HTP ELX-400, ELX-500, ELX-650, ELX-800, ELX-1000 User Manual

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Installation

DANGER

NOTICE

WARNING

Start-Up

Maintenance

Parts

Warranty

Elite XL®

Commercial Boilers

ELX-400 / 500 / 650 / 800 / 1000 / 1500 / 2000 Models*

*”B” Denotes Boiler Models,

”N” Denotes Natural Gas, “LP” Denotes Propane,

and “F” Denotes Floor Mount Models

Example Model: ELX-1000FBN

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

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

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

Heat Exchanger Bears the ASME “H”

Stamp

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

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

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

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

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

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

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

SPECIAL ATTENTION BOXES

The following dened terms are used throughout this manual to

DANGER

WARNING

CAUTION

NOTICE

bring attention to the presence of hazards of various risk levels or to important product information.

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

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

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

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

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

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

NOTICE is used to address practices not related to personal injury.

Foreword

This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included in this system, and additional publications including the National Fuel Gas Code - ANSI Z223.1 (latest versions), be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

For the Installer

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

Installations Must Comply With:

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

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

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

The latest version of the National Electrical Code, NFPA No. 70.

NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests specied in ANSI Z21.13

- latest edition.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

NOTICE

WARNING

The CSD-1 ASME Code, Section CW-400 requires that hot water heating and supply boilers have a) a UL 353 temperature control device, b) at least one (1) temperature-actuated control to shut o the fuel supply when system water reaches a preset operating temperature, c) a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout, and d) its own sensing element and operating switch. The temperature control system integrated into the 928 control provided with this heating appliance complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature dierence between the inlet and the outlet sensor, which is aected by boiler water ow. If this temperature dierence exceeds 55°F (typically because of low water ow or very low heat load), the control will reduce the maximum fan speed. If the temperature dierence exceeds 60°F, the control will eectively sense there is little or no water ow or heat load and shut the boiler down. The controller will restart automatically once the temperature dierence has dropped below 55°F and the minimum o time (anti-cycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 210°F, the boiler is put into a hard lockout and requires manual reset to restart.

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

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

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

• This boiler does not include a standing pilot.

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

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

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

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

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

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

• This boiler is not used for space heating.

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

• This boiler is equipped with a tankless coil.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

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.

Table of Contents

Part 1 - General Safety Information 5

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

Part 2 - Before You Start 6

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

Part 3 - Prepare the Boiler 9

A. Locating the Boiler 9 B. Flooring 10 C. Leveling 10 D. Clearances for Service Access 10 E. Residential Garage and Closet Installations 11 F. Exhaust Vent and Intake Pipe 11

1. Direct Vent of Exhaust and Intake 11

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space 12

G. Carbon Monoxide Detectors 12 H. Prevent Combustion Air Contamination 12 I. Removing a Boiler from a Common Vent System 13 J. Water Chemistry Requirements* 13 K. Outdoor Installations 14 L. Technical Specications 16

Part 4 - Piping 17

A. General Plumbing Information 17 B. Relief Valve 17 C. Backow Preventer 17 D. Expansion Tank 17 E. Circulators 18 F. Hydronic Piping with Circulators, Zone Valves, and Multiple Boilers 18 G. Circulator Sizing 19 H. Check / Control Water Chemistry 20 I. Plumbing 20 J. Fill and Purge Heating System 20 K. Freeze Protection Fluids 20 L. Zoning with Zone Valves 21 M. Zoning with Circulators 21 N. Multiple Boilers 21 O. Applications* 22

Part 5 - Venting 23

A. General 23 B. Approved Materials for Exhaust Vent and Intake Pipe 24 C. Additional Requirements for Installation in Canada 24 D. Exhaust Vent and Intake Pipe Location 25 E. Exhaust Vent and Intake Pipe Sizing 26 F. Exhaust Vent and Intake Pipe Installation 26 G. Applications 27

1. Direct Vent Installation of Exhaust and Intake 27

2. Power Venting, Room and Indoor Combustion Ventilation Requirements 29

Part 6 - Condensate Removal 30 Part 7 - Wiring - 400 - 1500 Models 31

A. Installation Must Comply With 31

WARNING

B. Field Wiring 31 C. Line Voltage Wiring for Standard Boiler 32 D. Alarm Connections 32 E. Low Voltage Connections for Standard Boiler 32 F. Thermostat 32 G. Outdoor Sensor 32 H. Indirect Sensor 32 I. UL 353 Internal Low Water Cut-O (Factory Installed) 32 J. Wiring of Cascade System Communication Bus 32 K. Cascade Master System Pump and Sensor Wiring 33 L. Cascade Follower Pump and Sensor Wiring 33 M. Variable Speed Pumping 33 N. Optional 0-10 Volt Building Control Signal 34 O. Optional High Gas Pressure Switch 34 P. Optional Low Gas Pressure Switch 34 Q. Optional High Limit Manual Reset 34

Part 8 - Wiring - 2000 Models 38

A. Installation Must Comply With 38 B. Field Wiring 38 C. Line Voltage Wiring for Standard Boiler 38 D. Alarm Connections 38 E. Low Voltage Connections for Standard Boiler 39 F. Thermostat 39 G. Outdoor Sensor 39 H. Indirect Sensor 39 I. UL 353 Internal Low Water Cut-O (Factory Installed) 39 J. Wiring of Cascade System Communication Bus 39 K. Cascade Master Pump and Sensor Wiring 39 L. Cascade Follower Pump and Sensor Wiring 40 M. Variable Speed Pumping 40 N. Optional 0-10 Volt Building Control Signal 40 O. Optional High Gas Pressure Switch 40 P. Optional Low Gas Pressure Switch 41 Q. Optional High Limit Manual Reset 41

Part 9 - Gas Connections 45

A. Gas Piping 45 B. Gas Table 45 C. Check Inlet Gas Pressure 46 D. Boiler Gas Valve 47

Part 10 - Start-Up Preparation 48

A. Check / Control Water Chemistry 48 B. Check for Gas Leaks 48 C. Freeze Protection (When Used) 48 D. Fill and Test Water System 48 E. Check Thermostat Circuit(s) 49 F. Condensate Removal 49 G. Final Checks Before Starting Boiler 49

Part 11 - Start-Up Procedure 49

A. Control Overview 49 B. Navigation of the Touch Screen Display 50 C. Purge Air from the System 51 D. Single Boiler Initial Start-Up and Operation 51 E. Cascaded System Initial Start-Up and Operation 51 F. Lockout Condition - Cascade System 51 G. Cascade System Programming 52 H. Operating Instructions 52 I. Programming User Settings 53 J. Programming Installer Settings 56 K. Resetting the Maintenance Schedule 60 L. Service Mode - Setting and Verifying the Combustion Setting Testing the Internal LWCO 60

Part 12 - Boiler Monitoring 61

A. Status Screens 61 B. History Screens 64 C. Graphics Screen 66 D. Cascade Screen 66

Part 13 - Troubleshooting 68

A. Blocking 68 B. Fault (Lockout) 68 C. User Interface Display 68

Part 14 - Maintenance 74

A. Procedures 74 B. Combustion Chamber Coil Cleaning Instructions 74 C. Cleaning the Water Side of the Heat Exchanger 77

Part 15 - Shutdown 77

A. Shutdown Procedure 77 B. Failure to Operate 77

Part 16 - Replacement Parts 78 Part 17 - Installation Checklist 85 Part 18 - Maintenance Report 85

ELX Boiler Limited Warranty 87 Maintenance Notes 89 Customer Installation Record Form 90

Part 1 - General Safety Information

This boiler is approved for indoor or outdoor installations and is not intended for use as a pool heater. Clearance to combustible materials: 0” top, bottom, sides, and back. Boiler must have room for service: 24” front, 24” right side, and 18” left side are minimum recommended service clearances. (A combustible door or removable panel is acceptable front clearance.) 400 - 1000 Models have been approved for installation on combustible ooring. Do not install on carpeting. 1500 - 2000 MODELS ARE NOT APPROVED FOR INSTALLATION ON COMBUSTIBLE FLOORING. Install the boiler in a location where temperature and pressure relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan. Use only Category IV vent systems.

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

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

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

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied service technician. The

boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a re and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged boiler could result in property damage, severe personal injury, or death. NOTE: Boiler damage due to ood or submersion is considered an Act of God, and IS NOT covered under product warranty.

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

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

NOTE: If the boiler is exposed to the following, do not operate. Immediately call a qualied service technician.

1. Fire

2. Damage

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

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

NOTICE

CAUTION

WARNING

CAUTION

Due to low water content of the boiler, improperly sizing the boiler in regard to heating load will result in excessive boiler cycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.

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

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

A. Improper Combustion

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

B. Gas

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

C. When Servicing the Boiler

E. Freeze Protection

NOTE: Consider piping and installation when determining boiler

location.

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

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

NOTE: Loops Serving Indirect Water Heaters (IWHs)

Glycol used in IWH loops should be food grade propylene glycol, FDA rated as “generally recognized as safe” (GRAS). If using a glycol / potable water mix, the water chemistry must meet the requirements in this manual. The glycol content of the liquid must not exceed 50%, unless the manufacturer species a dierent ratio. Glycol should be checked periodically to prevent it from becoming acidic. Please refer to guidelines provided by the glycol manufacturer regarding glycol maintenance.

NOTE: Glycol not recognized as GRAS may only be used in closed loop CH applications.

NOTE: HTP DOES NOT WARRANT THE BOILER AGAINST FREEZERELATED DAMAGE.

The boiler control is equipped with freeze protection that activates based on internal water temperature.

NOTE: Freeze protection will not be active if the boiler loses power.

F. High Elevation Installations

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

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

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

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

D. Boiler Water

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

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

Part 2 - Before You Start

UNCRATING THE BOILER - Any claims for damage or shortage in

shipment must be led immediately against the transportation company by the consignee.

A. What’s in the Box

Remove all sides of the shipping crate of the boiler. Components included with the boiler:

• Outdoor Sensor (7250P-319)

• Intake / Exhaust Screens (400 - 500 Models [7550P-995], 650

- 1000 Models [7550P-996], 1500 - 2000 Models [7550P-997])

• Installation Manual and Warranty

• User’s Information Manual

• Tear Down Instructions

• CSD-1 Form

• H-3 Data Sheet

B. How the Boiler Operates

Condensing technology intelligently delivers highly ecient hydronic heating while maximizing eciency by measuring data from the heating system. The following are features of the system and how they operate.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Stainless Steel / Steel Heat Exchanger

The highly ecient heat exchanger is designed to use the cold water return from the system and extract the last bit of heat before it is exhausted.

Modulating Combustion System

The combustion system modulates the output of the burner during operation to match system demand and achieve the control set point while in operation. The set point can change by internal or external signals to enhance the overall performance of the system.

Control

The integrated control system monitors the system and regulates fan speed to control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more. The 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 eciency. The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a cascade system sensor and a system pump in addition to its own boiler pump. Each of the follower boilers will have its own pump to provide maximum ow and control heat exchanger ow rate.

Electronic Touchscreen Display with Status Indicators

Digital controls with full color resistive touchscreen technology. The display allows the user to change system parameters and monitor system operation.

Gas Valve

The gas valve senses suction from the blower, allowing gas to ow only if powered and combustion air is owing.

Integrated Venturi

Controls air and gas ow into the burner.

Burner

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

Spark Ignition

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

Dual Supply Water Temperature Sensor / High Limit Water ECO

This dual sensor monitors the boiler outlet water temperature (System Supply). The control adjusts boiler ring rate so the supply temperature will match the boiler set point. The dual sensor in combination with the 928 control meets all requirements of a UL 353 water limiting control, eliminating the mechanical ECO and increasing safety and reliability.

Return Water Temperature Sensor

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

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Electrical eld connections with terminal strips

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

Supplied Condensate Collection System with Clean Out

This boiler is a high eciency appliance and will produce condensate. The condensate collection system has a oat switch which monitors condensate level and prevents condensate from backing up into the combustion system. Inside the collection system is a built in trap which seals the combustion system from the connected drain. This condensate should be neutralized to avoid damage to the drainage system or piping.

Flow Protection

The ow switch is designed to protect the boiler during low ow conditions. The boiler control also monitors ow through the heat exchanger by monitoring the return and supply sensors and will shut down the burner before overheating occurs. The ow switch activates at 4 GPM for 400 - 1000 Models; 9 GPM for 1500 - 2000 Models.

Outdoor Sensor

The control adjusts unit set point based on the outdoor temperature measured by this sensor to provide greater eciency.

0-10 Volt Input

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

0-10 Volt Output A (Congured through Control System)

0-10 Volt Output A is congured through the boiler’s control system. 0-10 Volt Output A is related to one of the following boiler values: boiler power, cascade power, fan speed, alarm status, temperature setting based on outdoor reset curve, ame, or pump.

0-10 Volt Output B (Congured through Control System)

0-10 Volt Output B is congured through the boiler’s control system, and is related to one of the following boiler values: boiler power, cascade power, fan speed, alarm status, temperature setting based on outdoor reset curve, or ame.

UL 353 Internal Low Water Cuto (LWCO)

The supplied internal Low Water Cuto in conjunction with the 928 control meets UL 353 requirements to function as a safety, locking out the boiler when water level is inadequate for safe operation. See Service Mode, this manual, to test LWCO function.

Boost Timer Function

This function temporarily overrides the outdoor reset curve in order to satisfy a thermostat setpoint in a short amount of time, especially during a relatively warm day.

Flue Temperature Modulation

As an additional safety feature, if the ue temperature exceeds 200oF, the control will modulate the boiler down based on the vent temperature, rather than the supply temperature. If the ue temperature exceeds 210oF the control will lock out the boiler.

HTP Link

HTP Link allows the installer to connect the boiler to WiFi, providing the user / installer with tools to remotely monitor the system, optimize eciency, and aid in troubleshooting.

System Sensor (Optional)

This sensor is designed to be used in a cascade system. The system pipe sensor measures the temperature of return water and communicates with the control system to modulate the ring rate of the connected boilers. NOTE: When using a system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system eciency.

Indirect Tank Sensor (Optional)

Monitors storage tank temperature.

C. Optional Equipment

Optional equipment available from HTP (and Part #):

• System Sensor (7250P-324)

• Indirect Tank Sensor (7250P-325)

• High and Low Gas Pressure Switch Kit with Manual Reset (500 Model [7550P-999], 650 - 2000 Models [7550P-988])

• 4” Stainless Steel Vent Termination Kit (V2000)

• 6” Stainless Steel Outside Termination Vent Kit (V3000)

• 8” Stainless Steel Elbow (7550P-067)

• 8” Stainless Steel to PVC / CPVC Vent Pipe Adapter (7550P-064)

• Mechanical Manual Reset High Temperature Limit (6300P-998)

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

• 928 PC Connection Kit (7450P-330)

• Condensate Neutralizer (7350P-611)

• Condensate Removal Pump (554200)

• Isolation Valve Kit (400 - 1000 Models [7550P-985], 1500 - 2000

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Models [7550P-986])

• Outdoor Installation Kit (400 - 1000 Models [7550P-987], 1500 2000 Models [7550P-982])

• Stack Rack Kit (400 - 500 Models [7550P-983], 650 - 1000 Models [7550P-984])

• Flush Kit (7550P-606)

• Fuel Conversion Kits (See Table Below)

Model Description Kit Number

ELX-400 LP to NG Conversion Kit 7550P-200

ELX-400 NG to LP Conversion Kit 7550P-201

ELX-500 LP to NG Conversion Kit 7550P-202

ELX-500 NG to LP Conversion Kit 7550P-203

ELX-650 LP to NG Conversion Kit 7550P-204

ELX-650 NG to LP Conversion Kit 7550P-205

ELX-800 LP to NG Conversion Kit 7550P-206

ELX-800 NG to LP Conversion Kit 7550P-207

ELX-1000 LP to NG Conversion Kit 7550P-314

ELX-1000 NG to LP Conversion Kit 7550P-208

ELX-1500 LP to NG Conversion Kit 7550P-309

ELX-1500 NG to LP Conversion Kit 7550P-310

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Part 3 - Prepare the Boiler

CAUTION

WARNING

CAUTION

Remove all sides of the shipping crate to allow the boiler to be moved into its installation location. The boiler is heavy. At least two individuals and special equipment (pallet jack, forklift, etc.) are needed to properly handle the boiler. If surface ooring is rough, take care not to damage the boiler when moving it into position.

• Never close existing ventilation openings

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

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

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

2. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

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

Figure 1 - Moving the ELX - 1500 - 2000 Models Shown

COLD WEATHER HANDLING - If the boiler has been stored in a very

cold location (BELOW 0 the components come to room temperature. Failure to do so could

result in damage to the boiler.

Carefully consider installation when determining boiler location. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

F) before installation, handle with care until

A. Locating the Boiler

DO NOT INSTALL the Elite XL OUTDOORS without an optional Outdoor Installation Kit. Follow the instructions included with the optional Outdoor Installation Kit when installing the boiler outdoors. Installing the boiler outdoors without an optional Outdoor Installation Kit WILL VOID the warranty, and could result in property damage, severe personal injury, or death.

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

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

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32oF / 0oC

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

• Avoid continuously high levels of humidity

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

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

The service life of the boiler’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly inuenced by proximity to damp and salty marine environments. In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of boiler components. In these environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity, and hence potential corrosion will be minimized.

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

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

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

• System leaks

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

• Incorrectly sized expansion tank

6. Clean and ush system when reinstalling a boiler.

NOTE: When installing in a minimum 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.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

CAUTION

WARNING

Use extreme care not to drop the boiler or cause bodily injury while lifting the boiler. Failure to follow these instructions could result in property damage, severe personal injury, or death.

B. Flooring

400 - 1000 Models ONLY are approved for installation on combustible ooring, but must never be installed on carpeting. 1500 - 2000 MODELS ARE NOT APPROVED FOR INSTALLATION ON COMBUSTIBLE FLOORING. Failure to follow these instructions could result in re, property damage, severe personal injury, or death.

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

C. Leveling

In order for the condensate to properly ow out of the collection system, the area where you locate the boiler must be level. Location must also fully support the weight of the lled boiler. See Figures 2 - 4.

INCORRECT

Figure 4 - Leveling - 1500 - 2000 Models

1500 - 2000 Models ONLY - After the boiler has been installed level

in the nal location the decorative skirts may be installed. These can be found in the boiler cabinet. Use the included bolts to install the front skirt (1) before proceeding to the side skirts (2). See Figure 5.

CORRECT

INCORRECT CORRECT

Figure 2 - Leveling - 400 - 1000 Models

TURN WHEEL TO THE RIGHT TO LOWER RUBBER FOOT

TURN WHEEL TO THE LEFT TO RAISE RUBBER FOOT

RAISE

Figure 3 - Caster Wheel Adjustment - 400 - 1000 Models ONLY

LOWER

LP-517-W 01/24/19

LP-666-R 01/03/19

Figure 5 - 1500 - 2000 Models - Installing Decorative Skirts

D. Clearances for Service Access

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

NOTE: If you do not provide the minimum clearances shown in Figure 6 it might not be possible to service the boiler without removing it from the space.

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

NOTE: In multiple boiler installations, ensure an 18” minimum clearance is maintained between boilers.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

24"

CAUTION

WARNING

DANGER

WARNING

18"

Figure 6 - Recommended Service Clearances

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

24”

24"

LP-666-M 10/31/18

E. Residential Garage and Closet Installations

Check with your local Authority Having Jurisdiction for requirements when installing the boiler in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

Precautions

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

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

• When raising the boiler ensure the entire bottom and fully lled weight of the boiler are fully supported.

