HTP EL-399 User 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

Models*

EL-80 / 110 / 150 / 220 / 299 / 301 / 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. 5.20.14

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.

LP- 293 REV. 5.20.14

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.

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.

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.

LP- 293 REV. 5.20.14

The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death. Damage or failure of this product (or the system in which it is installed) due to unauthorized use IS NOT COVERED BY WARRANTY.

NOTICE

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

 A modulating combustion system that adjusts firing rate based on heat demand.  Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor. The outdoor sensor

is supplied by HTP, Inc. with this boiler.

 This boiler does not include a standing pilot.  This boiler is designed and shipped to assure the highest efficiency operation possible. Such high efficiency is

achieved by limiting heating circuit water temperature to 140°F when there is no anticipated heat load, based upon the outdoor sensor and the Outdoor Reset Curve (sensor response curve) in the boiler software.

 This feature may be over-ridden as described below in specific installations:  The boiler control is equipped with an outdoor sensor override for use with building management systems or in

cascaded systems (for systems with total input of 300,000 BTU/hr or greater). See statement below for an important notice on the use of the override.

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

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

decreases.

 This boiler is not used for space heating.  This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.  This boiler is equipped with a tankless coil.

NOTICE

The CSD-1 ASME Code, Section CW-400 requires that hot water heating and supply boilers have a) a UL 353 temperature control device, b) at least one (1) temperature-actuated control to shut off the fuel supply when system water reaches a preset operating temperature, c) a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout, and d) its own sensing element and operating switch.

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

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.

TABLE OF CONTENTS

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

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

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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 ........................................................................................................................................................ 9

C. OPTIONAL EQUIPMENT ......................................................................................................................................................... 10

PART 3 – PREPARE BOILER LOCATION ............................................................................................................................... 11

A. BEFORE LOCATING THE BOILER ......................................................................................................................................... 11

B. LEVELING AND DIMENSIONS ................................................................................................................................................ 12

C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 12

D. RESIDENTIAL GARAGE INSTALLATION ............................................................................................................................... 14

E. EXHAUST VENT AND INTAKE PIPE....................................................................................................................................... 14

F. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 15

G. REMOVING A BOILER FROM A COMMON VENT SYSTEM ................................................................................................. 15

H. UNCRATING THE BOILER ...................................................................................................................................................... 16

PART 4 – BOILER PIPING ........................................................................................................................................................ 16

A. GENERAL PIPING INFORMATION ......................................................................................................................................... 16

B. RELIEF VALVE ........................................................................................................................................................................ 17

C. BACKFLOW PREVENTER ...................................................................................................................................................... 17

D. SYSTEM WATER PIPING METHODS ..................................................................................................................................... 17

E. CIRCULATORS ........................................................................................................................................................................ 18

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS ...................................................... 18

G. PIPING DETAILS* .................................................................................................................................................................... 19

H. PIPING INSTALLATION ........................................................................................................................................................... 23

I. CIRCULATOR SIZING ............................................................................................................................................................... 23

J. CHECK/CONTROL WATER CHEMISTRY ............................................................................................................................... 25

K. FILL AND PURGE HEATING SYSTEM .................................................................................................................................... 26

L. GLYCOL ANTIFREEZE SOLUTIONS ....................................................................................................................................... 26

M. ZONING WITH ZONE VALVES ............................................................................................................................................... 26

N. ZONING WITH CIRCULATORS ............................................................................................................................................... 27

O. MULTIPLE BOILERS ............................................................................................................................................................... 27

PART 5 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL ........................................................................... 27

A. GENERAL ................................................................................................................................................................................ 27

B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE .................................................................................... 28

C. REQUIREMENTS FOR INSTALLATION IN CANADA ............................................................................................................. 28

D. EXHAUST VENT AND INTAKE PIPE LOCATION ................................................................................................................... 29

E. EXHAUST VENT AND INTAKE PIPE SIZING .......................................................................................................................... 32

