dioxide content

____% CO2

High Fire

____%

CO2

Low Fire

Check and adjust (if necessary) carbon
monoxide content

____ppm

CO

High Fire

____ ppm

CO

Low Fire

4) Verify
system
operation

Turn up thermostat to verify wiring
connections

5) Record
ionization
current

Check uA reading at d7 on the status
menu (see start-up section)

____ uA

High Fire

____ uA

Low Fire

6) Indirect
water heater

Verify safety and operation of the
indirect water heater, record settings

____de

____dh

7) Convert
the boiler

If necessary, convert the boiler to the
proper gas type

Locate the stickers in the appropriate
locations on the boiler

Verify combustion settings after gas
conversion, Carbon Dioxide

____% CO2

High Fire

____%

CO2

Low Fire

Verify combustion settings after gas
conversion, Carbon Monoxide

____ppm

CO

High Fire

____ppm

CO

Low Fire

Mail in the conversion registration

8)Record
system
settings

Record heating curve, record steps

____*8

____*9

____*10

____*11

Notes:

BOILER START-UP REPORT

91

Table 28

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!

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.

INSPECTION ACTIVITIES

DATE LAST COMPLETED

PIPING

1st YEAR

2nd YEAR

3rd YEAR

4th 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 intake and exhaust 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 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.

Spark Electrode

Clean. Set gap at ¼”.

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 hose

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.)

MAINTENANCE REPORT

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 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. Installer must also inform the owner that the lack of
proper care and maintenance of the boiler may result in a hazardous condition.

92

Check gas pipe for
leaks

Check piping for leaks. Verify that all are properly
supported.

COMBUSTION

CO/CO2 Levels

Check CO and CO2 levels in Exhaust (See Start-up
Procedures for ranges). Record at high and low fire.

SAFETIES

ECO (Energy Cut
Out)

Check continuity on Flue and Water ECO. Replace if
corroded.

Thermistors

Check wiring. Verify 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 29 - *Continue annual maintenance beyond the 4th year as required.

93

94

95

96

MAINTENANCE NOTES

Customer’s Name:

Installation Address:

Date of Installation:

Installer’s Code/Name:

Product Serial Number(s):

Combustion Setting at Time of Installation:

Comments:
Installer’s Phone Number:

Signed by Installer:

Signed by Customer:

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.

97

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 Representative.

Distributor/Dealer: Please insert contact details.

LP- 293 REV. 3.29.12