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

The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the boiler. For power venting installations using room air for combustion, refer to the venting section, this manual, for descriptions of conned and unconned spaces. Do not install the boiler in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.

F. Exhaust Vent and Intake Pipe

The boiler is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.

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

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

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

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

Vents must be properly supported. Boiler exhaust and intake connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the boiler and the balance at 4’ intervals. Boiler must be readily accessible for visual inspection for rst 3’ from the boiler. Failure to properly support vents could result in property damage, severe personal injury, or death.

1. Direct Vent of Exhaust and Intake

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

combustion air contamination, see Table 1.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

WARNING

Conned space is space with volume less than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. When drawing combustion air from inside a conventionally constructed building to a conned space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space oor. Each opening should have a free area of one square inch per 1,000 BTU/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2). If the conned space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual.

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

Failure to provide an adequate supply of fresh combustion air can cause poisonous ue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 1.

Figure 7 - Direct Vent Examples

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

This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 1. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply sucient combustion air based on the boiler input. Never obstruct the supply of combustion air to the boiler. If the boiler is installed in areas where indoor air is contaminated (see Table 1) it is imperative that the boiler be installed as direct vent so that all combustion air is taken directly from the outdoors into the boiler intake connection. Unconned space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details.

G. Carbon Monoxide Detectors

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

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

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent oor level. b. In the event that these requirements cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

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

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

H. Prevent Combustion Air Contamination

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

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

WARNING

DANGER

WARNING

in Table 1. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool or laundry facilities. These areas always contain contaminants.

Products to Avoid

Spray cans containing

uorocarbons

Permanent wave solutions Swimming pools

Chlorinated waxes / cleaners Metal fabrication plants

Chlorine-based swimming pool

chemicals

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water

softening

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid

Cements and glues New building construction

Antistatic fabric softeners used in

clothes dryers

Chlorine-type bleaches, laundry

detergents, and cleaning solvents

Adhesives used to fasten building

products

Table 1 - Products and Areas Likely to Have Contaminants

NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to

the limited warranty for complete terms and conditions.)

Areas Likely to Have

Contaminants

Dry cleaning / laundry areas

and establishments

Beauty shops

Photo processing plants

Furniture renishing areas

and establishments

Remodeling areas

Garages and workshops

I. Removing a Boiler from a Common Vent System

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

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

When removing an existing boiler, follow the steps below.

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

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

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

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

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

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

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

Figure 8 - CO Warning Label

J. Water Chemistry Requirements*

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

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

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

• Water pH between 6.5 and 8.5

• pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale build-up.

• Maintain water pH between 6.5 and 8.5. Check with litmus paper or have it chemically analyzed by a local water treatment company.

• If the pH is not between 6.5 and 8.5, consult a local water treatment company for solutions.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

• Hardness between 5 and 12 grains (71.3 and 205 mg/L)*

• Hardness levels above the required amounts can lead to lime scale build-up throughout the system. Water below 5 grains/gallon (71.3 mg/L) may be over softened.

• Consult local water treatment companies for unusually hard water areas (above the required amounts) or for other treatment solutions if water is being over softened (below 5 grains/gallon [71.3 mg/L]).

• Chloride concentration less than 150 ppm (mg/L)

• Do not ll appliance or operate with water containing chlorides in excess of 150 ppm (mg/L).

• Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm (mg/L).

• Do not connect the appliance to directly heat swimming pool or spa water.

• Total Dissolved Solids (TDS) between 100 and 450 ppm (mg/L)*

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

charged particles that are dissolved in water.

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

corrosion potential due to increased conductivity in the water.

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

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

*NOTE: The amount of Hardness ppm (mg/L) + TDS ppm (mg/L) must be less than 450 ppm (mg/L) total. For Example:

WATER CHEMISTRY NOTES:

1. Avoid exposing the heat exchanger water tubes to oxygen to prevent internal corrosion. System leaks and continuous makeup water will introduce oxygen into the system, increasing the opportunity for internal corrosion and possibly reducing the life of the heat exchanger and system components.

2. Leaks in the boiler or piping must be repaired at once to prevent excessive make-up water. It is recommended to install a water meter to regularly check the amount of make-up water entering the system. Make-up water volume should not exceed 5% of the total system volume per year. When make-up water is added, ensure chemical additives (glycol, corrosion inhibitors, etc.) are added to maintain the correct level.

3. Regularly monitoring pH, chlorides, TDS, and hardness levels can prolong the life of the appliance by reducing mineral scale buildup, corrosion, and erosion. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.

4. A corrosion inhibitor approved for use with stainless steel heat exchangers (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner recommended by the manufacturer.

Elite XL outdoor models are intended for warm weather applications. DO NOT install the Elite XL outdoors in areas prone to freezing (below 32oF / 0oC). Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death. Failure of Elite XL or components due to incorrect operating conditions IS NOT covered by product warranty.

Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust vent must be pitched a minimum of 1/4” per foot back to the Elite XL to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

General Outdoor Installation Guidelines

1. The Elite XL must not be installed outdoors in freezing climates. Elite XLs installed outdoors must be vented with listed UV-resistant vent materials per the following instructions and installed with the optional factory-supplied Outdoor Installation Kit.

2. Keep venting areas free of obstructions, and combustible and ammable materials. Keep the air intake and exhaust vent terminations free of obstructions.

3. Do not install directly on the ground. Install on a concrete, brick, block, or other non-combustible pad.

4. Install unit in a location that avoids opportunities for exhaust gas recirculation.

5. Clearances around outdoor installations may change over time. Make sure the growth or trees, shrubs, landscaping, etc. is properly maintained.

6. Do not install in locations where building runo will spill onto the unit.

7. Multiple unit installations require at least a 4’ (48 in.) clearance between exhaust vents.

8. Locate unit at least 3’ (36 in.) away from any overhang.

9. Follow the outdoor kit instructions when locating / venting the unit.

COUPLING

SCREEN

THE VENT MUST TERMINATE AT LEAST 24" ABOVE THE TOP OF THE UNIT

K. Outdoor Installations

DO NOT INSTALL the Elite XL OUTDOORS without an optional Outdoor Installation Kit. Follow the instructions included with the optional Outdoor Installation Kit when installing the VWH outdoors. Installing the VWH outdoors without an optional Outdoor Installation Kit WILL VOID the warranty, and could result in property damage, severe personal injury, or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Figure 9 - Outdoor Venting Installation

SCREEN

LP-666-AB

06/30/20

ELX-400-1000

ELX-1500-2000

WATER SUPPLY

WATER RETURN

G H

WATER RETURN

GAS

AIR INTAKE

EXHAUST

CONDENSATE

2" CLEANOUT

AIR INTAKE

LP-666-P 04/06/20

EXHAUST

CONDENSATE

2" CLEANOUT

MODEL # A B C D E F G H J K L M N O P Q R

ELX400-500

ELX650-1000 56.5

ELX1500

ELX2000 80.0

41.0 26.0

60.8 31.8

40.7

17.9 35.0 4.1 10.1 10.5 12.6 16.1 20.5 22.0 6.1 8.1 25.8 35.0 2.8*

67.5

39.2 44.8 51.2 3.4 7.4 7.5 11.9 14.4 24.4 31.8 4.6 6.5 22.7 39.1

Figure 10 - ELX Specications and Dimensions - NOTE: All Dimensions Are Approximate - *FOR REFERENCE ONLY

Model Water Connection Vent Size Air Intake Gas Connection Condensate

400

500

650

2" NPT

800

1000

1500

2000 2”

Table 2 - ELX Adapter Dimensions and Specications

2 1/2” Flange 8” 8”

4" 4" 1"

6" 6"

1-1/4"

1-1/2”

3/4" PVC

1” PVC

lp-666 Rev. 003 Rel. 004 Date 9.3.20

L. Technical Specications

Model 400 500 650 800 1000 1500 2000

Installation Indoor or Outdoor (with Optional Kit), Floor Standing, Fully Condensing

Minimum / Maximum Input (Btu/Hr) 39,900 / 399,000 50,000 / 500,000 65,000 / 650,000 80,000 / 800,000

Heating Capacity (MBH) 387 485 630 776 970 1,455 1,940

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

Minimum Combined Vent Run 10 feet 15 feet

Maximum Combined Vent Run 4” (125 feet) 6” (125 feet) 8” (150 feet)

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

Packaging

Dimensions

(in Inches)

Shipping Weight (lbs) 538 545 680 700 745 1400 1750

Gas Supply Pressure 3.5” to 14” WC (NG or LP)

Manifold Pressure Min / Max NG/LP: -0.08” WC NG: -0.07” WC

Power Supply 120V 60 Hz, 20A

Customer Connection Board Fuse

Amperage Ratings

General Operating Conditions

Ignition System Direct Electronic Spark Ignition / Flame Rectication

Burner System Premixed Fuel Modulation / Stainless Steel Burner

Gas Valve System Pneumatic Gas Valve

Dimensions

(in Inches)

Boiler Water Content (Gallons) 3.8 4.3 5.6 6.6 8.1 12.9 16.25

Minimum Flow Rate @ 20oF ∆T at

Low Fire (GPM)

Flow Switch Activation (GPM) 4 9

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

DHW Indirect Setpoint Temperature

Range

Water Pressure

(PSI)

W 32.25 43.25

H 49.625 64.25

D 48 64 76 86

2 Amps 5 Amps

Product Approvals and Requirements: ANSI Z21.13 / CSA 4.9, CSD-1 ASME Code

W 26 31.8

H 41 60.8

D 40.7 56.5 66.5 79

4 5 6.5 8 10 15 20

Heat Exchanger

MAWP

Pressure Relief

Valve

Minimum Ambient Temperature: Greater than 32oF (0oC)

70 – 185oF

160

100,000 / 1,000,000

150,000 / 1,500,000

3.5” to 10.5” WC (NG ONLY)

WYE, 60Hz,

200,000 / 2,000,000

208/3PH

15A/Leg

Control Panel 7” Full Color Touch Screen

Main Controller 928 SIT Control

Connection Sizes

Materials

Safety Devices

Table 3 - Technical Specications

Supply / Return 2” NPT 2 1/2” Flange

Gas Inlet 1” NPT 1 1/4” NPT 1 1/2” NPT 2” NPT

Cabinet Powder Coated Galvaneal Steel

Heat Exchanger 316L Stainless Steel Water Tube

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Flame Rectier Probe, Dual Water Supply Temperature Sensor / High Limit (210oF), Freeze Protection, Condensate

Trap with Float, Dual Flue Sensor (210oF), Blocked Vent Pressure Switch, Internal UL 353 Approved Low Water

Cut-O (LWCO), High Resolution Flow Switch

Part 4 - Piping

WARNING

CAUTION

WARNING

CAUTION

WARNING

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

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

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

A. General Plumbing Information

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

The control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the water level in the heat exchanger. Some codes/jurisdictions may require additional external controls.

Use two wrenches when tightening water piping at boiler. Use one wrench to prevent the boiler return or supply line from turning. Failure to prevent piping connections from turning could cause damage to boiler components.

NOTE: The addition of a high temperature limiting device is important if the boiler is used to indirectly heat domestic hot water.

B. Relief Valve

Connect discharge piping to a safe disposal location by following these guidelines.

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

RE-INSPECTION OF RELIEF VALVES: Valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary,

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

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

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

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

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

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

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

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

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

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

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

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

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

C. Backow Preventer

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

All piping methods in this manual use primary / secondary connections to the boiler loop. This is to avoid the possibility of inadequate ow through the boiler. For other piping methods, consult your local HTP representative or refer to Applications in this manual.

D. Expansion Tank

Expansion Tank and Make-Up Water

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

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

Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual boiler failure can result due to excessive make-up water addition. SUCH

FAILURE IS NOT COVERED BY WARRANTY.

DO NOT install automatic air vents on closed type expansion tank

systems. Air must remain in the system and return to the tank to provide an air cushion. An automatic air vent would cause air to leave the system, resulting in improper operation of the expansion tank.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

Model Heat Exchanger Volume (Gallons)

400 3.8

500 4.3

650 5.6

800 6.6

1000 8.1

1500 12.9

2000 16.25

Table 4 - Heat Exchanger Volume

2. The expansion tank must be located as shown in Applications, this manual, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

3. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system ll connection at the same point as the expansion tank connection to the system.

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

E. Circulators

Never use dielectric unions or galvanized steel ttings 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.

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

DO NOT use the boiler circulator in any location other than the ones shown in this manual. The boiler circulator location is selected to ensure adequate ow through the boiler. Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insucient ow.

SIZING SPACE HEAT SYSTEM PIPING

Size the piping and components in the space heating system using recognized design methods.

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

The boiler is designed to function in a closed loop hydronic system. The included temperature and pressure gauge 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. 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 the boiler circulator, valves, and other components. Observe minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by non-combustible materials. On a boiler installed above radiation level, some states and local codes require a low water cut o device. This is provided standard on the boiler. Check with local codes for additional requirements. If the boiler supplies hot water to heating coils in air handler units, ow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle. Chilled water medium must be piped in parallel with the boiler. Freeze protection for new or existing systems must use glycol specically formulated for this purpose. This glycol must include inhibitors that will prevent it from attacking metallic system components. Make certain that the system uid is checked for the correct glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping. Example: 50% by volume glycol solution expands 4.8% in volume for the temperature increase from 32oF to 180oF, while water expands 3% over the same temperature rise.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

ELX-400 ELX-500 ELX-650 ELX-800 ELX-1000 ELX-1500 ELX-2000

G. Circulator Sizing

In addition, the boiler heat exchanger has a minimum total water ow rate that must be taken into account when sizing the circulator. Pressure drops are listed in the table below.

Model

400 39 12.0 26 7.2 19 4.0

500 48 11.4 32 5.4 24 3.2

650 63 11.5 42 6.2 31 4.0

800 77 12 52 6 39 3

1000 96 14.0 64 7 48 4.7

1500 146 16 97 7.6 73 4.7

2000 194 21 129 11.5 97 6.7

Table 5 - Pressure Drop at Various Temperature Rises

GPM Ft / Hd GPM Ft / Hd GPM Ft / Hd

The boiler heat exchanger does have a pressure drop which must be considered in system design.

20oF 30oF 40oF

ELX-400

ELX-500

Pressure Loss (Feet of Head) +/- 10%

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

ELX-650

ELX-800

Flow Rate (GPM)

ELX-1000

ELX-1500

ELX-2000

Figure 11 - Pressure Drop through the Boiler

The chart below represents the combined ow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit. To size, simply add up the number of boilers and the required ow rates for the system design temperature. Example: (5) 1000 boilers with a design of 30oF temperature rise with each boiler having an individual ow rate of 64 GPM. To correctly size the manifold feeding these boilers, you would need a pipe size of 6”.

Model

400 3 3 4 4 5 5 5

500 3 4 4 5 5 5 6

650 4 4 5 5 6 6 6

800 4 5 5 6 6 8 8

1000 4 5 6 6 8 8 8

1500 5 6 8 8 8 10 10

2000 6 6 8 8 10 10 12

Table 6 - Multiple Boiler Manifold Piping - NOTE: Table based on water velocity less than Five (5) feet per second.

2 3 4 5 6 7 8

Number of Units and Recommended Common Header Pipe Sizes in Inches

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

H. Check / Control Water Chemistry

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

• Water pH between 6.5 and 8.5

• Hardness between 5 and 12 grains (71.3 and 205 mg/L)

• Chloride concentration less than 150 ppm (mg/L)

• Total Dissolved Solids (TDS) between 100 and 450 ppm (mg/L)

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

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

Clean system to remove sediment*

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

2. For zoned systems, ush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.)

3. Flush system until water runs clean and you are sure piping is free of sediment. *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 of this manual.

Test/replace freeze protection uid

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

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

I. Plumbing

Piping Components Heating System Piping

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

Check Valves

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

Isolation Valves

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

Anti-Scald Mixing Valve

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

Steel Flanges

Field supplied. Recommended for unit serviceability.

Pressure Relief Valve

Factory supplied on boiler. The pressure relief valve is sized to ASME specications. Storage tank may require additional relief valves depending on local codes.

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

Basic steps are listed below that will guide the installation of the boiler.

1. Connect the system return marked “Inlet”.

2. Connect the system supply marked “Outlet”.

3. Install purge and balance valve or shut o valve and drain on system return to purge air out of each zone.

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

5. Install a pressure reducing valve on the cold feed make-up water line (15 PSI nominal on the system return). 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. Consult the tank manufacturer’s instructions for specic information relating to expansion tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. The relief valve is installed at the factory. A pipe discharge line should be installed to discharge 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.

Minimum Water Pipe Size

Model Size

400 - 1000 2” NPT

1500 - 2000 2 1/2” Flange

Table 7 - Minimum Pipe Size

J. Fill and Purge Heating System

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

• Close the other side of the balance and purge valve or the shut o valve after the drain.

• Open rst zone balance and purge or drain valve to let water ow out the hose. If zone valves are used, open the valves one at a time manually. (NOTE: You should check the valve manufacturer’s instructions prior to opening valves manually, so as not to damage the valves.)

• Manually operate ll valve regulator. When water runs out of the hose, you will see a steady stream of water (without bubbles). Close balance and purge valve or drain to stop the water from owing. Disconnect the hose and connect it to next zone to be purged.

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

For installation that incorporates standing iron radiation and systems with manual vents at the high points, follow previous section and, starting with the nearest manual air vent, open until water ows out. Then close vent. Repeat procedure, working your way toward the furthest air vent. It may be necessary to install a basket or magnetic strainer in an older system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary.

Upon completion, make sure that the ll valve is in the automatic position and each zone balance and purge or shut o is in an open position and zone valves are positioned for automatic operation.

K. Freeze Protection Fluids

Use only inhibited 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%.

1. Glycol in hydronic applications is specially formulated for this purpose, and includes inhibitors that prevent the glycol from attacking metallic system components. Make certain that the system uid is checked for the correct glycol concentration and inhibitor level.

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

3. Anti-freeze solutions expand more than water. For example: A 50% by volume solution expands 4.8% in volume for a temperature

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

increase from 32oF to 180oF, while water increases 3% over the same temperature rise. Allowances must be made for this expansion in the system design.

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

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

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

L. Zoning with Zone Valves

1. When zoning with zone valves, connect the boiler to the system as shown in Applications. The primary/secondary piping shown ensures the boiler loop will have sucient ow. It also avoids applying the high head of the boiler circulator to the zone valves.

2. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Applications.

M. Zoning with Circulators

1. When using circulator zoning, connect the boiler to the system as shown in Applications. NOTE: The boiler circulator cannot be used for a zone. It must only supply the boiler loop.

2. Install a separate circulator for each zone.

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

N. Multiple Boilers

1. Connect multiple boilers as shown in Applications.

2. All piping shown is reverse return to assure balanced ow throughout the connected boilers.

3. Each connected boiler must have its own circulator pump to assure adequate ow.

4. Connect DHW (domestic hot water) piping to indirect storage water heater as shown in Applications.

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

O. Applications*

*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 congurations could result in improper ow 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 ow / check valves with weighted seats at or near the appliance to prevent gravity circulation.

FIGURE NOTES:

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

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

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

4. Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees.

