HTP ELP-199 User Manual

Elite Plus

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.

Heating Boiler

INSTALLATION

START-UP

MAINTENANCE

PARTS

Models

ELP-110 / ELP-199

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-294 REV. 2.20.14

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-294 REV. 2.20.14

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 of 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 boiler must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

INSTALLATIONS MUST COMPLY WITH:

Authority Having Jurisdiction, local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant

Valley Road, Cleveland, OH 44131. In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario,

Canada 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-294 REV. 2.20.14

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.

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.

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

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 ............................................................................................................................... 11

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

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B. LEVELING ................................................................................................................................................................................ 12

C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................. 13

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

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

F. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 14

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

H. UNCRATING THE BOILER ...................................................................................................................................................... 15

PART 4 – BOILER PIPING ........................................................................................................................................................ 15

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

B. RELIEF VALVE ......................................................................................................................................................................... 16

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

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

E. CIRCULATORS ........................................................................................................................................................................ 17

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS ...................................................... 17

G. PIPING DETAILS* .................................................................................................................................................................... 18

H. PIPING INSTALLATION ........................................................................................................................................................... 24

I. CIRCULATOR SIZING ............................................................................................................................................................... 24

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

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

L. GLYCOL ANTIFREEZE SOLUTIONS ....................................................................................................................................... 27

M. ZONING WITH ZONE VALVES................................................................................................................................................ 27

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

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

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

A. GENERAL ................................................................................................................................................................................. 28

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

C. REQUIREMENTS FOR INSTALLATION IN CANADA .............................................................................................................. 29

D. EXHAUST VENT AND INTAKE PIPE LOCATION.................................................................................................................... 30

E. EXHAUST VENT AND INTAKE PIPE SIZING .......................................................................................................................... 33

F. LONGER VENT RUNS ............................................................................................................................................................. 33

G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 34

H. SIDEWALL VENTING W/ TEE (INTAKE) AND COUPLING (EXHAUST) ................................................................................. 35

I. VERTICAL VENTING W/ TEE (INTAKE) AND COUPLING (EXHAUST) ................................................................................... 36

J. HORIZONTAL VENTING ........................................................................................................................................................... 37

K. UNBALANCED FLUE / VERTICAL VENT ................................................................................................................................ 38

L. VENTING THROUGH AN EXISTING SYSTEM ................................................................ ........................................................ 38

1. CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM .................................................................................................. 39

2. VENTING AS A CHASE .............................................................................................................................................................. 40

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

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

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

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

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

PART 7 – FIELD WIRING .......................................................................................................................................................... 44

A. INSTALLATION MUST COMPLY WITH: .................................................................................................................................. 44

B. FIELD WIRING TERMINATIONS .............................................................................................................................................. 44

C. FIELD WIRING ......................................................................................................................................................................... 44

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

E. ALARM CONNECTIONS .......................................................................................................................................................... 45

F. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER ................................................................................................. 45

G. THERMOSTAT ......................................................................................................................................................................... 45

H. OUTDOOR SENSOR ............................................................................................................................................................... 45

I. INDIRECT SENSOR .................................................................................................................................................................. 46

J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL ............................................................................................................ 46

K. SYSTEM SENSOR (CASCADE MASTER BOILER ONLY) ...................................................................................................... 46

L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS ..................................................................................................... 46

M. CASCADE MASTER AND FOLLOWER WIRING .................................................................................................................... 47

PART 8 – START-UP PREPARATION...................................................................................................................................... 50

A. CHECK / CONTROL WATER CHEMISTRY ............................................................................................................................. 50

B. FREEZE PROTECTION (WHEN USED) .................................................................................................................................. 50

C. FILL AND TEST WATER SYSTEM .......................................................................................................................................... 51

D. CHECK FOR GAS LEAKS ........................................................................................................................................................ 51

E. CHECK THERMOSTAT CIRCUITS .......................................................................................................................................... 52

F. CONDENSATE REMOVAL ....................................................................................................................................................... 52