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F. LONGER VENT RUNS ............................................................................................................................................................. 32

G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 33

H. SIDEWALL VENTING .............................................................................................................................................................. 34

I. VERTICAL VENTING................................................................................................................................................................. 35

J. HORIZONTAL VENTING .......................................................................................................................................................... 36

K. UNBALANCED FLUE / VERTICAL VENT ................................................................................................................................ 37

L. VENTING THROUGH AN EXISTING SYSTEM ........................................................................................................................ 37

1. CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM ................................................................................................. 38

2. VENTING AS A CHASE .............................................................................................................................................................. 39

M. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE .................................................... 40

PART 6 – GAS PIPING .............................................................................................................................................................. 42

A. GAS CONNECTION ................................................................................................................................................................. 42

B. GAS PIPING ............................................................................................................................................................................. 42

C. CHECK INLET GAS PRESSURE............................................................................................................................................. 43

D. BOILER GAS VALVE ............................................................................................................................................................... 44

PART 7 – FIELD WIRING .......................................................................................................................................................... 45

A. INSTALLATION MUST COMPLY WITH: .................................................................................................................................. 45

B. FIELD WIRING TERMINATIONS ............................................................................................................................................. 45

C. FIELD WIRING ......................................................................................................................................................................... 45

D. LINE VOLTAGE WIRING FOR STANDARD BOILER .............................................................................................................. 45

E. ALARM CONNECTIONS .......................................................................................................................................................... 46

F. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER ................................................................................................. 46

G. THERMOSTAT ........................................................................................................................................................................ 46

H. OUTDOOR SENSOR ............................................................................................................................................................... 46

I. INDIRECT SENSOR .................................................................................................................................................................. 47

J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL ........................................................................................................... 47

K. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT ................................................................................................ 47

L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS .................................................................................................... 47

M. CASCADE MASTER PUMP AND SENSOR WIRING.............................................................................................................. 49

N. CASCADE FOLLOWER PUMP AND SENSOR WIRING ......................................................................................................... 49

PART 8 – START-UP PREPARATION...................................................................................................................................... 54

A. CHECK / CONTROL WATER CHEMISTRY ............................................................................................................................. 54

B. CHECK FOR GAS LEAKS ....................................................................................................................................................... 55

C. FREEZE PROTECTION (WHEN USED) .................................................................................................................................. 55

D. FILL AND TEST WATER SYSTEM .......................................................................................................................................... 55

E. PURGE AIR FROM WATER SYSTEM ..................................................................................................................................... 55

F. CHECK THERMOSTAT CIRCUIT(S) ....................................................................................................................................... 56

G. CONDENSATE REMOVAL ...................................................................................................................................................... 56

H. FINAL CHECKS BEFORE STARTING BOILER ...................................................................................................................... 57

I. CASCADE SYSTEM .................................................................................................................................................................. 57

J. LOCKOUT CONDITION ............................................................................................................................................................ 57

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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.

PART 9 – START-UP PROCEDURE ......................................................................................................................................... 58

A. CONTROL OVERVIEW ............................................................................................................................................................ 58

B. NAVIGATION OF THE DISPLAY ............................................................................................................................................. 58

C. OPERATING INSTRUCTIONS ................................................................................................................................................ 59

D. PROGRAMMING BOILER SETTINGS ..................................................................................................................................... 59

E. PROGRAMMING THE SYSTEM SETTING ............................................................................................................................. 60

F. SYSTEM SETTING PROGRAM NAVIGATION ........................................................................................................................ 60

G. RESETTING THE MAINTENANCE SCHEDULE ..................................................................................................................... 62

PART 10 – START-UP PROCEDURES FOR THE INSTALLER ............................................................................................... 63

A. BOILER CONTROL STATUS MENU ....................................................................................................................................... 63

B. CASCADE MENU ..................................................................................................................................................................... 65

C. BOILER TEST MODE ACCESS ............................................................................................................................................... 65