5. Piping shown is Primary/ Secondary.

6. The minimum pipe size for connecting an HTP indirect red water heater is 1”.

7. DO NOT down size the boiler heating loop connections.

8. System ow (Secondary Loop) must be greater than the boiler’s Primary Loop ow.

9. Installations must comply with all local codes.

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

11. See Multiple Boiler Manifold Piping chart, this manual, when sizing and installing a multiple boiler system.

BOILER CIRCULATOR

INDIRECT

TANK

PURGE VALVE(TYP)

MAY SUBSTITUTE FOR

LOW LOSS HEADER

4 PIPE DIA. SPACING

FROM SYSTEM

CHECK VALVE

DHW CIRCULATOR

MAXIMUM

CHECK VALVE

Y-STRAINER (RECOMMENDED)

Figure 12 - Single Boiler Space Heating with Indirect Priority

MAY SUBSTITUTE FOR

LOW LOSS HEADER

FROM SYSTEM

DHW CIRCULATOR

4 PIPE DIA. SPACING MAX

BOILER CIRCULATOR

CHECK VALVE

PURGE VALVE

BALL VALVE

BALL VALVE TYPICAL

Figure 13 - Cascaded Boilers with Indirect Priority on One

BALL VALVE TYPICAL

AIR SEPARATOR

CHECK VALVE

AIR SEPARATOR

Y-STRAINER RECOMMENDED

SYSTEM CIRCULATOR

SYSTEM SENSOR

PRESSURE GAUGE

CHECK VALVE

TO SYSTEM

MAKE-UP WATER

BACK FLOW PREVENTER

PRESSURE REDUCING VALVE

EXPANSION TANK

LP-666-C 12/20/18

SYSTEM CIRCULATOR

TO SYSTEM

MAKE-UP WATER

BACKFLOW PREVENTOR

PRESSURE REDUCING VALVE

EXPANSION TANK

LP-666-D 12/20/18

An ASSE 1017 thermostatic mixing valve is recommended on all indirect water heaters if the hot water temperature leaving the heater is above 119oF. Failure to do so could result in substantial property damage, serious injury, or death.

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Part 5 - Venting

DANGER

WARNING

DANGER

WARNING

Exhaust

LP-179-JJ

11/30/17

Length

Greater than

Six (6) Inches

Enclosed

Space

Within First Three (3) Linear Feet of

Appliance Exhaust Vent Adapter

The boiler must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect nished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual. Failure to properly install the vent system will result in severe personal injury or death.

A. General

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

1. Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/ CGA B149, and / or applicable provisions of local building codes.

3. This boiler must be vented with materials, components, and systems listed and approved for Category IV appliances.

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

NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors. NOTE: Care must be taken to prevent condensate freezing in the exhaust vent pipe system. See local, state, provincial, and national codes for best practices to prevent condensate freezing in the exhaust vent pipe system.

Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent pipe is properly beveled and seated before insertion into the ue adapter. Failure to do so could result in property damage, severe personal injury, or death.

Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust vent must be pitched a minimum of 1/4” per foot back to the boiler to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

Due to the extreme ammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’ responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.

• DO NOT insulate the rst three (3) linear feet of the exhaust vent run.

• CPVC, Polypropylene, or Stainless Steel pipe material MUST be used if the rst three (3) linear feet of the exhaust vent run passes through an enclosed space greater than 6” in length, such as a wall. NOTE: Only Stainless Steel pipe material may be insulated.

• If CPVC is used to meet these requirements, the balance may be installed with approved PVC pipe.

• If Polypropylene or Stainless Steel is used to meet these requirements, the balance of the vent run must be installed with the same material.

• Failure to comply with this warning could result in property damage, severe personal injury, or death.

It is required to insert exhaust and intake screens into the vent terminations to prevent blockage caused by debris or birds. Failure to keep terminations clear could result in property damage, severe personal injury, or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

WARNING

DANGER

B. Approved Materials for Exhaust Vent and Intake Pipe

Item Material

Pipe and Fittings Approved for Intake ONLY ABS* ANSI/ASTM D2661 ANSI/ASTM D2661

PVC Schedule 40/80 UL-1738 or ANSI/ASTM D1785

Pipe Approved for

Intake OR Exhaust Vent

PVC-DWV Schedule 40/80 UL-1738 or ANSI/ASTM D2665

CPVC Schedule 40/80 UL-1738 or ANSI/ASTM F441

Polypropylene UL-1738 or ULC-S636

Stainless Steel AL29-4C Certied for Category IV and Direct Vent Appliance Venting

Standards for Installation In:

United States Canada

UL-1738 or ULC-S636

PVC Schedule 40

Pipe Fittings

Pipe Cement

Pipe Primer PVC / CPVC ASTM F656

• The exhaust and intake components installed with this appliance must be used for near appliance piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID appliance warranty.

• PVC / CPVC pipe and ttings of the same diameter are considered interchangeable.

• The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in exhaust venting systems is prohibited.

• Covering non-metallic vent pipe and ttings with thermal insulation is prohibited.

• DO NOT connect PVC/CPVC to Polypropylene without an approved vent connector.

• Any transition to Polypropylene MUST be done in the vertical within ve (5) feet of the appliance.

• When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the appliance vent connection, and at the termination when using a PVC termination kit. DO NOT mix AL29-4C piping from dierent manufacturers unless using adapters specically designed for the purpose by the manufacturer.

• A double wall vent or insulated material may be used when using stainless steel vent material in a freezing climate.

• *ABS may be used for air intake applications ONLY.

• Contact the venting material manufacturer if there is any question about the applicability of the proposed venting material.

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

Table 8 - Approved Materials for Exhaust Vent and Intake Pipe

PVC Schedule 80

CPVC Schedule 40 UL-1738 or ANSI/ASTM F438

CPVC Schedule 80 UL-1738 or ANSI/ASTM F439

ABS* ANSI/ASTM D2235 ANSI/ASTM D2235

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

UL-1738, ANSI/ASTM D2466

or D2665

UL-1738, ANSI/ASTM D2467

or D2665

UL-1738 or ULC-S636

IPEX System 636 Cements and

Primers

DO NOT mix components from dierent venting systems without proper adapters. The vent system could fail, causing leakage of ue products into the living space. Use only the approved pipe and tting materials, and primer and cement specically designed for the material used, as listed in the above table. Failure to do so could result in property damage, serious injury, or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death.

C. Additional Requirements for Installation in Canada

1. Installations must be made with a vent pipe system certied to ULC-S636. Additionally, you may use AL29-4C stainless steel venting to comply with Canadian requirements.

2. The rst three (3) feet of vent pipe from the boiler ue outlet must be readily accessible for visual inspection.

3. The components of the certied vent system must not be interchanged with other vent systems or unlisted pipe / ttings.

D. Exhaust Vent and Intake Pipe Location

B M

LP-179-CC

FIXED

CLOSED

OPERABLE

CLOSED

OPERABLE

FIXED

03/28/17

DETAIL

INSIDE CORNER

Exhaust Vent Terminal

Intake Pipe Terminal

Area Where Intake Terminal Is Not Permitted

WARNING

Figure 14 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada

DESCRIPTION US CANADA

A Clearance above grade, veranda, porch, deck, or balcony 1 foot (30 cm)

Direct Vent 1 foot

B Clearance to window or door that may be opened

Power Vent

4 ft below or to side of

opening; 1 ft above opening

C Clearance to permanently closed window *

Vertical clearance to ventilated sot located above the terminal within

a horizontal distance 2 feet (61 cm) from the center line of the terminal

E Clearance to unventilated sot *

F Clearance to outside corner *

G Clearance to inside corner *

Clearance to each side of center line extended above meter / regulator

assembly

I Clearance to service regulator vent outlet *

Clearance to nonmechanical air supply inlet to building or

the combustion air inlet to any other appliance

K Clearance to mechanical air supply inlet

Clearance above paved sidewalk or paved driveway located

M Clearance under veranda, porch deck, or balcony * 1 foot (30 cm)

Table 9 - Vent Termination Clearances - *NOTE: For clearances not specied in ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada, please use clearances in accordance with local installation codes and the requirements of the gas supplier.

on public property

Direct Vent 1 foot

Power Vent

4 ft below or to side of

opening; 1 ft above opening

3 feet above if within 10 feet

horizontally

Direct Vent *

Power Vent 7 feet (2.13 m)

3 feet (91 cm)

Above a regulator

within 3 feet (91 cm)

horizontally of the

vertical center line of

the regulator vent outlet

to a maximum vertical

distance of 15 ft (4.5 m)

3 feet (91 cm)

6 feet (1.83 m)

7 feet (2.13 m)

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

For each oor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the heater. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with these requirements could result in product damage, severe personal injury, or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

WARNING

DANGER

E. Exhaust Vent and Intake Pipe Sizing

1. The exhaust vent and intake pipe size is 4”, 6”, or 8”, depending on model.

2. The maximum total equivalent length of exhaust vent and intake pipe should not exceed 125 feet for 400 to 1000 models, and 150 feet for 1500 and 2000 models.

a. The equivalent length of elbows, tees, and other ttings are listed in the Friction Loss Table.

Friction Loss Equivalent in Piping and Fittings

Fittings or Piping

90 Degree Elbow 5’

45 Degree Elbow 3’

Coupling 0’

Air Inlet Tee 0’

One Foot of Straight Pipe 1’

V Series Vent Kit 1’

AL29 4c Vent Terminal 1’

Table 10 - NOTE: Consult Polypropylene venting instructions for friction loss and pressure drop equivalents.

b. For example: If the exhaust vent is 6” in diameter, has two 90o elbows, and 10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet. Further, if the 6” intake pipe has two 90o elbows, one 45o elbow, and 10 feet of PVC pipe, the following calculation applies: Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. The total equivalent length is 43 feet, well below the maximum of 125 feet. c. Eort should be made to keep a minimum dierence in equivalent length between the exhaust vent and intake pipe.

3. The minimum total equivalent length is 10 feet for 400 to 1000

models, and 15 feet for 1500 and 2000 models.

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

Failure to provide the minimum total vent length could result in property damage and improper product operation.

Equivalent Feet

4” 6” 8”

4. When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe.

NOTE: The use of colored primer is recommended. NOTE: DO NOT CEMENT POLYPROPYLENE PIPE. Follow manufacturer’s instructions for proper installation. NOTE: Clean and dry the boiler adapters.

DO NOT use primer or cement on the boiler adapters.

a. Clean all pipe ends and ttings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.) b. Dry t piping to ensure proper t up before assembling any joint. The pipe should go a third to two-thirds into the tting to ensure proper sealing after cement is applied. c. Priming and Cementing:

i. Handle ttings and pipes carefully to prevent contamination of surfaces. ii. Apply a liberal even coat of primer to the tting socket and to the pipe end to approximately 1/2” beyond the socket depth. iii. Apply a second primer coat to the tting socket. iv. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the tting socket along with an even coat of approved cement to the tting socket. v. Apply a second coat of cement to the pipe. vi. While the cement is still wet, insert the pipe into the tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sucient cement was not applied and joint could be defective. vii. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

8" PVC PIPE

(FIELD SUPPLIED)

8" PVC COUPLING

(FIELD SUPPLIED)

8" CPVC PIPE

STARTER PIECE

MINIMUM 12" LONG

(FIELD SUPPLIED)

8" PVC TO STAINLESS STEEL (FNS)

ADAPTER

(AVAILABLE FROM FACTORY)

7550P-064

Total maximum equivalent length of exhaust vent and intake pipe must not exceed the lengths dened in this manual. Failure to keep the total equivalent length below the maximum lengths determined in this manual will result in faulty boiler operation, substantial property damage, serious personal injury, or death.

F. Exhaust Vent and Intake Pipe Installation

All joints of positive pressure vent systems must be sealed completely to prevent leakage of ue products into the living space. Failure to do so could result in property damage, serious injury, or death.

1. Use only solid PVC, CPVC, or stainless steel pipe or a Polypropylene vent system approved for use with Category IV appliances. ABS pipe material may be used on air intake piping only.

2. Work from the boiler to exhaust vent or intake air termination. Do not exceed the lengths given in this manual for the vent or air piping.

3. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends. Chamfer the outside of each pipe end to ensure even cement distribution when joining.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

STAINLESS STEEL (FNS) ELBOW (AVAILABLE FROM FACTORY)

7550P-067

LP-666-AA

04/01/20

Figure 15 - 1500 and 2000 Models - Near Boiler PVC/CPVC Venting (Flue Connections from the Factory are sized for Stainless Steel Venting)

5. Ensure the vent is located where it will not be exposed to prevailing winds.

6. In all roof venting applications, exhaust discharge must point away from the pitch of the roof.

7. If the exhaust vent is to be terminated in a walled o area (such as a roof with a parapet wall), ensure the exhaust vent terminates a minimum of 10’ from nearest wall and extends level with or above the top of the wall. This will ensure ue gas does not get trapped and possibly recirculated into the intake air pipe, which could contaminate the combustion air.

8. To prevent water leakage, install adequate roof ashing where the pipe enters the roof.

9. Do not locate vent over public walkways, driveways, or parking lots.

Condensate could drip and freeze, resulting in a slip hazard or damage

GREATER (TYP)

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

OR GRADE, WHICHEVER IS

VENT KIT

EXHAUST

ANTICIPATED SNOW LEVEL

EXTERIOR WALL

06/23/15

LP-505-A

Sidewall Venting with Kit

WARNING

to vehicles and machinery.

10. Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully consider venting installation and location.

11. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼” per foot to allow condensate to drain from the vent pipe.

12. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.

13. In vacant chimney applications, install and seal a rain cap over existing chimney openings.

14. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

15. Do not use the boiler to support any piping.

16. Ensure the outdoor exhaust vent and intake pipe terminations are screened to prevent blockage caused by debris or birds.

17. Maximum Snow Level Determination: These installation instructions reference snow levels in establishing a minimum height for the installation of exhaust vent or air intake terminations. Snow levels shall be determined as follows:

a. The installation location may, by ordinance, designate how snow levels are calculated in that location; or b. In the absence of specic ordinances, snow levels shall be calculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service’s 10 year statistics for the installation location/geographical area.

In addition:

• Total length of vent piping shall not exceed the limits specied in this manual.

• The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.

• The ue products coming from the exhaust vent will create a large plume when the heater is in operation. Avoid venting in areas that will aect neighboring buildings or be considered objectionable.

• DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.

• DO NOT vent near sot vents, crawl space vents, or other areas where condensate or vapor could create a nuisance or hazard or cause property damage.

• DO NOT vent where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valve, or other equipment.

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

• The vented gas fueled appliance shall not be installed so its combustion, ventilation, or dilution air is obtained from a bedroom or bathroom.

• Signage: Whenever any through-the-wall (horizontal or sidewall) vent is installed less than seven feet above the nished grade, a metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height of eight feet above grade directly in line with the exhaust vent terminal. The sign shall read, in print no less than 0.5 inches in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

• Marking of Exhaust Vent and Intake Pipe: Piping used for ventilation, make-up, or combustion air intake shall be labeled as follows: a. Throughout the entire developed length:

i. Labels must be placed every ten feet for exposed/visible piping; or ii. Labels must be placed every three feet for concealed piping.

b. At all changes of direction;

c. On each side of a penetration through a partition, wall or ceiling; and d. The labels shall be black lettering that:

i. Indicates that the piping is used for ventilation, make-up, or combustion air intake, and ii. The letters shall be sized equal to a minimum of the pipe diameter. However, for piping with a diameter exceeding two inches, said lettering does not need to be larger than two inches.

G. Applications

1. Direct Vent Installation of Exhaust and Intake

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

Figure 16 - Sidewall Venting with Tee and Coupling and Optional Kit

NOTE: These drawings are meant to demonstrate system venting

only. The installer is responsible for all equipment and detailing required by local codes. Ensure the terminations are screened to prevent blockage caused by debris or birds.

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

Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated vent piping could result in property damage, serious personal injury, or death due to ue gas leakage.

An unbalanced vent system can be installed ONLY when the exhaust is in the vertical position. Failure to do so could result in serious personal injury or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

Two Pipe Sidewall Venting

Two Pipe Roof Venting with Intake (Elbow) and Exhaust (Coupling)

MAINTAIN MIN 12" CLEARANCE

ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE

WHICHEVER IS HIGHER

24"

EXHAUST

AIR INTAKE

12" OVER MAXIMUM SNOW LEVEL OR 24" WHICHEVER IS GREATER

LP-666-G 10/18/18

Two Pipe Sidewall Venting with Intake (Elbow) and Coupling (Exhaust)

400 - 1000 Models ONLY

12" MIN.

GREATER (TYP)

LP-505-A

06/23/15

EXHAUST

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS

Insert Intake/Exhaust Screen into Coupling

with Couplings (Intake and Exhaust)

1500 - 2000 Models ONLY!

EXHAUST

INSERT EXHAUST SCREEN INTO COUPLING

12" MIN.

1" MIN.

Insert Intake/Exhaust Screen into Open End of Elbow

1" MIN.

EXTERIOR WALL

INTAKE

EXTERIOR WALL

Figure 17 - Roof Venting with Stainless Steel and Tee and Coupling

Figure 18 - Unbalanced Venting - Roof Exhaust and Sidewall Intake

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

OR GRADE, WHICHEVER IS

GREATER (TYP)

LP-505-A

10/30/18

INSERT SCREEN INTO COUPLING

Figure 19 - Sidewall Venting with Elbow and Coupling (400 - 1000 Models) and Couplings Only (1500 - 2000 Models ONLY)

INTAKE

NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. Ensure the terminations are screened to prevent blockage caused by debris or birds.

An unbalanced vent system can be installed ONLY when the exhaust is in the vertical position. Failure to do so could result in serious personal injury or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

2. Power Venting, Room and Indoor Combustion Ventilation Requirements

When using an indoor combustion air installation, the mechanical room MUST be provided with properly sized openings, and/or be of sucient volume to assure adequate combustion air and proper ventilation for all gas red appliances in the mechanical room to assure adequate combustion air and proper ventilation. The requirements shown here are for the boiler only. Additional gas red appliances in the mechanical room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances. This must be done in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1. This boiler can be vented using mechanical room air only for combustion. No combustion air openings are needed when the boiler is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 BTU/hr of all installed gas red appliances and the building MUST NOT BE of “Tight Construction”. TIGHT CONSTRUCTION: A building with less than .4 ACH (air changes per hour). For buildings of “Tight Construction”, provide air openings into the building from the outside. Indoor and outdoor combustion air may be combined by applying a ratio of available volume to required volume times the required outdoor air opening(s) size(s). This must be done in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1.

1. If air is taken directly from outside the building with no duct, provide two permanent openings to the mechanical room each with a net free area of one square inch per 4000 BTU/hr input. See Figure 20.

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 BTU/hr input. See Figure 21.

3. If air is taken from another interior space combined with the mechanical room:

a. Two spaces on same story: Each of the two openings specied should have a net free area of one square inch for each 1000 BTU/ hr input, but not less than 100 square inches. b. Two spaces on dierent stories: One or more openings should have a net free area of two square inches per 1000 BTU/hr.

See Figure 22 for reference.

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 BTU/hr. This opening must be located within 12” of the top of the enclosure. See Figure 23. Combustion air requirements are based on the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1, CGA Standard CAN/CSA B149.1 in Canada. Check all local code requirements for combustion air. All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12” of the ceiling, and one must be within 12”of the oor of the mechanical room. Each opening must have a net free area as specied in Table

11. Single openings shall commence within 12” of the ceiling. The minimum dimension of air openings should not be less than 3”.

Combustion air supply must be completely free of any ammable vapors that may ignite, or chemical fumes which may be corrosive to the boiler. See Table 1 for a list of combustion air contaminants. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, ue connectors, and the vent system. The result is improper combustion and premature boiler failure. Such failure IS NOT covered under warranty. EXHAUST FANS: Any fan or appliance which exhausts air from the mechanical room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of ue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.