G. FINAL CHECKS BEFORE STARTING BOILER ....................................................................................................................... 52

H. CASCADE SYSTEM ................................................................................................ ................................................................ . 53

PART 9 – CONTROL AND DISPLAY OVERVIEW ................................................................................................................... 53

A. CONTROL OVERVIEW ............................................................................................................................................................ 54

B. MENU STRUCTURE ................................................................................................................................................................ 54

C. NAVIGATION OF THE DISPLAY.............................................................................................................................................. 54

D. START-UP INSTRUCTIONS ................................................................................................................................ .................... 55

E. INITIALIZING SCREENS .......................................................................................................................................................... 56

PART 10 – CONTROL MAIN SCREENS................................................................................................................................... 56

A. STAND-ALONE BOILER MAIN SCREENS .............................................................................................................................. 56

B. CASCADE MASTER MAIN SCREENS ..................................................................................................................................... 57

PART 11 – USER MENU SCREENS ......................................................................................................................................... 58

A. DESCRIPTION OF THE USER MENU ..................................................................................................................................... 58

B. BOILER STATUS SCREENS ................................................................................................................................................... 58

C. BOILER SETTINGS SCREENS................................................................................................................................................ 58

D. CASCADE STATUS ................................................................................................................................................................. 59

PART 12 – INSTALLER MENU SCREENS ................................................................ ............................................................... 59

A. BOILER STATUS INSTALLER ................................................................................................................................................. 60

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B. BOILER CONFIGURATION ...................................................................................................................................................... 61

C. CENTRAL HEATING SETTINGS ............................................................................................................................................. 62

D. DOMESTIC HOT WATER SETTINGS ...................................................................................................................................... 63

E. CASCADE SETTINGS .............................................................................................................................................................. 63

F. SYSTEM TEST ......................................................................................................................................................................... 65

G. LAMBDA CONSTANT .............................................................................................................................................................. 65

PART 13 – START-UP PROCEDURE ....................................................................................................................................... 66

A. INSTALLER MENU .................................................................................................................................................................. 66

B. PURGING AIR FROM THE WATER SYSTEM ................................................................ ................................ ......................... 66

C. SELECTING THE GAS TYPE AND PREPURGE INITIAL FAN SPEED ................................................................................... 66

1. GAS TYPE ................................................................................................................................................................................... 66

2. PREPURGE INITIAL FAN SPEED .............................................................................................................................................. 67

D. MODIFYING THE BOILER CONFIG, CH-SETTINGS, AND DHW-SETTINGS ................................................................ ........ 67

1. BOILER CONFIG MENU ............................................................................................................................................................. 67

2. CENTRAL HEATING SETTINGS ................................................................................................................................................ 68

3. DHW SETTINGS .......................................................................................................................................................................... 68

E. USER MENU BOILER SETTINGS ............................................................................................................................................ 69

F. CASCADE FOLLOWER MAIN SCREENS ................................................................................................................................ 69

PART 14 – TROUBLESHOOTING ............................................................................................................................................ 69

A. BOILER ERROR CODES ......................................................................................................................................................... 70

B. USER INTERFACE DISPLAY ................................................................................................................................................... 70

1. LOCKOUT ERROR CODES ........................................................................................................................................................ 70

2. BLOCKING ERROR CODES ....................................................................................................................................................... 71

3. LAMBDACONSTANT LOCKOUT CODES .................................................................................................................................. 72

4. LAMBDACONSTANT BLOCKING CODES ................................................................................................................................ 72

PART 15 – MAINTENANCE ...................................................................................................................................................... 73

A. MAINTENANCE PROCEDURES .............................................................................................................................................. 73

B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER ........................................................................ 74

BOILER START-UP REPORT ................................................................................................................................................... 78

MAINTENANCE REPORT ......................................................................................................................................................... 78

MAINTENANCE NOTES .................................................................................................................................................................. 82

HTP CUSTOMER INSTALLATION RECORD FORM...................................................................................................................... 83

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This boiler 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 boiler has been approved for closet installation. Do not install this boiler directly on carpeting. For installation on combustible flooring. Category IV vent systems only.