PART 11 – TROUBLESHOOTING ............................................................................................................................................ 66

A. BOILER ERROR CODE ........................................................................................................................................................... 66

B. BOILER ERROR ...................................................................................................................................................................... 66

C. BOILER FAULT ........................................................................................................................................................................ 66

D. USER INTERFACE DISPLAY .................................................................................................................................................. 67

PART 12 – MAINTENANCE ...................................................................................................................................................... 72

A. MAINTENANCE PROCEDURES ............................................................................................................................................. 72

B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER ....................................................................... 73

C. CLEANING WATER SIDE OF HEAT EXCHANGER ................................................................................................................ 74

D. MAINTAINING THE CONDENSATE SYSTEM ........................................................................................................................ 74

BOILER START-UP REPORT ................................................................................................................................................... 79

MAINTENANCE REPORT ......................................................................................................................................................... 79

MAINTENANCE NOTES ................................................................................................................................................................. 83

HTP CUSTOMER INSTALLATION RECORD FORM ..................................................................................................................... 84

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 exhaust vent and intake pipe 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 highefficiency heat exchanger can be damaged by build-up or corrosion due to sediment. HTP recommends a suction strainer in this type of system.

 Do not use petroleum-based cleaning or sealing compounds in boiler

system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

 Do not use “homemade cures” or “boiler patent medicines”.

Substantial property damage, damage to boiler, and/or serious personal injury may result.

 Continual fresh make-up water will reduce boiler life. Mineral buildup

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

NOTE: DO NOT add cold make up water to the system when the boiler is hot. Thermal shock can potentially cause cracks in the heat exchanger. Such damage IS NOT covered by warranty.

LP- 293 REV. 5.20.14

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.

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

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 #7250P-211)  Pressure Relief Valve (Part #7250P-080)  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 EL299/301, 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.

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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. 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)

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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.

 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-80/110/150/220/299/301, Part # 7350P-611 for EL-399)  Flow Switch Kit (Part # 7450P-213 for EL-80/110/150/220, Part # 7450P-214 for EL-299/301, Part # 7450P-215 for EL-399)  Vision II (Part # 7250P-322)

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

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

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.

LP- 293 REV. 5.20.14

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.

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.

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.

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

Figure 2 – Recommended Service Clearances

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

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.

LP- 293 REV. 5.20.14

Figure 3 - LP-285-B

LP- 293 REV. 5.20.14

Vents must be properly supported. The boiler exhaust and intake connections are not designed to carry heavy weight. Vent support

brackets must be within 1’ of the boiler and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’ from the boiler.

Figure 4

D. RESIDENTIAL GARAGE INSTALLATION

PRECAUTIONS

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

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

well off the floor.

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

E. EXHAUST VENT AND INTAKE PIPE

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.

LP- 293 REV. 5.20.14

Ensure that the intake air will not contain any of the contaminants below. For example, do not pipe intake 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).

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.

Figure 5 - CO Warning Label

You must also install air intake piping from outdoors to the boiler flue adaptor. The resultant installation is categorized as direct vent (sealed combustion). NOTE: To prevent combustion air contamination, see Table 1 in this section when considering exhaust vent and intake pipe termination.

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

F. PREVENT COMBUSTION AIR CONTAMINATION

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

Table 1

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.

LP- 293 REV. 5.20.14

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.

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.

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.

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

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

LP- 293 REV. 5.20.14

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.

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.

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

B. RELIEF VALVE

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

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.

LP- 293 REV. 5.20.14

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 / EL-301

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 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.

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 noncombustible 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

LP- 293 REV. 5.20.14

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

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.

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.

LP- 293 REV. 5.20.14

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.

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. LP- 293 REV. 5.20.14

Figure 8 – LP-293-O NOTES:

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

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

3. Piping shown is Primary/Secondary.

4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained

above the minimum flow rates published on p. 28, this manual.