Minimum Recommended Combustion Air Supply to Mechanical

Room

Figure 20 Figure 21

Model

400 100 100 200 200

500 125 125 250 250

650 163 163 325 325

800 200 200 400 400

1000 250 250 500 500

1500 375 375 750 750

2000 500 500 1000 1000

Model

400 400 400 800 134

500 500 500 1000 168

650 650 650 1300 217

800 800 800 1600 267

1000 1000 1000 2000 335

1500 1500 1500 3000 500

2000 2000 2000 4000 667

Table 11 - Indoor Combustion Air Sizing

*Outside Air from 2 Openings

Directly from Outdoors

Top Opening,

Inside Air from 2 Ducts Delivered from Interior

Same Story

Top Opening,

Bottom

Opening, in

Figure 22 Figure 23

Space

Bottom

Opening, in

*Outside Air from 2 Ducts

Delivered from Outdoors

Top

Opening, in

Dierent

Stories

Top

Opening, in

*Outside

Air from 1

Opening

Outdoors,

Bottom

Directly

from

2 1

The above requirements are for the boiler only; additional gas red appliances in the mechanical room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances. No combustion air openings are needed when the boiler is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 BTU/hr of all installed gas red appliances. Buildings MUST NOT be of *”Tight Construction”.

Outside air openings shall communicate with the outdoors.

Combined interior space must be 50 cubic feet per 1,000 BTU/hr

input. Buildings MUST NOT be of *”Tight Construction”.

Under no circumstances should the mechanical room ever be under negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit. Failure to follow these instructions could result in property damage or personal injury.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Figure 20 - Combustion Air from Outdoors

Figure 21 - Combustion Air through Ductwork

Part 6 - Condensate Removal

NOTE: Check with your local gas company to determine if

combustion condensate disposal is permitted in your area. In the state of Massachusetts, condensate must be neutralized before entering a drain. This boiler is a high eciency appliance, and therefore produces condensate: a by-product of the combustion process. A condensate collection system with an internal oat switch monitors condensate level to prevent it from backing up into the combustion system. See Figure 24 for condensate connection and cleanout locations. Condensate from the boiler is slightly acidic with a pH of 3.2 - 4.5. To avoid long term damage to the drainage system and to meet local code requirements, HTP recommends neutralizing condensate with a Condensate Neutralizer Kit (Part # 7350P-611). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the condensate. The neutralizer kit should be checked annually and the limestone chips replenished if necessary. When replacing the limestone chips, take care to ensure chips are no smaller than ½” to avoid blockage in condensate piping (refer to Figure 25 for piping of the condensate neutralizer.)

Figure 22 - Combustion Air from Indoors

Figure 23 - Combustion Air from Outdoors - Single Opening

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Figure 24 - Condensate Connection and Cleanout Locations

CAUTION

WARNING

CAUTION

CONDENSATE NEUTRALIZER

PIPE HANGER

ASSEMBLIES

FOR SUPPORT

FLOOR DRAIN

CONDENSATE

NEUTRALIZER

Figure 25 - Condensate Piping

WITHOUT PUMP

HORIZONTAL LINES

MUST BE INSTALLED WITH

A PITCH OF 1/4" PER FOOT

SWEAT PVC TEE OPEN TO ATMOSPHERE (TO PREVENT VACUUM)

PIPE HANGER

FOR SUPPORT

NOTES:

1. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, increase the condensate line and place a tee in the line before the condensate neutralizer to properly reduce vacuum lock in the drain line.

2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be subject to corrosion or deterioration.

3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate line from freezing temperatures or any type of blockage. In installations that may encounter sustained freezing conditions, the use of heat tape is recommended to avoid freezing of the condensate line. It is also recommended to bush up the condensate line size and terminate condensate discharge as close to the unit as possible. Longer condensate runs are more prone to freezing. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.

4. Support of the condensate line may be necessary to avoid blockage of the condensate ow.

5. To allow proper drainage on longer horizontal condensate runs, tubing size may need to increase and a second line vent may be required. NOTE: To clean out condensate trap, see Maintenance section.

CONDENSATE NEUTRALIZER

ASSEMBLIES

CONDENSATE

WITH PUMP

SWEAT PVC TEE OPEN TO ATMOSPHERE (TO PREVENT VACUUM)

PUMP

CONDENSATE

NEUTRALIZER

HORIZONTAL LINES MUST BE INSTALLED WITH A PITCH OF

1/4" PER FOOT

Part 7 - Wiring - 400 - 1500 Models

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

Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death.

It is of extreme importance that this unit be properly grounded. It is very important that the building system ground is inspected by a qualied electrician prior to making this connection. Electrical power must only be turned on when the boiler is completely lled with cold water. Failure to follow these instructions could result in component or product failure, serious injury, or death.

Electrical Shock Hazard - Turn o electrical power supply at service entrance panel before making any electrical connections. Failure to follow to do so could result in serious injury, or death.

LP-666-N 11/01/18

The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The condensate pump should have an overow switch to prevent property damage from spillage. Condensate from the boiler will be slightly acidic (pH from 3.2 to 4.5). Install a neutralizing lter if required by local codes.

Is is very important that condensate piping be no smaller than 3/4”. Use a tee at the condensate connection with a branch vertically up and open to the atmosphere to prevent a vacuum that could obstruct the ow of condensate from the boiler. To prevent sagging and maintain pitch, condensate piping should be supported with pipe supports.

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

Label all wires prior to disconnecting them when servicing the boiler. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions may result in property damage or personal injury.

Wiring must be NEC Class 1. If original wiring supplied with the boiler must be replaced, use only TEW 105 oC wire or equivalent. Boiler must be electrically grounded as required by the National Electrical Code, ANSI/NFPA 70 - Latest Edition.

A. Installation Must Comply With

1. National Electrical Code and any other national, state, provincial, or local codes or regulations.

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

B. Field Wiring

All connections made to the boiler in the eld are done inside the electrical junction box located on the right side of the unit when viewed from the front. Multiple knockout locations are available to route eld wires into and out of the electrical junction box. The control used in the boiler is capable of directly controlling 2 pumps in standard mode and 3 pumps when congured as a cascade master boiler. An external contactor relay or motor starter is required. The Field Connection Board has separate, clearly marked terminal

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

strips for line voltage and low voltage wiring. Special jacks are provided for trouble-free cascade system wiring using standard CAT3 or CAT5 patch cables.

C. Line Voltage Wiring for Standard Boiler

NOTE: A termination plug is included in the CAT 3 / CAT 5 Bus

Connection Point, labeled J6 in Figure 29. DO NOT REMOVE THIS PLUG! Doing so will aect boiler operation and void warranty.

1. Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals L (Line), N (Neutral), and G (Ground) (shown in Figure 27).

2. A line voltage fused disconnect switch may be required to be externally mounted and connected according to local wiring codes.

3. Connect the boiler pump relay COIL contacts as shown in Figure 27 to the terminals marked CL (BOILER HOT) and CN (BOILER NEUT).

4. Connect an externally provided 120VAC line to the COMMON terminal of the boiler pump relay.

5. Connect the NO relay contact to the LINE input of the boiler pump.

6. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the pump.

7. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

8. If using DHW, connect the DHW pump relay COIL contacts as shown in Figure 27 to the terminals marked DL (DHW HOT) and DN (DHW NEUT).

9. Connect an externally provided 120VAC LINE to the COMMON terminal of the DHW pump relay.

10. Connect the NO relay contact to the LINE input of the DHW pump.

11. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the DHW pump.

12. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the DHW pump.

D. Alarm Connections

The control includes a dry contact alarm output. This is an SPDT circuit, rated at 5 amps at 120 volts. This contact can be used to activate an alarm light or bell or notify a building management system if the boiler goes into a lockout condition. The circuit between the common and ALARM NC terminals is closed during normal operation and the circuit between the common and ALARM NO is open during normal operation. HTP oers an Alarm System Kit (part # 7350P-602).

E. Low Voltage Connections for Standard Boiler

1. All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 27.

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

F. Thermostat

1. Connect the room thermostat to the terminals marked TT- and TT+ of the Field Connection Board (shown in Figure 30). Alternately, any dry contact closure across these terminals will cause the boiler to run. Caution should be taken to ensure neither of the terminals becomes connected to ground.

2. Mount the thermostat on an inside wall as centrally as possible to the area being heated, but away from drafts or heat producing devices such as television sets that could inuence the ability of the thermostat to measure room temperature.

G. Outdoor Sensor

NOTE: There is no connection required if an outdoor sensor is not used

in this installation.

1. If using an outdoor sensor, connect wires for sensor to the terminals marked OUT- and OUT+, shown in Figure 30 of the Field Connection Board. Caution should be used to ensure neither of these terminals becomes connected to ground.

2. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet.

400 - 1500 Models

Figure 26 - Knockout Locations - 400 - 1500 Models Only

3. Mount the outdoor sensor on an exterior surface of the building, preferably on the north side in an area that will not be aected by direct sunlight and will be exposed to varying weather conditions.

H. Indirect Sensor

NOTE: There is no connection required if an indirect water heater is

not used in this installation.

1. The boiler will operate an indirect red water heater with either a thermostat type aquastat installed in the indirect tank, or an HTP 7250P-325 tank sensor. When a tank sensor is used, the control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user selected set point by more than the user selected oset. The demand will continue until the sensor measures that the indirect water heater temperature is above the set point.

2. Connect the indirect tank sensor (7250P-325) to the terminals marked DHW- and DHW+, shown in Figure 30 on the Field Connection Board of the Master boiler.

Failure to use the correct sensor may result in tank temperature being either above or below set point, and could result in decreased performance, substantial property damage, or heightened risk of injury or death due to scalds.

Caution should be used to ensure neither of these terminals becomes connected to ground.

NOTE: If sensor wires are located in an area with sources of potential electromagnetic interference (EMI), the sensor wires should be shielded, or the wires routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the boiler.

I. UL 353 Internal Low Water Cut-O (Factory Installed)

The supplied internal Low Water Cuto (LWCO) meets UL 353 requirements to function as a safety, locking out the boiler when water level is inadequate for safe operation. See Service Mode, this manual, for instructions on how to test and reset the Internal LWCO.

J. Wiring of Cascade System Communication Bus

1. A Cascade Bus Termination Plug has been installed on the customer connection board of this boiler. The purpose of this plug is to stabilize communication between multiple boilers and reduce electrical “noise”. See Figure 29 for Cascade Bus Termination Plug installation detail. NOTE: It is important that the termination plug in multiple boilers (cascaded units) be installed as depicted in Figure 29. Leave the plug installed in the J6 port on the Master boiler. Remove the plug on intermediate Follower boilers. Move the plug to the J7 port on the nal Follower boiler.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

2. Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers. These cables are readily available at any oce supply, computer, electronic, department or discount home supply store in varying lengths. If you possess the skills you can also construct custom length cables. NOTE: Shielded three-conductor cable may be used as an alternate method to connect cascade wiring. Connect the three wires of the shielded cable to the screw terminals labelled BUS A, BUS B, and BUS G. Observe proper polarity across all cascaded units. See Figure 30. NOTE: All termination plugs must be installed as described in Figure 29 to ensure proper cascade operation.

3. It is recommended to use the shortest length cable that will reach between the boilers and create a neat installation. Do not run unprotected cables across the oor where they may become wet or damaged. Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet.

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

5. Connect the boilers in a daisy chain conguration. It is best to wire the boilers using the shortest wire runs rather than trying to wire them in the order that they are addressed. The communication bus jacks on the customer connection panel are interchangeable so you can use either one or both in any order to connect the cable. If you have connected the boilers to each other properly, there will be no open communication connection ports.

K. Cascade Master System Pump and Sensor Wiring

1. Connect the system pump relay COIL contacts as shown in Figure 27 to the terminals marked SL (SYSTEM HOT) and SN (SYSTEM NEUT).

2. Connect an externally provided 120VAC line to the COMMON terminal of the system pump relay.

3. Connect the NO relay contact to the LINE input of the system pump.

4. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the system pump.

5. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the system pump.

6. Connect the system pipe sensor to the terminals marked SYS- and SYS+. See Figure 30.

7. Connect the outdoor sensor (if used) to the terminals marked OUTand OUT+.

8. Connect the signal to start the system to the terminals marked TTand TT+. NOTE: This signal can come from a room thermostat or a dry contact closure. No power of any voltage should be fed into either of these terminals.

L. Cascade Follower Pump and Sensor Wiring

If the boiler will control the boiler pump:

1. Connect the boiler pump relay COIL contacts as shown in Figure 28 to the terminals marked CL (BOILER HOT) and CN (BOILER NEUT).

2. Connect an externally provided 120VAC line to the COMMON terminal of the boiler pump relay.

3. Connect the NO relay contact to the LINE input of the boiler pump.

4. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the pump.

5. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

If the boiler will be connected directly to an indirect red water heater:

6. If using DHW, connect the DHW pump relay COIL contacts as shown in Figure 28 to the terminals marked DL (DHW HOT) and DN (DHW NEUT).

7. Connect an externally provided 120VAC LINE to the COMMON terminal of the DHW pump relay.

8. Connect the NO relay contact to the LINE input of the DHW pump.

9. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the DHW pump.

10. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the DHW pump.

If the boiler will be connected to an alarm bell or light:

The normally closed alarm contact may be used to turn a device o if the boiler goes into lockout mode. The alarm contacts are rated 5 amps at 120 VAC.

1. To connect an alarm device, connect the power for the device to the common (ALARM Center) terminal. Connect the alarm device hot wire to the NO (ALARM NO) terminal. Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device. See Figure 28.

2. To connect a device that should be powered o during a boiler lockout condition, follow the same instructions as above and use the NC (ALARM NC) terminal rather than the ALARM NO terminal. NOTE: In a cascade system, the alarm output of the boiler addressed as #1 will activate if any boiler has a lockout condition. The alarm of boilers addressed #2-7 will only activate if a lockout condition occurs on that specic boiler.

M. Variable Speed Pumping

Variable speed pump support is available on the primary loop of all models. This feature controls pump speed via an analog 0-10VDC signal supplied via the 0-10VA connection on the Field Connection Board. When this feature is in use, an installer selected Delta T is maintained with the Supply and Return sensors, increasing eciency and providing better system temperature control. When the dierence between the Supply and Return temperatures is greater than the desired setting, the pump will increase speed and ow to compensate. Conversely, if the Delta T is less than the desired setting, the pump will decrease speed and ow to compensate. NOTE: This feature may be used in Primary / Secondary piping arrangements ONLY!

Variable Speed Pumping Wiring:

1. Connect the boiler pump relay COIL contacts as shown in Figure 27 to the terminals marked CL (BOILER HOT) and CN (BOILER NEUT).

2. Connect an externally provided 120VAC line to the COMMON terminal of the boiler pump relay.

3. Connect the NO relay contact to the LINE input of the boiler pump.

4. Connect the Neutral of the externally provided 120VAC to the NEUTRAL input of the pump.

5. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

NOTE: The connections shown are suitable for a maximum continuous pump draw of 2 amps at 120 volts. If the pump requires 2 amps or less at 120 volts, a relay is not required, and the pump may be wired directly into the CN, CL, and CG terminals on the Customer Connection Board.

6. Connect the 0-10V input wires on the variable speed pump to the 0-10VA output on the Field Connection Board. Connect the positive pump input wire to 0-10VA+, and the negative wire to 0-10VA-. NOTE: When making wiring connections, ensure proper polarity or the system will not operate properly.

N. Optional 0-10 Volt Building Control Signal

1. A signal from a building management system may be connected to the boiler to enable remote control. This signal should be a 0-10 volt positive-going DC signal. When this input is enabled using the installer menu, a building control system can be used to control the set point temperature or ring rate of the boiler. The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the boiler will be in standby mode, not ring. When the signal rises above 1.5 volts, the boiler will ignite. As the signal continues to rise towards its maximum of 10 volts, the boiler will increase in either set point temperature or ring rate depending on the setting of Function 17 in the Installer Menu. See this manual for details on the setting of Functions 16 and 17 for this option. When the signal drops below 1.3 volts the boiler will stop ring.

2. Connect a building management system or other auxiliary control signal to the terminals marked 0-10V+ and 0-10V– on the Field Connection Board (shown in Figure 30). Caution should be used to ensure that the 0-10V+ connection does not become connected to ground.

P. Optional Low Gas Pressure Switch

1. If an optional low gas pressure switch is used, it should be installed on the side of the gas valve. This is normally closed and will open if the pressure goes below 2” w.c. on the inlet side.

2. Locate the two pigtails hanging from the electrical box inside of the boiler cabinet. Remove and discard the jumper plug from one of the unused pigtails.

3. Connect the low gas pressure switch to the pigtail that you removed the jumper plug from.

Q. Optional High Limit Manual Reset

NOTE: Follow the more detailed instructions included with the high

limit manual reset kit for proper installation steps.

1. Thread the control well into the tting provided on the manifold using teon thread tape.

2. Insert the control probe into the control well.

3. Secure the high limit manual reset box to the control well.

4. Locate and disconnect the red high limit manual reset wires in the boiler harness from each other. Connect those two red wires to the wires on the manual reset box.

5. When installation is complete, power up the boiler and test the reset according to the provided instructions. If the reset operates properly, set the high limit temperature as described in the provided instructions. When done, create a demand and observe boiler function to verify the installation is working properly.

O. Optional High Gas Pressure Switch

1. If an optional high gas pressure switch is used, it should be installed on the side of the gas valve. This is normally closed and will open if the pressure goes above 15.5” w.c. on the outlet side.

2. Locate the two pigtails hanging from the electrical box inside of the boiler cabinet. Remove and discard the jumper plug from one of the unused pigtails.

3. Connect the high gas pressure switch to the pigtail that you removed the jumper plug from.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

GREEN (GROUND)

400-1500 HIGH VOLTAGE

CUSTOMER CONNECTION BOARD

SINGLE BOILER AND CASCADE MASTER

120V LINE

120V NEUT

120V GND

** REQUIRED WHEN PUMP CURRENT > 2 AMPS

N G

SYSTEM

PUMP

DHW

PUMP

BOILER

PUMP

RELAY

PUMP

RELAY

PUMP

RELAY

WHITE (NEUTRAL)

BLACK (HOT)

LINE VOLTAGE

IN 120VAC

POWER SWITCH

BLOWER

LP-666-X 09/20/19

BLK/BLU

BLACK

LED1

N G

SWITCH

2A2A2A

PUMP

POWER

FAN

15A

5V DC (USB)

WIFI POWER

LED2

GROUND J6

ALARM

LED3

Figure 27 - Cascade Master and Single Boiler High Voltage Wiring - 400 - 1500 Models

GREEN (GROUND)

WHITE (NEUTRAL)

400-1500 HIGH VOLTAGE

CUSTOMER CONNECTION BOARD

CASCADE FOLLOWER

120V LINE

120V NEUT

120V GND

N G

BOILER

PUMP

** REQUIRED WHEN PUMP CURRENT > 2 AMPS

PUMP

RELAY

BLACK (HOT)

LINE VOLTAGE

IN 120VAC

LED1

LED2

LED3

N G

2A2A2A

PUMP

POWER

GROUND J6

POWER SWITCH

BLK/BLU

SWITCH

BLOWER

BLACK

FAN

15A

5V DC (USB)

WIFI POWER

ALARM

Figure 28 - Cascade Follower High Voltage Wiring - 400 - 1500 Models

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Figure 29 - Cascade Termination Plug Detail

ELX 400-2.0 LOW VOLTAGE

CUSTOMER CONNECTION BOARD

SINGLE BOILER AND CASCADE MASTER

CASCADE BUS

TERMINATION PLUG

INSTALLED HERE

CASCADE BUS

ELX 400-2.0 LOW VOLTAGE

CUSTOMER CONNECTION BOARD

CASCADE FOLLOWER

CASCADE BUS

CASCADE BUS TERMINATION PLUG INSTALLED HERE IN FINAL CASCADED BOILER

BIC 928

P10

BUS G BUS B BUS A

0-10 VOLT -

OUT A +

0-10 VOLT -

OUT B +

EXT LWCO

SYSTEM SENSOR

0-10V

INPUT

THERMOSTAT

OUTDOOR SENSOR

DHW SENSOR

BIC 928

Figure 30 - Cascade Master and Single Boiler Low Voltage Wiring, and Cascade Follower Low Voltage Wiring

P10

BUS G BUS B BUS A

EXT LWCO

LP-666-X2 09/18/19

lp-666 Rev. 003 Rel. 004 Date 9.3.20

ELX-400-1500

WIRING DIAGRAM

120 VAC LINE

P1-1

POWER

SWITCH

15A

DUAL FLUE SENSOR

LWCO

DUAL SUPPLY SENSOR

PROBE

JUMPER JUMPER

OPTIONAL

LOW GAS

PRESSURE

HIGH GAS

PRESSURE

FLOWSWITCH

BLOCKED VENT PRESSURE SW.