LP-294 REV. 2.20.14

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.

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 cause by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.

Be sure to disconnect electrical power before opening the boiler cabinet. Failure to do so could result in an electrical shock, serious injury or death.

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.

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

B. IMPROPER COMBUSTION

C. GAS

In event of gas supply failure, safety valve discharge, or overheating, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the boiler.

D. WHEN SERVICING THE BOILER

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

E. BOILER WATER

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

damaged. This can result 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.

LP-294 REV. 2.20.14

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

Consider boiler piping and installation when determining boiler location.

 Continual fresh make-up water will reduce boiler life. Mineral buildup reduces heat transfer, overheats the stainless steel heat

exchanger, and causes failure. Addition of oxygen by make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once.

 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.

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 20 mGL.  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 the heat exchanger at least once a year to prevent lime scale buildup. To clean the heat exchanger, follow the procedure in Part 16 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  Pressure Relief Valve  Indirect Sensor  Outdoor Sensor  Intake PVC Tee with Screens  Exhaust PVC Coupling with Screens  Outlet Combination Fitting  Installation Manual  Warranty

LP-294 REV. 2.20.14

 CSD-1 Form  H-3 Data Sheet

B. HOW BOILER OPERATES

Elite Plus® condensing technology intelligently delivers highly efficient hydronic heating by adjusting for altitude and fuel (liquid propane or natural gas) without the need for conversion or physical adjustment. 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 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 mass flow to control boiler output. This allows the boiler to deliver the amount of heat energy required and nothing more.

The control can be set to monitor outdoor temperature through an outdoor sensor to regulate boiler set point. The system can be further enhanced by installing an indirect water heater to provide domestic hot water.

The control can regulate the output of up to sixteen boilers through its cascade system function. The cascade system controls up multiple boilers in such a way that they function as one system. This allows for greater turn down ratios, minimizing downtime and maximizing efficiency.

The cascade system establishes one boiler as the master and the connected boilers as followers. The master requires a sensor providing set point temperature feedback 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 installer to change system parameters and monitor outputs.

Start Up – Learning Behavior – When the boiler is first powered on, it may have some unsuccessful starts. This happens because the boiler control is learning about the system through its sensors.

Integrated Air Mass Flow Sensor and Modulating Gas Valve – An air mass flow sensor is integrated into the boiler fan. When the fan receives a demand from the control, it engages and automatically adjusts for external influences like air density or system pressure drop.

Burner – Constructed of high grade stainless steel, the burner provides a wide range of firing rates using premixed air and gas fuel. Heat Load Limit Management – The heat load will automatically adapt during operation because of circumstances like wind, chimney

draft, low ionization current, etc. In the same way, the maximum heat load will adapt to too high counter pressure in the exhaust gas pipe or if the gas pressure is too low.

Post Heating and Backflow Prevention in Standby Mode – To prevent overheating, the fan will run at minimum mass flow when the burner is too hot. If the boiler is not running and backflow is detected, the fan will run at minimum mass flow for up to 5 hours after heat demand.

Step Modulation – On receiving a Central Heating demand, the boiler will start at minimum output and gradually increase by steps to provide precise output for even small heating systems.

Spark Ignition – The burner is ignited by applying high voltage through the system spark electrode. This spark ignites mixed gas off of the burner.

Flame Sensing – When the burner is lit, an ionization probe senses the flame. Supply Water Temperature Sensor – This sensor monitors boiler outlet water temperature (System Supply). The control adjusts the

boiler firing rate so the supply temperature will match the set point.

Return Water Temperature Sensor – Monitors boiler return water temperature (System Return). Flue Sensor – Monitors flue temperature and protects the exhaust gas PVC piping. Temperature and Pressure Gauge – Allows the user to monitor system temperature and pressure.

LP-294 REV. 2.20.14

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.

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 boiler wiring.