5. Installations must comply with all local codes.

LP- 293 REV. 5.20.14

Figure 9 – LP-293-P NOTES:

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

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

3. Piping shown is Primary/Secondary.

4. System flow (secondary loop) should be greater than the boiler primary loop flow. In all cases, the boiler primary loop flow rate must be maintained

above the minimum flow rates published on p. 28, this manual.

5. Installations must comply with all local codes.

LP- 293 REV. 5.20.14

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

MINIMUM BOILER FLOW RATES

MODEL

MINIMUM FLOW RATE (GPM)

EL-80

5.3

EL-110

7.3

EL-150

EL-220

14.6

El-299 / EL-301

El-399

HEAT EXCHANGER PRESSURE DROP CHART

Model

Flow Rate Δ P’

Flow Rate

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

GPM

21 GPM

22 GPM

EL-80

10’

14’

17’

21’

26’ * * * * * * * * * * * *

EL-110 * *’

15’

17’

22’

25’

33’ * * * * * * * * * *

EL-150 * * * *

12’

15’

17’

19’

22’

27’ * * * * * * * EL-220 * * * * * * * * * 8’

10’

11.5’

13’

15’

16.5’

17’

19’

EL-299 EL-301

* * * * * * * * * * * * * * 13’

14’

15’

EL-399 * * * * * * * * * * * * * * * *

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.

I. CIRCULATOR SIZING

The heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator. These minimum water volumes are listed in Table 3 below.

Table 3 – Minimum Heat Exchanger Water Volumes

The heat exchanger has a pressure drop that must be considered in your system design. Refer to Table 4 for pressure drop through the heat exchanger.

LP- 293 REV. 5.20.14

MULTIPLE BOILER MANIFOLD PIPING

Flow Rate (GPM)

100

110

Pipe Dia. (Inches)

2 2 2 2 2

2½

2½ 3 3 3 3 3 3

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

0 50 100 150 200 250

Pipe Diameter Size (Inches)

Combined Boiler Water Flow (GPM)

Multiple Boiler Manifold Piping

Flow Rate

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

GPM

38 GPM

39 GPM

EL-80 * * * * * * * * * * * * * * * * * EL-110 * * * * * * * * * * * * * * * * * EL-150 * * * * * * * * * * * * * * * * * EL-220

21’

23’

24’ * * * * * * * * * * * * * *

EL-299 EL-301

16.5’

18’

20’

22’

24’

26’

29’

33’

36’ * * * * * * * *

EL-399 * * * 12.9’

13.6’

14’

15.7’

17’

18’

19.4’

21’

22.5’

26’

28’

31’

34’

39’

Table 4 – NOTE: *Do not operate boiler at these flow settings as it will damage the heat exchanger or related components.

Table 5

SYSTEM TEMPERATURE RISE CHART

Model

20°Δt

25°Δt

30°Δt

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

EL-110

25’

11 GPM

17’

9.1 GPM

12’

7.3 GPM

EL-150

27’

15 GPM

17’

12.5 GPM

12’

10 GPM

EL-220

19’

22 GPM

13’

18.3 GPM

12’

14.6 GPM

EL-299 EL-301

29’

29 GPM

18’

24.5 GPM

13’

20 GPM

EL-399

39’

39 GPM

19’

32.5 GPM

13’

26 GPM

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”.

Table 6

Figure 10

Table 7

LP- 293 REV. 5.20.14

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.

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 6 and Table 7. Reducing pipe size can restrict flow rate through the water boiler, causing inadvertent short cycling and poor system performance.

Check valves:

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

Water boiler isolation valves:

Field supplied. Full port ball valves are required. 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.

LP- 293 REV. 5.20.14

MINIMUM PIPE SIZES

EL 80/110/150/220

1” NPT or Copper

EL 299/301

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%.

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.

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.

Table 8

K. FILL AND PURGE HEATING SYSTEM

1. Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain.

2. 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).

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.

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.

LP- 293 REV. 5.20.14

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