CONDENSATE

OUTDOOR

DHW TANK

0-10 VOLT

TT TERMINALS

RS485 BUS

P10-5

P10-6

J6-5

J6-4

J6-3

J7-5

J7-4

J7-3

0-10V A OUT

0-10V B OUT

XLWCO

JUMPER

SYSTEM

LOW VOLTAGE CONNECTION BOARD

P10-3

P10-4

P10-1 P10-2

P10-7 P10-8

P9-6

P9-5

P9-3

P9-4

P9-1

P9-2

P10-10

P10-9

BLUE

RETURN SENSOR

P9-9

P9-8

P9-10

J7-2

BLK

WHT

GRN

HMI DISPLAY

P1-3

X11-1

X11-4

X11-2

X-2

BRN/BLUE

ORN

WHITE

PINK

RED

X7-8 X7-18

RED

X6-6

X6-7

X6-15

X6-16

X10-7

X14-2

X11-5

X10-6

X10-7

X10-4

X10-1

X9-7 X9-6

X9-4

X9-1

X9-3

X9-2

X8-1

X8-2

X5-19

X5-20

X5-17

X5-7

J5-18

J5-8

J5-11

J5-2

J5-1

J5-13

J5-3

J5-14

J5-4

J5-15

J5-5

J5-16

J5-6

MANUAL RESET HIGH LIMIT (OPTIONAL)

X5-15 X5-16

X6-10

X7-3 X7-13

X7-2 X7-12

X7-4

X7-14

X6-8

X6-17

X7-1

X7-11

X6-9

X6-18

X7-5

X7-15

X5-8

X5-6

X6-1 X5-14

X6-3 X6-12

X6-2

X5-14

X5-1

X5-2

X5-9

X6-4

X5-14

X6-5

X5-13

X7-7

X7-17

X5-7

X5-13

BRN

BLK

TAN

YEL

ORN

WHITE

BROWN

RED

PINK

RED

GRN

LT. GRN

LT. BLUE

RED RED/BLUE

GRY BLUE

BLK/BLUE

RED/BLUE

GRN/LT BLUE

RED BLUE

RED

BLUE

BROWN

WHITE

PPL

RED

X7-9 X7-19

PROTECTED BY AN INTERNAL

6.3 AMP FUSE

928

CONTROL

RED

BURNER DOOR ECO

* NOTE: "J" REFERENCES FIELD CONNECTION BOARD

J7-3

P1-2

PWM

RED

+24V

WHT

HALL

NEG

LT. BLUE

WHT

NEUT.

BLOWER

MOTOR

SPARK TRANSFORMER

BLK

J7-8

J7-3

J7-7

J7-6

BLK

WHT

BRN

BLUE

GAS VALVE

BLK/BLUE

ALARM

BLK/BLUE

ALARM

COM

ALARM

HIGH VOLTAGE CONNECTION BOARD

HOT BLACK

ORANGE SPARK CAB LE TO SPARK ELECTROD E

FLAME RECTIFICATION

P4-3

LED3

P4-2

P3-3

LED2

P3-2

P2-3

LED1

P2-2

P5-3

P5-2

P5-1

NEUTRAL

PROBE

CH PUMP

DHW PUMP

SYSTEM PUMP

Figure 31 - Internal Connection Diagram - 400 - 1500 Models

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

CAUTION

Part 8 - Wiring - 2000 Models

Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death.

Electrical Shock Hazard - Turn o electrical power supply at service entrance panel before making any electrical connections. Failure to follow to do so could result in serious injury, or death.

A. Installation Must Comply With

1. National Electrical Code and any other national, state, provincial, or local codes or regulations.

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

B. Field Wiring

All connections made to the boiler in the eld are done inside the electrical junction box located in the front and left sides of the unit. The High Voltage electrical junction box is located on the left side of the boiler, and the Low Voltage Field Connection Board is located to the right of the BIC928 control, on the control panel. Multiple knockout locations are available to route eld wires into and out of the electrical junction box. The control used in the boiler is capable of directly controlling 2 pumps in standard mode and 3 pumps when congured as a cascade master boiler. An external contactor relay or motor starter is required. The High and Low Voltage Field Connection Boards have separate, clearly marked terminal strips for line voltage and low voltage wiring. Special jacks are provided for trouble-free cascade system wiring using standard CAT3 or CAT5 patch cables.

Ground goes to the G terminal. Neutral goes to N. The three Hot legs connect to the L1-L3 terminals.

3. A line voltage fused disconnect switch may be required to be externally mounted and connected according to local wiring codes.

CH Pump Wiring

Connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P2 NO (Normally Open).

1. Connect the boiler pump relay COIL Line input to the TOP terminal of P2 NO (Normally Open).

2. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

3. Connect the Line of an externally provided 120VAC service to the NO CONTACT of the pump relay.

4. Connect the other NO relay CONTACT to the LINE input of the boiler pump.

5. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

6. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

DHW Pump Wiring

1. Connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P4 NO (Normally Open).

2. Connect the DHW pump relay COIL Line input to the TOP terminal of P4 NO (Normally Open).

3. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of pump relay.

4. Connect the Line of an externally provided 120VAC service to the NO CONTACT of the pump relay.

5. Connect the other NO relay CONTACT to the LINE input of the DHW pump.

6. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

7. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

LOW VOLTAGE - 2000 Model

SYS PUMP PORT

DHW PUMP PORT

CH PUMP PORT

208VAC-3P WYE

VOLTAGE

INPUT

C. Line Voltage Wiring for Standard Boiler

NOTE: A termination plug is included in the CAT 3 / CAT 5 Bus

Connection Point, labeled J6 in Figure 36. DO NOT REMOVE THIS PLUG! Doing so will aect boiler operation and void warranty.

1. All high voltage cables should enter the boiler through the provided knock out holes as shown in Figure 32.

2. Connect the 208VAC-3P WYE conguration incoming power wiring to the ve pin terminal connector labeled 208VAC 3P IN of the High Voltage Field Connection Board (shown in Figure 33).

lp-666 Rev. 003 Rel. 004 Date 9.3.20

HIGH VOLTAGE 2000 Model

Figure 32 - Knockout Locations - 2000 Model Only

D. Alarm Connections

WARNING

circuit between the common and ALARM NO is open during normal operation. HTP oers an Alarm System Kit (part # 7350P-602).

E. Low Voltage Connections for Standard Boiler

1. All low voltage cables should enter the electrical junction box through the provided knock out holes as shown in Figure 32.

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

F. Thermostat

1. Connect the room thermostat to the terminals marked TT- and TT+ of the Field Connection Board (shown in Figure 37). Alternately, any dry contact closure across these terminals will cause the boiler to run. Caution should be taken to ensure neither of the terminals becomes connected to ground.

G. Outdoor Sensor

NOTE: There is no connection required if an outdoor sensor is not used

in this installation.

1. If using an outdoor sensor, connect wires for sensor to the terminals marked OUT+ and OUT- on the Low Voltage Field Connection Board. Caution should be used to ensure neither of these terminals becomes connected to ground.

2. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet.

H. Indirect Sensor

NOTE: There is no connection required if an indirect water heater is

not used in this installation.

2. Connect the indirect tank sensor (7250P-325) to the terminals marked DHW+ and DHW- on the Low Voltage Field Connection Board.

Caution should be used to ensure neither of these terminals becomes

connected to ground. NOTE: If sensor wires are located in an area with sources of potential electromagnetic interference (EMI), the sensor wires should be shielded, or the wires routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the boiler.

I. UL 353 Internal Low Water Cut-O (Factory Installed)

J. Wiring of Cascade System Communication Bus

1. A Cascade Bus Termination Plug has been installed on the customer connection board of this boiler. The purpose of this plug is to stabilize communication between multiple boilers and reduce electrical “noise”. See Figure 36 for Cascade Bus Termination Plug installation detail. NOTE: It is important that the termination plug in multiple boilers (cascaded units) be installed as depicted in Figure 36. Leave the plug installed in the J6 port on the Master boiler. Remove the plug on intermediate Follower boilers. Move the plug to the J7 port on the nal Follower boiler.

2. Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers. These cables are readily available at any oce supply, computer, electronic, department or discount home supply store in varying lengths. If you possess the skills you can also construct custom length cables. NOTE: Shielded three-conductor cable may be used as an alternate method to connect cascade wiring. Connect the three wires of the shielded cable to the screw terminals labelled BUS A, BUS B, and BUS G. Observe proper polarity across all cascaded units. See Figure 37. NOTE: All termination plugs must be installed as described in Figure 36 to ensure proper cascade operation.

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

K. Cascade Master Pump and Sensor Wiring

SYS Pump Wiring

1. On the High Voltage Field Connection Board in the rear of the boiler, connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P6 NO (Normally Open).

2. Connect the boiler pump relay COIL Line input to the TOP terminal of P6 NO (Normally Open).

3. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

4. Connect the Line of an externally provided 120VAC service to the NO CONTACT of the pump relay.

5. Connect the other NO relay CONTACT to the LINE input of the boiler pump.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

6. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

7. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

8. On the Low Voltage Field Connection Board in the front of the boiler, connect the system pipe sensor to the terminals marked SYS+ and SYS-.

9. Connect the outdoor sensor (if used) to the terminals marked OUT+ and OUT-.

10. Connect the signal to start the system to the terminals marked TT+ and TT-. NOTE: This signal can come from a room thermostat or a dry contact closure. No power of any voltage should be fed into either of these terminals.

L. Cascade Follower Pump and Sensor Wiring

1. If it is desired to have the boiler control the boiler pump, connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P2 NO (Normally Open).

2. Connect the boiler pump relay COIL Line input to the TOP terminal of P2 NO (Normally Open).

3. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

4. Connect the Line of an externally provided 120VAC service to the NO CONTACT of the pump relay.

5. Connect the NO relay CONTACT to the LINE input of the boiler pump.

6. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

7. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

8. If you are using an indirect red water heater connected directly to the follower boiler. Connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P4 NO (Normally Open).

9. Connect the DHW pump relay COIL Line input to the TOP terminal of P4 NO (Normally Open).

10. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

11. Connect the Line of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

12. Connect the other NO relay CONTACT to the LINE input of the DHW pump.

13. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

14. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump. If desired, an alarm bell or light can be connected to the alarm contacts of the boiler. The normally closed alarm contact may be used to turn a device o if the boiler goes into lockout mode. The alarm contacts are rated 5 amps at 120 VAC. To connect an alarm device, connect the power for the device to the center terminal of the three terminal barrier strip labelled ALARM (P8). Connect the alarm device hot wire to the top terminal of the three terminal barrier strip labelled ALARM (P8). Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device. To connect a device that should be powered o during a boiler lockout condition, follow the same instructions as above and use the bottom terminal of ALARM NC rather than the top ALARM NO terminal. NOTE: In a cascade system, the alarm output of the boiler addressed as #1 will activate if any boiler has a lockout condition. The alarm of boilers addressed #2-7 will only activate if a lockout condition occurs on that specic boiler.

M. Variable Speed Pumping

Variable speed pump support is available on the primary loop of all models. This feature controls pump speed via an analog 0-10VDC signal supplied via the 0-10VA connection on the Customer Connection Board. When this feature is in use, an installer selected Delta T is maintained with the Supply and Return sensors, increasing eciency and providing better system temperature control. When the dierence between the Supply and Return temperatures is greater than the desired setting, the pump will increase speed and ow to compensate. Conversely, if the Delta T is less than the desired setting, the pump will decrease speed and ow to compensate. NOTE: This feature may be used in Primary / Secondary piping arrangements ONLY!

Variable Speed Pumping Wiring:

1. On the High Voltage Field Connection Board, connect the Line of an externally provided 120VAC service to the CENTER terminal of the three terminal barrier strip labelled P2 NO (Normally Open).

2. Connect the boiler pump relay COIL Line input to the TOP terminal of P2 NO (Normally Open).

3. Connect the Neutral of an externally provided 120VAC service to the Neutral COIL terminal of the pump relay.

4. Connect the Line of an externally provided 120VAC service to the NO CONTACT of the pump relay.

5. Connect the other NO relay CONTACT to the LINE input of the boiler pump.

6. Connect the Neutral of an externally provided 120VAC service to the Neutral input of the pump.

7. Connect the Earth Ground of the externally provided 120VAC to the Earth Ground input of the pump.

8. On the Low Voltage Field Connection Board, connect the 0-10v input wires on the variable speed pump to the terminals marked 0-10VA+ (Positive) and 0-10VA- (Negative). NOTE: When making wiring connections, ensure proper polarity or the system will not operate properly.

N. Optional 0-10 Volt Building Control Signal

2. Connect a building management system or other auxiliary control signal to the terminals marked 0-10V+ and 0-10V– on the Field Connection Board (shown in Figure 37). Caution should be used to ensure that the 0-10V+ connection does not become connected to ground.

O. Optional High Gas Pressure Switch

2. Locate the two pigtails hanging from the electrical box inside of the boiler cabinet. Remove and discard the jumper plug from one of the unused pigtails.

3. Connect the high gas pressure switch to the pigtail that you removed the jumper plug from.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

P. Optional Low Gas Pressure Switch

1. If an optional low gas pressure switch is used, it should be installed on the side of the gas valve. This is normally closed and will open if the pressure goes below 2” w.c. on the inlet side.

2. Locate the two pigtails hanging from the electrical box inside of the boiler cabinet. Remove and discard the jumper plug from one of the unused pigtails.

3. Connect the low gas pressure switch to the pigtail that you removed the jumper plug from.

Q. Optional High Limit Manual Reset

NOTE: Follow the more detailed instructions included with the high

limit manual reset kit for proper installation steps.

1. Thread the control well into the tting provided on the manifold using teon thread tape.

2000 MODEL HIGH VOLTAGE

CUSTOMER CONNECTION BOARD

SINGLE BOILER AND CASCADE MASTER

LINE IN

BOILER

PUMP

EXTERNAL

RELAY

2. Insert the control probe into the control well.

3. Secure the high limit manual reset box to the control well.

4. Locate and disconnect the red high limit manual reset wires. Connect the two red wires to the manual reset box.

SYSTEM

PUMP

LINE IN

EXTERNAL

LINE IN

DHW

PUMP

RELAY

EXTERNAL

LINE IN

RELAY

LINE IN

LINE

VOLTAGE IN

208VAC 3 PH

Figure 33 - Cascade Master and Single Boiler High Voltage Wiring - 2000 Model

BLUE (HOT)

BLACK (HOT)

WHITE (NEUT)

GREEN (GRND)

ALARM

RED (HOT)

Notes for Dry Contact Wiring:

• Each internal relay operates a set of two (2) dry contact terminal blocks.

• Each block has an NO (Normally Open) or NC (Normally Closed) option.

• The pump relay can be connected to either terminal block.

• The other terminal block operates identically to the rst, and can be used to operate valves, lights, or other pumps.

DHW

SYS

Figure 34 - Dry Contact Wiring

Detail - 2000 Model

lp-666 Rev. 003 Rel. 004 Date 9.3.20

2000 MODEL HIGH VOLTAGE

CUSTOMER CONNECTION BOARD

CASCADE FOLLOWER

LINE

VOLTAGE IN

208VAC 3 PH

BLUE (HOT)

BLACK (HOT)

WHITE (NEUT)

GREEN (GRND)

ALARM

RED (HOT)

EXTERNAL

LINE IN

RELAY

BOILER

PUMP

LINE IN

DHW

SYS

LP-666-X4

09/20/19

Figure 35 - Cascade Follower High Voltage Wiring - 2000 Model

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Figure 36 - Cascade Termination Plug Detail

ELX 400-2.0 LOW VOLTAGE

CUSTOMER CONNECTION BOARD

SINGLE BOILER AND CASCADE MASTER

CASCADE BUS

TERMINATION PLUG

INSTALLED HERE

CASCADE BUS

ELX 400-2.0 LOW VOLTAGE

CUSTOMER CONNECTION BOARD

CASCADE FOLLOWER

CASCADE BUS

CASCADE BUS TERMINATION PLUG INSTALLED HERE IN FINAL CASCADED BOILER

BIC 928

P10

BUS G BUS B BUS A

0-10 VOLT -

OUT A +

0-10 VOLT -

OUT B +

EXT LWCO

SYSTEM SENSOR

0-10V

INPUT

THERMOSTAT

OUTDOOR SENSOR

DHW SENSOR

BIC 928

Figure 37 - Cascade Master and Single Boiler Low Voltage Wiring, and Cascade Follower Low Voltage Wiring

ELX 2.0

HIGH VOLTAGE

INTERFACE BOARD

5 VDC (USB)

5VDC TO

DONGLE

BLK

WHT

GRN

J11

FROM HVCB-1 J2

BLK/BLU

POWER SWITCH

X11

TO BIC928

BLK

WHT

GRN

P10

BUS G BUS B

BUS A

EXT LWCO

LP-666-X2 09/18/19

TO GAS

VALVE

LP-666-X3

POWER SWITCH

12/13/19

Figure 38 - 2000 Model Interface Board (Factory Wired - For Troubleshooting Purposes)

lp-666 Rev. 003 Rel. 004 Date 9.3.20

0-10V IN

P10-7

XJ5-7

RED

X6-14

P10-6

XJ5-17

X6-1

P10-5

GRAY

-+-

XJ5-18

X6-2

OUT

P10-4

P10-3

P10-2

XJ5-19

XJ5-20

LT. BLUE

LT. GRN

X5-6

X5-8

P10-1

RED

LP-666-B

6/19/2020

P9-3

XJ5-14

WHT

X7-17

P9-2

XJ5-5

XLWCO

P9-1

XJ5-15

BRN

X7-7

SYS

P10-10

XJ5-6

PPL

X5-13

P10-9

XJ5-16

PPL

X5-7

P10-8

RED/BLUE

BUS C

BUS A

0-10V A OUT

-+-

P9-6

P9-5

XJ5-3

BLUE

RED

X6-5

X5-14

XJ5-13

BLUE

0-10V B OUT

P9-4

XJ5-4

RED

X6-4

X5-13

BUS B

P9-9

LOW GAS

PRESSURE

OPTIONAL

** **

HIGH GAS

PRESSURE

RED

BROWN

X8-8

X6-17

X-2

HMI DISPLAY

PROBE

FLAME RECTIFICATION

BLK

X12

X11-5

P9-8

P9-10

4 5 34 5 3

XJ5-1

XJ5-11

XJ5-2

GRN

BLK/BLUE

RED

X5-9

X5-1

X5-2

DHW

WI-FI DONGLE POWER

USB CABLE

GRN

BLK

WHT

ELX-2000

X11-1 GND

J5-2 N OUT

J5-3 L1 OUT

WIRING DIAGRAM

X11-3 N OUT

X11-4 L1 OUT

7550-053 HV INTERFACE

J11-4 L1 IN

7550-052 HV CCB

208 3P IN

J11-3 N IN

J2-3 L1 IN

J11-1 GND

J2-3 L1 IN

J11-1 GND

J2-2 N IN

J1-1 L3 OUT

BLUE

X11-1

X11-2

X11-4

BRN

BLK

X5-15

X5-16

DUAL FLUE SENSOR

J5-1 GND

J2-1 GND

J1-2 L2 OUT

J1-3 L1 OUT

BLK

RED

TAN

YEL

X6-10

X7-13

X7-3

DUAL SUPPLY SENSOR

POWER

SWITCH

ORN

X7-2

X7-12

LWCO

PROBE

SYSTEM PUMP

LINE IN

FUSE

HOLDER

BROWN

WHITE

X7-14

X7-4

LINE IN

FS6

NOCNC

LED3

SYS

15A FUSE

X9-7

X9-6

X9-4

BLK

GAS VALVE

LINE IN

PUMP RELAY

FS5

NOCNC

BLK

BLUE

X9-1

X9-2

WHT

BLUE

DHW PUMP

X9-3

BRN

LINE IN

FS4

NOCNC

DHW

RED

X7-1

(OPTIONAL)

FLOWSWITCH

JUMPER

PUMP RELAY

FS3

NOCNC

LED2

RED

X7-11

LINE IN

PINK

X6-9

X6-18

BLOCKED VENT

PRESSURE SW.