Condensation Collection System – This boiler is a high efficiency appliance, and will produce condensate. The collection system has a float switch to monitor and prevent condensate from backing into the combustion system. Inside the collection system there is a built in trap which seals the combustion system from the connected drain. Condensate should be neutralized to avoid damage to the drainage system or piping.

Outdoor Sensor – The outdoor sensor monitors outdoor temperature and adjusts boiler set point to provide greater efficiency. Condensate Flue Check System – The check system prevents exhaust from backing into the cabinet. Test Mode – Allows installer to test combustion or operation of pumps when commissioning system and check pump operation during

maintenance and service procedures.

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 (V1000)  4” Stainless Steel Outside Termination Vent Kit (V2000)  3” Polypro Vent Kit (Part # 8400P-001)  3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)  Condensate Neutralizer (Part # 7450P-212)

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

LP-294 REV. 2.20.14

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.

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.

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

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.

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

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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.

MODEL*

A B C D E F G H J K L

SHIPPING WEIGHT

ELP-110

19 9 3

27.3

11.8

7.4

5.8

2.2

113

ELP-199

18 6 27.3

11.8

7.4

4.3 9 2.2

164

MODEL

BTU/INPUT

LOW – HIGH FIRE

DOE HEATING

IBR

SUPPLY / RETURN

EXHAUST / INTAKE

GAS CONNECTION

ELP-110

22,000-110,000

20,200-101,000

88,000

3/4"

ELP-199

44,000-199,000

40,600-203,000

177,000

3/4"

C. CLEARANCES FOR SERVICE ACCESS

See Figure 3 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.

Figure 3 – Specifications and Dimensions Drawing

Table 1 – Dimensions and Weights

Table 2 - Specifications

LP-294 REV. 2.20.14

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.

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).

D. RESIDENTIAL GARAGE INSTALLATION

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.

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 3 in this section when considering exhaust vent and intake pipe termination.

Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall. Venting methods are detailed in the Venting Section. Do not attempt installation using any other means. Be sure to locate the boiler so exhaust vent and intake piping can be routed through the building and properly terminated. Exhaust vent and intake piping lengths, routing, and termination method must 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 3

LP-294 REV. 2.20.14

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.

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

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.

Figure 4 - 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

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

LP-294 REV. 2.20.14

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, 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.

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.

Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler is designed to 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.

B. RELIEF VALVE

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

LP-294 REV. 2.20.14

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 local HTP representative or refer to the detailed piping drawings 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.

ADDED VOLUME TO SYSTEM BY ELITE PLUS BOILER

ELP-110

1.7 Gallons

ELP-199

2.6 Gallons

Undersized expansion tanks cause system water to be lost from the relief valve and 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.

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 (Part 4, Section G. Piping Details).

D. SYSTEM WATER PIPING METHODS

EXPANSION TANK AND MAKE-UP WATER

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

Table 4

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 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 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.

LP-294 REV. 2.20.14

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

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 correct glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the glycol solution manufacturer. Allowance should be made for expansion of the glycol solution in 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 boiler to prevent gravity circulation.

LP-294 REV. 2.20.14

Figure 5 – Single Boiler with Zone Valves, DHW Priority, and Outdoor Reset – Primary/Secondary - NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. The minimum pipe size for connecting a SuperStor indirect water heater is 1”

5. The minimum pipe size for connecting an Elite Plus is 1.25”

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

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

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

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

LP-294 REV. 2.20.14

Figure 6 – Single Boiler with Zone Valves and DHW Priority – Single Temperature – Standard Piping

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. The minimum pipe size for connecting a SuperStor indirect water heater is 1”

5. The minimum pipe size for connecting an Elite Plus is 1.25”

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

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

8. Piping shown is Standard. VERY IMPORTANT: Minimum flow rates outlined in the manual must be maintained to minimize short cycling.

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

LP-294 REV. 2.20.14

Figure 7 – Single Boiler with Pumps and DHW Priority, Outdoor Reset – Primary/Secondary