CH PUMP

LINE INLINE IN

LINE IN

FS2

NOCNC

RED

X7-5

CONDENSATE

LED1

GRN

X7-15

PUMP RELAY

FS1

NOCNC

X10-6

ORN

PINK

CH PUMP

DHW PUMP

ORN

PINK

X10-5

X10-6

X10-1

X10-4

RED

SYSTEM PUMP

RED

X10-4

X8-1

BLK/BLU

ALARM

BLK/BLU

X8-1

928

X8-2

CONTROL

BRN/BLUE

X14-2

X7-6

SPARK

TRANSFORMER

ORANGE SPARK CABLE

TO SPARK ELECTRODE

J17-5

J17-4

FS2

NOCNC

RL1

X7-16

X10-8

BLK

X10-7

WHT

X6-6

X6-7

BLK

RED

PWM

+24V

L1L2L3

BLK

RED

X6-15

X6-16

WHT

LT. BLU

NEG

HALL

BLOWER

RED

BLU

X7-8 X7-18

RED

X7-9 X7-19

CONTACTOR

BURNER DOOR ECO

HIGH LIMIT

(OPTIONAL)

MANUAL RESET

Figure 39 - Internal Connection Diagram - 2000 Models

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Part 9 - Gas Connections

WARNING

CAUTION

Failure to follow all precautions could result in re, explosion, severe injury, or death.

It is very important that the boiler is connected to the type of gas noted on the rating plate. “LP” for liqueed petroleum, propane gas, or “NG” for natural gas. Do not do a gas conversion without an approved gas conversion kit (not included). Prior to turning the gas on, all gas connections must be approved by the local gas supplier or utility, in addition to the governing authority. Failure to follow these instructions could result in property damage, serious injury, or death.

The gas supply shall have a minimum of no less than 3.5” water column, a maximum inlet pressure of no greater than 14” water column (350 mm) (10.5” w.c. [2.6 kPa] for 1500 and 2000 models), and ½ pound pressure (3.5 kPa). The entire piping system, gas meter, and regulator must be sized properly to prevent excessive pressure drop (greater than 0.5” WC) as stated in the National Fuel Gas Code. This information is listed on the rating plate.

UL recognized fuel gas detectors are recommended in all enclosed natural gas applications where there is a potential for an explosive mixture of fuel gas to accumulate. The installation of these detectors should be made in accordance with the detector manufacturer’s recommendations, and/or local laws. Failure to install fuel gas detectors in these applications could result in re, explosion, property damage, severe personal injury, or death.

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

The gas connection on the boiler is 1” NPT for 400 - 650 models, 1 1/4” NPT for 800 - 1000 models, 1 1/2” NPT for 1500 models, and 2” NPT 2000 models. It is mandatory that this tting is used for connection to a eld fabricated drip leg as shown in the illustration per the National Fuel Gas Code. You must ensure that the entire gas line to the connection at the boiler is no smaller than the unit supplied connection. Once all inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum inlet pressure, you must isolate the boiler from the gas line. In order to do this, shut the gas o using factory and eldinstalled gas cocks. This will prevent high pressure. Failure to do so may damage the gas valve. In the event the gas valve is exposed to a pressure greater than ½ PSI, 14” w.c. (3.5 kPa) (10.5” w.c. [2.6 kPa] for 1500 and 2000 models), the gas valve must be replaced. Never use an open ame (match, lighter, etc.) to check gas connections.

A. Gas Piping

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

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

3. In Canada, the Manual Shuto must be identied by the installing contractor.

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

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

6. Sealing compound must be approved for gas connections. Care must be taken when applying compound to prevent blockage or obstruction of gas ow which may aect the operation of the unit.

Do not use Teon tape on gas line pipe thread. Use a pipe compound rated for use with natural gases. Apply sparingly on male pipe ends, leaving the two end threads bare and ow unobstructed. Failure to follow these instructions could result in gas leakage or blockage, and result in re, explosion, property damage, severe personal injury, or death. Support gas supply piping with hangers, not by the boiler or its accessories. The boiler gas valve and blower will not support the weight of the piping. Make sure the gas piping is protected from physical damage and freezing, where required. Failure to follow these instructions could result in gas leakage, and result in re, explosion, property damage, severe personal injury, or death.

GAS SUPPLY

REQUIRED

MANUAL SHUT-OFF

(FIELD SUPPLIED)

UNION

DRIP LEG

Figure 40 - Gas Connection, 1500 - 2000 Models

Figure 41 - Tightening Gas Connection - 400 - 1000 Models

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

CSA or UL listed exible gas connections can be used when installing the boiler. Flexible gas connections have dierent capacities and must be sized correctly for the connected boiler ring rates. Consult with the ex line supplier to assure the line size is adequate for the job. Follow local codes for proper installation and service requirements.

LP-666-H 10/25/18

B. Gas Table

Refer to Table 12 to size the supply piping to minimize pressure drop between the meter or regulator and unit. Maximum capacity of pipe in cubic feet of gas per hour cannot have a pressure drop greater than .5 w.c. NOTE: For greater capacities, see NFPA 54, The National Fuel Gas Code.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

NOTICE

Natural Gas Supply Piping Capacity Chart - Schedule 40 metallic pipe size in nominal inches

(0.6 Specic gravity gas; 0.5” WC pressure drop)

Pipe Size

(Inches)

1 678 466 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

1 1/4 1390 957 768 657 583 528 486 452 424 400 N/A N/A N/A N/A

1 1/2 2090 1430 1150 985 873 791 728 677 635 600 532 482 443 412

2 4020 2760 2220 1900 1680 1520 1400 1300 1220 1160 1020 928 854 794

2 1/2 6400 4400 3530 3020 2680 2430 2230 2080 1950 1840 1630 1480 1360 1270

3 11300 7780 6250 5350 4740 4290 3950 3670 3450 3260 2890 2610 2410 2240

4 23100 15900 12700 10900 9660 8760 8050 7490 7030 6640 5890 5330 4910 4560

5 41800 28700 23000 19700 17500 15800 14600 13600 12700 12000 10600 9650 8880 8260

Table 12 - Gas Supply Piping Size Chart for Boilers - from NFPA 54, The National Fuel Gas Code

10 20 30 40 50 60 70 80 90 100 125 150 175 200

Capacity in Cubic Ft. Hr. by Length of Pipe in Straight Feet

C. Check Inlet Gas Pressure

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

1. IMPORTANT! Before you connect to the inlet pressure, shut o the gas and electrical power to unit.

2. Loosen the pressure tap with a small screwdriver. Refer to Figures 42 and 43 for location.

3. Each unit is equipped with a needle valve that will accept a 5/16 ID hose to connect to a digital manometer or liquid gauge to measure incoming pressure from 0-35” w.c.

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

5. Put the unit into manual test mode. In test mode, monitor pressure to assure it does not drop below 1 inch from its idle reading. If gas pressure is out of range or pressure drop is excessive, contact the gas utility, gas supplier, qualied installer, or service agency to determine correct action that is needed to provide proper gas pressure to the unit. If Gas Pressure is within normal range proceed to Step 6.

6. Exit test mode, then turn power o and shut o gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device. Tighten screw on the pressure tap and turn gas on. Check for leaks with soapy solution. Bubbles will appear on the pipe to indicate a leak is present.

Ensure the pressure tap screw is properly tightened to prevent gas leaks. Failure to do so could cause substantial property damage, severe personal injury, or death.

Strain on the gas valve and ttings may result in vibration, premature component failure and gas leakage, and result in re, explosion, property damage, severe personal injury, or death.

The gas piping must be sized for the proper ow and length of pipe to avoid pressure drop. The gas meter and regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1” w.c. (.87 kPa), the meter, regulator or gas line may be undersized or in need of service. You can attach a manometer to the incoming gas drip leg after removing the cap. The gas pressure must remain between 3.5” (.87 kPa) and 14” (3.5 kPa) (10.5” w.c. [2.6 kPa] for 1500 and 2000 models) during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the boiler. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines, or improper line sizing, will result in ignition failure. This problem is especially noticeable in NEW installations and empty tank situations. This situation can also occur when a utility company shuts o service to an area to provide maintenance to their lines. This gas valve must not be replaced with a conventional gas valve under any circumstances.

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

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

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

400 - 1000 Models - Natural or LP Gas

Minimum Pressure 3.5” WC

Maximum Pressure 14”WC

1500 - 2000 Models - Natural Gas ONLY!

Minimum Pressure 3.5” WC

Maximum Pressure 10.5”WC

Table 13 - Gas Pressure Requirements

Do not re (operate) the boiler until all connections have been completed and the heat exchanger is lled with water. Doing so will damage the boiler and void the warranty.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

D. Boiler Gas Valve

DANGER

GAS INLET

LP-550-O 10/26/18

INLET PRESSURE TEST POINT

OUTLET PRESSURE TEST POINT

OFFSET ADJUSTMENT

CAUTION: DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW WITHOUT A COMBUSTION ANALYZER.

THROTTLE ADJUSTMENT

NOTE: IF FOR ANY REASON THE

THROTTLE NEEDS TO BE ADJUSTED,

IT IS VERY IMPORTANT THAT A

COMBUSTION ANALYZER BE USED

TO ENSURE SAFE AND PROPER

OPERATION. TURN THE ADJUSTER

COUNTER CLOCKWISE TO INCREASE

THE GAS OR CLOCKWISE TO

DECREASE THE GAS SUPPLY. THIS

ADJUSTMENT COULD AFFECT

CO/CO% LEVELS. MAKE SURE THE

GAS OUTLET

Figure 42 - 400 and 500 Model Gas Valve

LEVELS CORRESPOND TO THE

CHART IN THIS MANUAL.

DETAIL B

SCALE 2 : 1

Figure 43 - 650 - 2000 Model Gas Valve - If Necessary, Use #40 Torx to Adjust Oset and Hex to Adjust the Throttle

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

Adjustments to the throttle screw or oset may only be made by a qualied gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction will result in re, explosion, property damage, severe personal injury, or death.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

CAUTION

WARNING

CAUTION

Part 10 - Start-Up Preparation

Thoroughly clean and ush any system that has used glycol before installing the boiler. Provide the customer with a material safety data sheet (MSDS) on the uid used.

A. Check / Control Water Chemistry

Chemical imbalance of your water can cause severe damage to your boiler and associated equipment, and may also aect eciency. You may have to have your water quality professionally analyzed to determine whether you need to install a water softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the boiler, as water quality will aect the reliability of the system. Outlined below are those water quality parameters which need to be met in order for the system to operate eciently for many years. Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH or other imbalance IS NOT covered by the warranty.

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

Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

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

• Water pH between 6.5 and 8.5

• Hardness less than 5 - 12 grains (71.3 - 205 mg/L)

• Chloride concentration less than 150 ppm (mg/L)

• Total Dissolved Solids (TDS) 100 - 450 ppm (mg/L)

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

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

Clean system to remove sediment*

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

2. For zoned systems, ush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.)

Test/replace freeze protection uid

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

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

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

B. Check for Gas Leaks

Before starting the boiler, and during initial operation, smell near the oor and around the boiler for gas odorant or any unusual odor. Remove boiler front door and smell interior of boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leaks at once.

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

C. Freeze Protection (When Used)

NEVER use automotive or standard glycol antifreeze. Do not use ethylene glycol made for hydronic systems. Use only freezeprotection uids certied by uid manufacturer as suitable for use with stainless steel boilers, veried in the uid manufacturer’s literature. Thoroughly clean and ush any system that has used glycol before installing the new boiler. Provide the boiler owner with a material safety data sheet (MSDS) on the uid used.

1. Determine the freeze protection uid quantity using total system water content following the uid manufacturer’s instructions. Remember to include expansion tank water content.

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

3. When using freeze protection uid with automatic ll, install a water meter to monitor water makeup. Freeze protection uid concentration may drop if there is a leak, reducing the freeze protection level.

D. Fill and Test Water System

Ensure the boiler is full of water before ring the burner. Failure to do so will damage the boiler. Such damage IS NOT covered by warranty, and could result in property damage, severe personal injury, or death.

1. Fill the system only after ensuring water chemistry meets the requirements listed in this manual.

2. Close the manual and automatic air vents and boiler drain valve.

3. Fill to the correct system pressure. Correct pressure will vary with each application.

a. Typical cold water ll pressure for a residential system is 12 psi. b. Pressure will rise when boiler is turned on and system water temperature increases. Operating pressure must never exceed the relief valve pressure setting.

4. At initial ll and during boiler startup and testing, check system thoroughly for leaks. Repair all leaks before proceeding further.

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

5. The system may have residual substances that could aect water chemistry. After the system has been lled and leak tested, verify that water pH and chloride concentrations are acceptable by sample testing.

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

E. Check Thermostat Circuit(s)

1. Disconnect the two external wires connected to the boiler thermostat terminals (low voltage terminal strip).

2. Connect a voltmeter across these two incoming wires with power supplied to the thermostat circuits. Close each thermostat, zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage reading does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the boiler low voltage terminal strip. Allow the boiler to cycle.

F. Condensate Removal

1. The boiler is a high eciency condensing boiler. Therefore, the unit has a condensate drain. Condensate uid is nothing more than water vapor, derived from combustion products, similar to that produced by an automobile when it is initially started. Condensation is slightly acidic (typically with a pH of 3 to 5) and must be piped with the correct materials. Never pipe the condensate using steel, copper, brass or other materials that will be subject to corrosion. Plastic PVC or CPVC pipe are the only approved materials. A condensate neutralizer, if required by local authorities, can be made up of lime crystals, marble or phosphate chips that will neutralize the condensate. This may be done by the installer or you may purchase a condensate neutralizer from HTP (7350P-611).

2. The boiler is equipped with a female socket weld tting connection (¾” in 400 to 1000 models and 1” in 1500 and 2000 models) that must be piped to a local drain. It is very important that the condensate line is sloped downward away from the boiler to a suitable inside drain. If the condensate outlet on the appliance is lower than the drain, you must use a condensate removal pump, available from HTP (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overow, which, if not corrected, could cause property damage.

3. If a long horizontal run is used, it may be necessary to create a vent in the horizontal run to prevent a vacuum lock in the condensate line.

4. Do not expose the condensate to freezing temperatures.

5. It is very important you support the condensation line to assure proper drainage.

G. Final Checks Before Starting Boiler

1. Read Startup Procedures within this manual for proper steps to start boiler. (See Startup Report to record steps for future reference.)

2. Verify the boiler and system are full of water and all system components are correctly set for operation.

Part 11 - Start-Up Procedure

FOR YOUR OWN SAFETY READ BEFORE OPERATING

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

2. BEFORE OPERATING: Smell all around the boiler area for gas. Be sure to smell next to the oor because some gas is heavier than air and will settle on the oor.

3. WHAT TO DO IF YOU SMELL GAS

• Do not try to light any boiler.

• Do not touch any electric switch, do not use any phone in your building.

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

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

• Turn o the gas shuto valve (located outside the boiler) so that the handle is crosswise to the gas pipe. If the handle will not turn by hand, don’t try to force or repair it, call a qualied service technician. Force or attempted repair may result in a re or explosion.

4. Do not use this boiler if any part has been under water. Immediately call a qualied service technician to inspect the boiler and to replace any part of the control system and any gas control that has been damaged.

5. The boiler shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.)

Failure to follow these instructions could result in property

damage, serious personal injury, or death.

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

A. Control Overview

The control is one of the primary safety devices of the boiler. It monitors the safety sensors of the boiler to assure safe and ecient operation. The control has many features associated with system design. This section addresses programming features, including History, Status, User Settings and Installer Settings, to help in customizing your control. It is important to fully understand control capabilities before customization, as its factory defaults may already t your system design and not require any adjustment at all.

3. Fill condensate trap with water.

4. Verify electrical connections are correct and securely attached.

5. Inspect exhaust vent and intake piping for signs of deterioration from corrosion, physical damage or sagging. Verify exhaust vent and intake piping are intact and correctly installed per Venting Section and local codes.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

B. Navigation of the Touch Screen Display

The touch screen display allows the installer to quickly navigate between appliance status screens and operating parameters, easing programming and troubleshooting. The display also provides informative messages about the operation of the appliance that are useful to both the installer and user. Many operating parameters can be viewed and adjusted with the display. The Home screen is described below.

Home Screen

Green Center Pane indicates appliance is Running or in Standby;

Current Appliance Operating Temperatures

Current Appliance Operating Details

Yellow Center Pane indicates

Orange Center Pane indicates Blocking Code;

Red Center Pane indicates Lockout Code

;

External Sensor and DHW Temperatures

Navigation

Bar

Internal

Lock: 205 F

F L

Supply

Delta T

Re turn

165 F

Lock: 210 F

175 F

155 F

Demand

Product RUNNING

- Command : CH thermostat demand

- Run Time: 525 days & 23 Hours

- Blocking: None

- Lock out: None

- 0 - 10V Input 0.00V Cascade Master

10:54:05AM

2-11-2020

Flame Current 6uA

Min. Flame Current 1u A

Setpoint:

Modulation: 80%

Reset

DHW

180 F

External

Outdoor Temp.

33 F

System Temp.

112 F

Indirect Storage Temp.

120 F

Setpoint

Service Mode

119 F

Actual Temp.

SYSDHWCH

Figure 44 - Display Home Screen

Navigation Bar

The Navigation Bar allows the installer / user to move quickly through the appliance control screens. The screens accessed by tapping these icons are described in depth below:

HTP Logo and Home

Tapping the HTP Logo or Home will return the installer / user to the Home Screen. The Home Screen allows the installer / user quick access to appliance internal operating temperatures, external temperature sensor readings, current CH and DHW setpoints and actual temperatures, appliance modulation percentage, operation details, and a Reset key.

History

The History screens allow the installer / user to view important items from the appliance’s history, including serial number, power on hours, ignition attempts, and the ten (10) most recent appliance Blocking and Fault codes.

Status

The Status screens detail the appliance’s current operating stats, including fan speed and temperature settings, and input and output settings.

Graphics

The Graphics function allows the installer / user to select and view real time system analytics. This function helps the installer / user ne tune system operation and aids in troubleshooting.

Cascade

Cascade lets the installer / user view cascade system stats, including the current operating status of all the boilers installed in the cascaded system.

User

The User function allows the installer / user to quickly set operating settings such as the boiler setpoint, dierential, oset, and DHW settings with easy to use slider bars.

Installer

Installer is accessed with a password, allowing the installer to customize the installation and oering quick access to set the Outdoor Reset Curve. Pump Service Mode and LWCO Test Mode are also accessed through the Installer function.

NOTE: Installer should only be accessed by a qualifed service technician. Reset

Tap Reset to clear any lockout code and return the appliance to normal operation.

Figure 45 - Display Navigation Bar

lp-666 Rev. 003 Rel. 004 Date 9.3.20

C. Purge Air from the System

To purge air from the system:

a. Connect a hose to the purge valve and route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and ll connection to the system. c. Close zone isolation valves. d. Open quick-ll valve on cold water make-up line. e. Open purge valve. f. Open the isolation valves one zone at a time. Allow water to run through the zone, pushing out the air. Run water until no noticeable air ow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged. g. Close the quick-ll water valve and purge valve and remove the hose. Open all isolation valves. Watch the system pressure rise to correct cold-ll pressure. It is recommended that you put the pumps into manual operation to assist in purging the circuits. h. Disconnect the wires that are connected to the THERMOSTAT terminals of the customer connection board. Apply power to the boiler. The display will show the Home Screen. i. Tap Installer on the display Navigation Bar to open the Installer settings. Then tap NEXT repeatedly to navigate to Service Mode. See Figure 52. When prompted for a password, enter “928”. j. Pump Service Mode allows quick access to run connected pumps and purge air from the lines. Tap the connected pumps On and O to toggle between running each pump in the system as required to help bleed out all entrapped air. Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet. Tapping Home and returning to the Home Screen will return the boiler to normal operation. k. After the system has operated for ve minutes, eliminate any residual air by using the manual air vents located throughout the system. l. If purge valves are not installed in the system, open manual air vents in the system one at a time, beginning with the lowest oor. Close vent when water squirts out. Repeat with remaining vents. m. After purging, rell system to correct pressure.

D. Single Boiler Initial Start-Up and Operation

When power is applied to the boiler, the control rst completes a power-up systems check and boots up the display. During this time the combustion fan may run. After boot up is complete the display will show the Home Screen and its accompanying data, including ring rate, modulation rate, and current boiler supply temperature. A green center pane indicates the boiler is in ready operating condition and either running or in standby, awaiting a demand for heat. If a fault is detected the center pane will display the appropriate blocking code (orange center pane) or lockout code (red center pane). NOTE: A service notication will result in a center pane that alternates between yellow and orange. When a demand for heat is received, the control begins the following demand sequence. The boiler rst turns on the pump. The control will measure the supply temperature. If it is below the set point temperature minus the ignition dierential the control will ignite the burner. After the burner is lit, the control modulates the ring rate to control the supply water temperature and meet the heat demand. When the thermostat or indirect water heater temperature is met, the control will extinguish the burner and run the combustion fan to purge gasses from the combustion chamber. In addition, the pump will run for a pump post purge interval. The control will then be in standby, waiting to process the next demand for heat. During this process, the control will extinguish the burner if it senses a dangerous or unsafe condition. If the control determines that a dangerous or unsafe condition has occurred, the control may lock out the boiler and prevent it from igniting until a maintenance person

diagnoses the problem, repairs it, and resets the control. In the event that the control goes into lockout, it will show a diagnostic code on the display, illuminate the red indicator, and close the alarm relay contacts to aid in recognition of the condition, diagnosis, and repair.

E. Cascaded System Initial Start-Up and Operation

Operation is slightly dierent if the boiler is part of a cascaded system. The control of each boiler in a cascaded system completes its own power up system check. One of the boilers in the cascade system is designated as the master boiler. After the master boiler completes its power up sequence, it checks the communication bus to see if any other boilers are present. If other boilers are present, the master control determines these follower boiler addresses. The master boiler control will recheck the bus every few seconds as long as it is powered up to update the status of the connected boilers. The master boiler control processes all heat demands and dictates which of the follower boilers should light and what ring rate the followers should try to achieve. When the master boiler receives a demand for heat, it determines which boiler is rst in the ring sequence and sends that boiler a command to begin a demand sequence. That boiler will then begin a demand sequence as described above. Once the boiler ignites, the master boiler control will increase the ring rate command to that boiler until the system sensor temperature is at the set point temperature plus the dierential, or that boiler is at a high ring rate. If the command from the master boiler control gets to the high ring rate of the follower boiler, but the system sensor is below the required temperature, the master boiler control will then tell the next boiler in the ring sequence to begin its demand sequence. The master boiler control will then begin to ramp up the ring rate command of that boiler. This process will continue while there is a demand until all boilers in the cascade system are at high re or the desired temperature of the system sensor is reached. If the system sensor temperature reaches set point and dierential before all boilers are at high re, the master control will modulate the cascade command signal to maintain the system sensor at set point and dierential until the demand is complete. Demand is complete when the system sensor is equal to the set point temperature. The master boiler control will extinguish all boilers that may be lit. If the demand decreases, the ring rate command and amount of boilers lit will decrease exactly opposite as described above. Whenever the master boiler control needs to re a follower boiler, it sends a ring rate command to that boiler. The follower boiler will respond to the command until its supply sensor temperature gets to be 5oF above the set point temperature plus the dierential, at which point the individual boiler will modulate on its own so as not to overheat. As a result, it is not uncommon to see the cascade output at maximum but individual boilers ring at less than their maximum ring rate.

F. Lockout Condition - Cascade System

Each boiler in the cascade system is responsible for its own safety functions. If any individual boiler control senses an unsafe condition, it will extinguish the burner and, if necessary, go into a lockout condition. In this way, every boiler in the system has its individual safety controls intact and operational, even if the ring of the boiler is under control of the master boiler. If any boilers are in a lockout condition, including the master boiler in the cascade system, the master control will recognize the lockout condition and skip over the boiler in the ring sequence. In the event that the system sensor fails, all boilers in the system will ignite simultaneously when there is a demand, and each boiler will individually regulate ring rates to maintain the master set point temperature at the individual supply sensors built into the boiler. If this should happen, the master boiler will display an E03 Blocking code, indicating that the system supply sensor has failed.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

G. Cascade System Programming

1. If the boiler is used alone, skip this section.

2. Programming the Master Boiler: a. Make sure there is no demand for heat being supplied to the boiler. b. Apply power to the boiler. c. Tap Installer in the display Navigation Bar to enter the Installer Menu. d. Tap NEXT and navigate to Installer #15. Ensure the Cascade Address is set to 0. NOTE: The Master Boiler MUST be addressed as 0. e. Ensure Installer #23, Cascade Mode, is set to the number of boilers in the system (ex: 0 for OFF, 6 for a 6 boiler system). f. Exit the Installer Menu.

3. Programming Follower Boilers:

NOTE: READ THE FOLLOWING BEFORE PROGRAMMING THE

FOLLOWER BOILERS

• The master boiler will share its alarm output with the follower boiler addressed as 1.

• If one of the follower boilers has an indirect red water heater connected to it, the address of this boiler must be 2 or greater.

• It is recommended but not necessary to address boilers in the order that they are wired.

• No two boilers can have the same address.

• It is not required to use all consecutive address numbers. Example: In a 2 boiler system with an indirect connected to the follower, the follower address would be 2 (address 1 is not used).

• Maximum amount of boilers in a cascaded system is eight (8).

a. Make sure there is no demand for heat being supplied to the master boiler. b. Apply power to the follower boiler you are working on. c. Tap Installer in the display Navigation Bar to enter the system setting program. d. Tap NEXT and navigate to Installer #15. Set the Cascade Address to 1 for the rst follower, 2 for the second follower, etc. depending on which boiler you are programming based on the above notes. This establishes the boiler as a follower in a cascaded system and enables data to be transferred as needed for the system to function at full capability. e. Ensure Installer #23, Cascade Mode, is set to the number of boilers in the system (ex: 0 for OFF, 6 for a 6 boiler system). f. Exit the Installer Menu.

H. Operating Instructions

Before operating the unit, it is important to verify that the gas line and water lines are connected to the boiler and fully purged. If you smell gas, STOP! Follow the safety instructions listed in the rst part of this section. If you do not smell gas, follow the next steps.

1. Turn down the thermostats before applying power to the boiler. If 0–10 volt or other inputs are used, make sure that they are set so there is no call for heat while programming. NOTE: An input of 1.5V is the minimum input to initiate a call for heat on the boiler.

2. Power on the boiler or boilers if a cascade system is used.

3. Next, check the User settings. Adjustment and factory defaults are outlined within this section. If a cascade system is used, it is important that all the boilers have the same User settings.

4. Next, check the System settings. Adjustments and factory defaults are outlined within this section. If a cascade system is used, it is important that the master boiler is programmed with the correct System settings.

5. Create a demand on the boiler or boilers if a cascade system is used. The user can monitor system functions when the boilers are operational.

6. If any boiler fails to start refer to the troubleshooting section in the back of this manual.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Boile r S ett i n g s 2

I. Programming User Settings

User Setting Program Access NOTE: Programming the boiler control is not possible when the boiler is ring. Make sure any input which can create a demand on the boiler,

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

NOTE: To change User Settings enter Access Code 600 when prompted.

User Setting Program Navigation

Use the touch screen sliders or input prompts to change the Boiler settings. Press SAVE to store changes. Press NEXT to advance to User Screen 2 - DHW Settings, and PREVIOUS to go back a screen. Listed below are the User Settings that can be programmed into the control.

User Screen 1 - Boiler Settings

BOILER

32 F

High Limit

32 F

Date Settings

05-02-2018

Time Settings

09:33 AM

Check on board clock.

Input 1 - Tap here to set the Date Input 2 - Tap here to set the Time

Figure 46 - User Screen 1 - Boiler Settings

50 F 190 F

Mi n Ma x

Setting Description

Adjusts the Central Heat Setpoint between the Factory programmed limits of 50oF and 190oF (Factory

Slider 1

Central Heat Setpoint 181 oF

Default 181F). NOTE: After changing the setpoint and tapping SAVE, the dierential slider will move, maintaining the dierential range. When changing the setpoint ensure the dierential remains at the desired setting.

Adjusts the “dierential”, or the temperature below setpoint at which the boiler will light (On Temp) during

Slider 2

Central Heat Dierential 28 oF

a call for heat. This is user adjustable between Setpoint minus 3 (burner lights at 3F below Setpoint) and Setpoint minus 29F (burner lights at 29F below setpoint). (Factory Default Setpoint minus 28oF). In the example above, a setpoint of 180F and dierential of 27F is desired. The setpoint slider is set at 180F. The On Temp slider is set at 153F (180 - 153 = 27). Tap SAVE to save the settings. NOTE: The current dierential from 3 - 29oF is displayed in a text box to the right and slightly below the slider.

Adjusts the high limit based upon the Central Heat Setpoint. This UL-353 compliant feature simplies testing and increases safety during boiler installation and inspection. This improvement allows the

Slider 3

Central Heat High Limits

installer to temporarily lower the high limit to a temperature far lower than the normal factory operating limit. For details on how to perform the test see Testing the High Limit on the following page. NOTE: High limit temperature cannot be permanently changed. After leaving the User menu the Factory settings will be restored.

Input 1

Date Settings

Input 2

Time Settings

Input 3

Temperature Display C or F

Table 14 - User Screen 1 Program Navigation

Allows the user to set the date. See the following page for setting the date.

Allows the user to set the time. See the following page for setting the time.

Toggle the switch near the oF or oC to switch temperature measurement from Fahrenheit to Celsius (Default is Fahrenheit).

Setpoint

180 F

240 F

On Temp

153 F

240 F

152 F

Min

Outdoo r Temperature

33 F

System Supply Temperature

174 F

Input 3 - Toggle here to select temperature measurement: F for Fahrenheit; C for Celsius

178 F

Max

Lock

210 F

SAVE

Use the Sliders to select Boiler

settings

Slider 1

Central Heat

Setpoint

Slider 2

Central Heat

Current

Central Heat

Slider 3

Central Heat

High Limit

Press SAVE to

save the Boiler

settings

Press NEXT

to go to User

Screen 2

(DHW Settings)

lp-666 Rev. 003 Rel. 004 Date 9.3.20

210

240 F

33 F

ess S

BOILER

32 F

March 2020 Cancel Ok

1 2 3 4

32 F

1. Tap the Month eld and select the desired month.

50 F 190 F

Mi n Ma x

High Limit

32 F

25 26

Date Settings

05-02-2018

Figure 47 - Setting the Date

2. Tap the Year eld and use the Up/Down arrows to select the desired year.

4. Tap “Ok”.

On Temp

153 F

7 8

152 F

Min

3. Tap the desired date.

11 12 13 14 15 16

19 20 21 22 23 24

27 28

29 30 31

5. Tap “SAVE”.

Outdoor Temperature

Setpoint

180 F

240

178 F

Max

Lock

210 F

SAVE

50 F 190 F

Mi n Ma x

h Limit

ettings

05-02-2018

Figure 48 - Setting the Time

Testing the High Limit

To test the Central Heat High Limit:

1. At the Home Screen, make note of the current boiler supply temperature.

2. Navigate to User Screen 1.

3. Tap on the High Limit slider. You will be prompted to input the Service Mode Access Code, 928. Click Ok.

4. Slide the High Limit below the current boiler supply temperature, but not below the boiler minimum. Tap Save.

5. Navigate to the Home Screen. The boiler should enter a lockout state and the operating screen will turn red.

6. Tap Reset at the Home Screen to clear the error code. The High Limit will automatically reset to the factory programmed temperature.

Press hour or minute eld to edit time.

02 55

On Temp

12h 24h AM

1 2 3 <---

153 F

152 F

Min

9 CANCEL

Outdoor Temperature

1. Tap the Hours or Minutes eld.

2. Tap the <--- Button to clear the eld.

3. Enter the new hours and/or minutes using the numerical keypad.

4. Select the desired time format (12h or 24h).

178 F

5. If 12h format is chosen, select the AM

Max

or PM button.

6. Tap OK.

7. Tap SAVE.

Lock

210 F

240 F

210 F

SAVE

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Boiler Settings 2

User Screen 2 - DHW Settings

DHW

32 F

Setpoint

119 F

95 F

Min Max

On Temp

112 F

101 F

Min

117 F

Max

181 F

240 F

Di: 7 F

Use the Sliders

to select DHW

settings

Slider 1

DHW

Setpoint

Slider 2

DHW

Dierential

Current

DHW

Dierential

Date Settings

05-02-2018

Time Settings

09:33 AM

Input 1 - Tap here to set the Date Input 2 - Tap here to set the Time

Figure 49 - User Screen 2 - DHW Settings

Setting Description

Slider 1

DHW Setpoint 119 oF

Slider 2

DHW Dierential 18 oF

Input 3

Temperature Display C or F

Table 15 - User Screen 2 Program Navigation

Outdoor Temperature

33 F

System Supply Temperature

SAVE

112 F

Input 3 - Toggle here to select temperature measurement: F for Fahrenheit; C for Celsius

Press SAVE to save the DHW

settings

Press PREVIOUS

to return to Boiler

Screen 1

(Boiler Settings)

Adjusts the DHW indirect tank set point from 95oF to 181oF (Factory Default 119oF). NOTE: After changing the setpoint and tapping SAVE, the dierential slider will change as well, maintaining the dierential range. When changing the setpoint ensure the dierential remains at the desired setting.

Adjusts the “dierential”, or the temperature below setpoint at which the boiler will light (On Temp) during a call for DHW. This is user adjustable between Setpoint minus 2 (burner lights at 2F below Setpoint) and Setpoint minus 18F (burner lights at 18F below setpoint). (Factory Default Setpoint minus 18oF). In the example above, a setpoint of 119F and dierential of 7F is desired. The setpoint slider is set at 119F, and then the On Temp slider is set at 112F (119 - 112 = 7). Tap SAVE. NOTE: The current dierential from 2 - 18oF is displayed in a text box to the right and slightly below the slider.

Toggle the switch near the oF or oC to switch temperature measurement from Fahrenheit to Celsius (Default is Fahrenheit).

lp-666 Rev. 003 Rel. 004 Date 9.3.20

OUTDOOR RESET CURVE

System Setting

Installer - Outdoor Reset Curve Screen

J. Programming Installer Settings

Installer Setting Program Access NOTE: Programming the boiler control is not possible when the boiler is ring. Make sure any input which can create a demand on the boiler,

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

NOTE: To change Installer Settings enter Access Code 925 when prompted.

Installer Setting Program Navigation

Use the touch screen sliders or input prompts to change the Installer settings. Press SAVE to store changes. Press NEXT to advance to the next screen, and PREVIOUS to go back a screen. The following are the Installer settings that can be programmed into the control.

Installer - Outdoor Reset Curve Screen

The Outdoor Reset Curve Screen provides the installer with a number of sliders to quickly and eciently set the outdoor reset curve. These settings can also be found in the Installer - Installer Menu. These settings are as follows:

212ºF

E T P O

I N T

32ºF

-40ºF 110ºF

32ºF

BOOST TIME

0min

Slider 4 - Set the Boost Time

Figure 50 - Installer - Outdoor Reset Curve Screen - NOTE: An Outdoor Sensor Must Be Used When Setting an Outdoor Reset Curve

Setting Description

Maximum Supply Temp 180 oF and Minimum Outdoor Temp 5 oF

Slider 2

Minimum Supply Temp 95 oF and Max Outdoor Temp 68 oF

Slider 3

Outdoor Shutdown Temp

Slider 4

Boost Time

Table 16 - Installer - Outdoor Reset Curve Screen

Slider 1

Sets the maximum design supply temperature based on the minimum outdoor design temperature. Default: 180oF (Range: 77oF to 190oF).

Sets the minimum outdoor design temperature for the system. Default: 5oF (Range: -42oF to 32oF).

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

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

Sets the outdoor temperature where the boiler will ignore central heating demands. Default: 68oF (Range 41oF to 122oF).

Boost Time temporarily overrides the Outdoor Reset Curve, bringing the boiler up to the maximum setpoint to satisfy a thermostat call in less time. For example, if 6 minutes is selected, and there has been a thermostat call for 6 minutes, the boiler will override the Outdoor Reset Curve and boost to the maximum setpoint until the call for heat is satised. The setpoint will stay at max for 6 minutes from the time the thermostat opens. After the 6 minutes have elapsed the setpoint will return to the Outdoor Reset Curve. Factory Default: 0 min (Range: 0-762 min in increments of 6 minutes.)

180ºF I 5ºF

OUTDOOR TEMP

Shut down

68ºF

Slider 3 - Set the Outdoor Shutdown Temperature

122ºF

762

95ºF I 68ºF

SAVE

Use the Sliders

to set the

Outdoor Reset

Curve

Slider 1

Maximum

Supply

Temperature

and

Minimum

Outdoor

Temperature

Slider 2

Minimum Supply

Temperature

and

Maximum

Outdoor

Temperature

Press NEXT to advance to the Installer Menu

Screens

Press SAVE to

save the Outdoor

Reset Curve

settings

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Installer - Installer Menu

The Installer Menu provides the installer with a number of settings to customize system operation. These settings are as follows:

Installer Menu

Installer #

1 3 6

9 10 11

Press PREVIOUS to

return to the

previous screen

Figure 51 - Installer - Installer Menu Screen

Installer # Description Detail

1 Mode

3 DHW Tank Max Temp

6 DHW Post Pump Time

7 Warm Weather Shuto

8 Min Outdoor Temp Sets the minimum outdoor design temperature for the system. Default: 5oF (Range: -42oF to 32oF).

9 Max Supply Temp

10 Max Outdoor Temp

11 Min Supply Temp

12 Min Boiler Temp

13 CH Post Pump Time

14 DHW Priority

15 Cascade Address

16 Optional Inputs

Description

Mode DHW Tank Max Temp DHW Post Pump Time

Warm Weather O

Min Outdoor Temp Max Supply Temp

Max Outdoor Temp

Min Supply Temp

Min Boiler Temp

Possible Values

95 to 185

0 to 10

41 to 122

-42 to 32 77 to 190

32 to 110 32 to 190

32 to 190

Current Values

INDIRECT

180.5 0

68.0

5.0

179.6

68.0

95.0

68.0

Units

Min

F F F F F F

Tap on an

Installer value

to view options

and/or change

the value

DISCARD SAVE NEXT

Press DISCARD to

return unsaved changes

to default settings

This is the Factory Program Mode. INDIRECT indicates that the control is congured correctly. This setting cannot be changed.

This is the maximum temperature that can be selected in boiler settings for the DHW tank. Factory Default is 180oF. (Range: 95oF to 185oF)

The indirect pump has the ability to post purge energy from the boiler to run the pump after the set point has been achieved. Please note that running the pump for a time greater than 5 minutes may cause tank energy to be released back to the heat exchanger. Factory Default of 1 Minute. (Range: 0 – 10 minutes)

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

Sets the maximum design supply temperature based on the minimum outdoor design temperature. Default: 180oF (Range: 77oF to 190oF).

Sets the maximum outdoor design temperature for the system design. Default: 68oF (Range 32oF to 110oF).

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

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

Allows the user to set the boiler pump post purge time once the thermostat is satised. Default: 1 minute (Range: 0 – 10 minutes).

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

Bus addressing boilers (maximum boilers allowed is eight (8) in a cascade system). Master Boiler address is 0 and Follower Boilers are addressed 1 thru 7. Default: 0 (Range: 0 – 15). NOTE: DO NOT USE ADDRESSES 8 - 15.

Allows the user to select optional inputs to control or monitor the system. Default: OFF (Range: O / 0-10 Volt / Booster Board).

Press SAVE to save

settings before moving

to another screen

Press NEXT to

advance to the

next screen

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Installer # Description Detail

Controls boiler CH setpoint according to the Outdoor Reset Curve. 1.5v will change the setpoint

17 0-10 Volt Function

18 Step Modulation Mode

19 Boiler Supply DHW

20 Water Safety Input

21 Error Outdoor Sensor

22 Adjust Boiler Output % Adjusts the boiler output down from 100% to 50%. Factory Default: 100%. (Range: 50% – 100%)

23 Cascade Mode

24 Cascade Rotation

25 Cascade DHW Mode

27 Error System Sensor

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

29 DHW Modulation Mode

30 Extra Boiler Mode

31 System Sensor Mode

32 Service Schedule

35 Service Schedule Day If the date function was selected, sets the day of next service reminder.

36 Telephone Allows the user to input a telephone number that will display when maintenance is required.

37 Modbus Mode

System Freeze

Protection

Service Schedule Year If the date function was selected, allows the user to set the year of the next service reminder.

Service Schedule Hours

Service Schedule

Month

to equal Installer 11, 10v will change the setpoint to Installer 9. If Fan Speed is selected, then 1.5v will cause the boiler to run at low re (min fan speed) and 10v will cause the boiler to go to high re (max fan speed). Factory Default = Temperature (Range: Temperature or Fan Speed).

Allows the user to turn ON step modulation, which regulates burner output in six steps at one minute intervals. Step modulation will start at the last modulation rate of the boiler and work up one minute at a time. Default: ON (Selection: OFF or ON).

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

The user can select various water safety inputs used in the boiler system. Default: Water Flow (Range: OFF / Water Pressure / Water Flow).

Allows the user to set the control to display a blocking or fault code if an outdoor sensor is open or shorted. NOTE: This does not stop the boiler from running. Factory Default: OFF (Range: ON / OFF / PHOENIX).

Allows the user to select cascade mode. Select 0 if boiler is operating alone. Choose 1 to establish a cascaded system. Factory Default: 0 (Range: 0 - 8). Ex: 0 for OFF, 1 for ON. NOTE: DO NOT USE NUMBERS 2 - 8. Doing so will result in a COMMON FLUE BLOCK error code. Always select 0 if boiler is operating alone or with Vision 3 panel.

Sets the number of hours before the rst boiler in the cascade ring rotation will be changed. NOTE: If this is set to 0, the ring order of the boilers will not rotate. Factory Default: 48 hours (Range: 0 – 240 hours).

NOTE: “SYS PMP OFF W/DHW” has been added to Function 25. This new setting only applies to a single boiler cascade. Depending on system piping, this option allows you to run both the CH and DHW pumps during a DHW call, but the SYS pump will NOT be energized during the DHW call. Factory Default: ENTIRE CASCADE (Range: ENTIRE CASCADE / DHW ON LOOP / ONLY MASTER / SYS PMP OFF W/DHW).

NOTE: This parameter is only active if the boiler is a cascade master. Allows the user to set the freeze protection when a system pump is used. Factory Default: OFF. Selection of temperature activates freeze protection. (Range: OFF, -58oF – 104oF).

Sets the control to display a blocking or fault code if the system sensor is open or shorted. NOTE: This does not stop the boiler (or boilers) from running. Factory Default: ON (Range: ON / OFF).

This parameter controls how the boiler modulates for a DHW demand. In NORMAL MOD mode, the boiler will modulate down from high re when there is a DHW demand. In MINIMUM MOD mode, the boiler will modulate up from low re when there is a DHW demand. This mode is useful to minimize short cycling when a large boiler and small indirect tank are used together. Factory Default: NORMAL MOD (Range: NORMAL MOD / MINIMUM MOD).

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

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

Selects a service date or time based on the boiler run hours to program the boiler maintenance schedule. Factory Default: OFF (Range: OFF / Run Hours / Date).

If the run hour function was selected, allows the user to set the number of run hours before the next service reminder.

If the date function was selected, sets the month of the next service reminder.

Enables Modbus/BACnet Mode on the appliance. Factory Default: OFF (Range: ON, OFF, AUTO). See Modbus/BACnet Instructions (lp-548) for details. NOTE: Turning this Mode “ON” without

a connected and powered Modbus communication adapter (p/n 7350P-636) will result in improper appliance operation. Service calls associated with this ARE NOT covered by warranty.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

NOTE: Modbus Mode must be enabled on the appliance as outlined above for the following parameters to be viewed and changed.

Installer # Description Detail

Sets the Modbus/BACnet address. The address space is comprised of 256 addresses. These are dened as follows:

38 Modbus Address

39 Modbus Speed

40 Modbus / Stop Parity

NOTE: The following parameters are displayed regardless if Modbus Mode is enabled.

55 CH Pump Priority

The following information details the 0-10V Output parameters described in Function 56 that can be read at a Building Management System. BOIL POWER - 0-10V output is proportional to boiler ring rate. 0V = Not Firing, 1.5V = Minimum Firing Rate, 10V = Maximum Firing Rate CASC POWER - When congured on the Cascade Master, 0-10V is proportional to the ring rate of the Cascaded System. 0V = Not Firing, 1.5V

= Minimum Firing Rate (One Boiler Lit), 10V = Maximum Firing Rate of all Connected Boilers

FAN SPEED - Output is proportional to boiler fan speed. 0V = Fan is O, 1.5V = Minimum Fan Speed, 10V = Maximum Fan Speed ALARM - 0V = Alarm is O, 10V = Alarm is On TEMPERATURE - Output follows boiler temperature setting based on outdoor reset. 0V = Minimum Boiler Temperature for Maximum Outdoor

Temperature Setting. 10V = CH (or cascade) temperature setting. This number will vary with the outdoor temperature so that the user can know what setpoint temperature the boiler is trying to achieve.

FLAME - Equals boiler Flame Current. 0V = 0ua, 10V = 10ua. PUMP - This output controls CH pump speed to maintain the desired Delta T. 0V = OFF, 2V (or output oset value greater than 2) = Minimum

Pump Speed, 10V = Maximum Pump Speed.

Damper Valve Logic

Enabled

Boost Time

(Same Value as the

Boost Slider in the

Outdoor Reset Screen)

0-10VA Output

Congure

• Address 0 is a broadcast address. The master can send data to address 0 and all followers will process the data.

• Addresses 1 – 247 are free to be assigned to Modbus devices on the bus. Each address can be assigned to only one Modbus device on the bus.

The Modbus speed (communication speed) can be set on the control display to either 9600 or 19200 baud. All HTP appliances, as well as any other device on the same bus and the Modbus/ BACnet master, must have the same baud rate setting. Select the highest baud rate that oers the most reliable communication performance over the bus.

NOTE: This setting only applies to Modbus operation. The BACnet protocol does not utilize parity for communication and this setting will have no eect. The parity/stop bits parameter of the Modbus/BACnet adapter must match the rest of the devices on the bus. Although it is common to set serial devices to use no parity, setting the parity to even or odd may improve communications reliability on all connected devices on the bus.

DO NOT USE

Temporarily overrides the Outdoor Reset Curve to bring the boiler up to the maximum setpoint to satisfy a thermostat call in less time. Factory Default: 0 min (Range: 0-762 min in increments of 6 minutes.) EXAMPLE: If 6 minutes is selected, and there has been a call for heat for 6 minutes, the boiler will override the Outdoor Reset Curve and boost to the maximum setpoint until the call for heat is satised. The boiler setpoint will stay at max for 6 additional minutes after the thermostat opens before returning to the Outdoor Reset Curve.

Controls whether the CH pump will meet a call for heat while also meeting or answering a DHW call. A setting of OFF will not run the CH pump while running the DHW pump; an ON setting will run the CH pump while simultaneously running the DHW pump. Factory Default: OFF (Range ON / OFF)

Controls the operation of the 0-10V A output on the Field Connection Board. Factory Default: PUMP (Range: BOIL POWER / CASC POWER / FAN SPEED / ALARM / TEMPERATURE / FLAME / PUMP).

57 O-10VA Output Oset

59 O-10VB Output Oset

60 CH dT Setting

61 Ostate Voltage OA1

Table 17 - System Setting Program Navigation

O-10VB Output

Congure

This value is added to the OFFSTATE VOLT OA1 value, to determine the total voltage output required at the minimum case. Factory Default: 1.5 (Range: 0.0 to 9.9)

Controls the operation of the 0-10V B output on the Field Connection Board. Factory Default: BOIL POWER (Range: BOIL POWER / CASC POWER / FAN SPEED / ALARM / TEMPERATURE / FLAME).

This value is added to the OFFSTATE VOLT OB1 value, to determine the total voltage output required at the minimum case. Factory Default: 1.5 (Range: 0.0 to 9.9)

Determines the desired temperature dierence between the SUPPLY and RETURN temperatures. Factory Default: 19F (Range: 0 - 47F)

Determines the voltage present in OA1 when the pump is supposed to be OFF. Factory Default:

0.0 (Range: 0.0 to 9.9)

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Installer - Service Mode - LWCO Test

WARNING

K. Resetting the Maintenance Schedule

It is highly recommended to call for service when the Home Screen center pane turns yellow on the display. After service is performed, reset the schedule for the next required service by using the following steps. Press Installer. Tap next until prompted to enter a password. Enter “928”. Press MAINTENANCE RESET button in the upper right corner of the Service screen to reset the selected Service Schedule.

NOTE: The Service Screen may also be directly accessed by tapping the SERVICE MODE button in the lower right corner of the Home Screen.

L. Service Mode - Setting and Verifying the Combustion Setting - Testing the Internal LWCO

NOTE: Service Mode can be accessed from the Home Screen or by scrolling through the Installer Settings. Input Access Code 928 when

prompted to enter Service Mode. Service Mode is intended to simplify fan testing, purging air from the water lines, testing the LWCO, and gas adjustment. The following gures and tables include details on use as well as recommended combustion settings by fuel type and boiler fan speeds. Automatic modulation does not take place while the controller is in Service Mode. However, the boilers will modulate down if the program set point is reached while running in Service Mode. It is recommended to enter Service Mode with the largest load possible to create such a heat demand that Service Mode will not be interrupted. To enter Service Mode tap Installer in the display Navigation Bar; then tap NEXT until you reach the Service Mode screens detailed in Figure 52, or use the SERVICE MODE button at the Home Screen. NOTE: The boiler will automatically exit Service Mode after 20 minutes of operation. Press the black up ^ and down v arrows to increase and decrease fan speed fty (50) RPM. Press the red up ^ arrow to go directly to max fan speed and high re. Press the blue down v arrow to go directly to min fan speed and low re.

Setting and Verifying the Combustion Setting

Enter Service Mode. At high re, use a calibrated combustion analyzer to test CO/CO2 measurements. Ensure the measurements meet those detailed in Table 18. If unable to reach these measurements, remove the calibrated combustion analyzer and bring it outdoors into fresh air. When the analyzer reads zero, conduct the test again. If still unable to get the required readings shown in the combustion chart, adjust the throttle screw on the gas valve in ¼ turn increments either in the positive (+) (counter-clockwise to increase fuel or CO2) or negative (-) (clockwise to decrease CO2) direction. When the CO/CO2 measurements meet those in Table 18 at high re, conduct the test at low re. Record the combustion measurements in this manual for future reference.

Testing the UL 353 Approved Internal LWCO

In Service Mode, locate Internal LWCO Test in the lower right hand corner of the screen. If the screen indicates that the Internal LWCO is READY to test, tap Test. See Figure 52. If the Internal LWCO trips properly, the screen will read LWCO FAULT F21. See Figure 52. Now tap Reset to reset the LWCO and clear the fault. To leave Service Mode, tap PREVIOUS to stay in the Installer menu or press Home.

Tap these Up and Down Arrows to set fan speed in 50 RPM increments

Combustion Settings on 400 - 1000 Models

Fan Speed

Natural Gas (NG)

Low High

Carbon Monoxide (CO) PPM Less than 200

Carbon Dioxide (CO2) % 9 - 10 1/2 8 1/2 - 9 1/2

Fan Speed

Propane (LP)

Low High

Carbon Monoxide (CO) PPM Less than 200

Carbon Dioxide (CO2) % 10 - 11 9 1/2 - 10 1/2

Combustion Settings on 1500 - 2000 Models

Fan Speed

Natural Gas (NG)

Low High

Carbon Monoxide (CO) PPM Less than 200

Carbon Dioxide (CO2) % 8 - 9 8 1/2 - 9 1/2

Table 18 - Combustion Settings - All Models

Tap these Up

and

Down Arrows

to go immediately

Maximum (Up)

and

Minimum (Down)

Fan Speeds

Service Mode

MAX

Set point

MIN

Actual

Current

fan speed

Toggle to turn

the Fan

ON and OFF

Figure 52 - Installer - Service Mode Screen

lp-666 Rev. 003 Rel. 004 Date 9.3.20

PWM

Service Mode

OFF

Supply

Return

Gas Valve: ON Flame Current: 4.7 uA

4500

40%

141 F

74 F

5000

4500

1700

Pump Service Mode

Boile r Pump

OFF

System

OFF

Press PREVIOUS to return to the previous screen

DW H

Pump

OFF

0-10 Volt

PRESS SERVICE RESET

AFTER PERFORMING

REQUIRED SERVICE

Maintenance Reset

Internal LWCO Test

Test

READY

Reset

Toggle to test Pump operation.

Press

to reset the

Maintenance

Schedule.

Tap Test to test

LWCO operation.

READY indicates

LWCO is ready

to test.

LWCO FAULT 21

indicates LWCO is

in fault.

Tap Reset

to Reset an

LWCO fault.

Status Screen 1

Part 12 - Boiler Monitoring

A. Status Screens

The boiler control has the ability to review system status. To access the Status screens, tap Status in the display Navigation Bar. Tap NEXT or PREVIOUS to swap between the screens. Tap Home in the display Navigation Bar to exit the Status screens.

Status

Conguratio n Indire ct

Hea t Fun ctions

Actual Blocking

Previou s

Burner D emand

Burner F unction

Lock-O ut

Bus C ontro l

Time S tamp

Bic

Boiler-Pa r

Water Pressure

Water Flow

Boo ster / 0-10V

Con densate

Water Level

No demand

Tap Blocking

Stand-by

Bus Master

09:31:10

5-2-18

BIC928

FX400BN

None

O

None

5.00

0.00

0.0

bar

Gl/m

Fan Speed Settings

Maximum Ind/Dir/Voy/Spa

Maximum Central Heating

Limit Step Modulation / Cascade

Minimum 1420 rp m

Ignition 3000 rpm

Fan

Setpoint 0 rp m

Act ual 95 rp m

PWM 0 %

Check O

5650 rp m

1413 rp m

Temperature Settings

CH / Pool Supply

Indirect/Direct/Voyager/Spa

Indir ect S upply 181

Minimum S upply

DT Pu mp CH 20 ºF

190

119

32 ºF

ºF

Actual Temperatures

Supply 137

Return

Flu e 125 S1/S2

F1/F2 125/125

Indir ect

Syste m

Boiler O utdoor

Intern

134/137

120

ºF ºF

ºF

ºF ºF

Figure 53 - Status Screen 1

Conguration This is the factory setting of the appliance. It should always read “Indirect”.

Heat Functions Lets the user know if the appliance is servicing a demand for heat. In this example, there is no demand.

Actual Blocking This would display a blocking code if the appliance was currently in a blocking state.

Burner Demand Will display a demand on the burner. In this example there is currently no demand.

Burner Function Displays the current burner state. Burner is in stand-by in this example.

Bus Control This displays the bus state of the appliance. The appliance in this example is the bus master.

Time Stamp Displays the time and date.

Water Pressure Not Used.

Water Flow Not Used.

Booster / 0-10V

Condensate 0 indicates an empty condensate trap. A number above 50 triggers a Condensate Full Lockout.

Water Level

Table 19 - Status Screen 1 - Status Table

Tapping the NEXT key advances to Status Screen 2

Status Table

Display Description

Previous Displays most recent blocking code. In this example, “Tap blocking” was the most recent.

Lock-Out Displays if the appliance is in lockout.

Bic Refers to the current control revision. “BIC928” in this example.

Boiler-Par Refers to the parameter set programmed into the appliance.

Displays the voltage on the optional input. This voltage is only relevant if an external 0-10 volt signal is being used to control the boiler.

Displays the “electrical resistance” between the LWCO probe, through the water, to ground. A value of 80 and above indicates a lack of water in the appliance (open circuit). A perfect connection to ground would indicate a level of 0.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Fan Speed Settings

Display Description

Maximum Ind/Dir/Voy/Spa

Maximum Central Heating

Limit Step Modulation / Cascade

Minimum

Ignition

Table 20 - Status Screen 1 - Fan Speed Settings

Display Description

Setpoint This is the current setpoint of the fan as determined by the control.

Actual This displays the actual fan RPMs.

PWM This is the current percentage of power being applied to the fan.

Check Will display “OK” if fan speed is within operating limits.

Table 21 - Status Screen 1 - Fan Table

Display Description

CH / Pool Supply Current CH Setpoint

Indirect/Direct/Voyager/Spa Current DHW Setpoint

Indirect Supply Maximum temperature that the boiler can supply to the indirect DHW HX input.

Minimum Supply Minimum temperature that the boiler can supply to the indirect DHW HX input.

DT Pump CH

Table 22 - Status Screen 1 - Temperature Settings Table

These settings describe the appliance fan speed settings. These settings are for reference only. Fan Speed Settings are programmed into the control at the factory and cannot be changed in the eld.

Fan Table

Temperature Settings Table

Current dT setting in degrees when a delta T pump has its 0-10v wires connected to P9-6 and P9-6 on the low voltage connection board.

Display Description

Supply Shows the actual supply temperature measured by the supply sensor.

Return Shows the actual return temperature measured by the return sensor.

Flue Displays the current boiler ue temperature.

S1 / S2

F1 / F2

Shows the actual temperatures measured at the appliance by the dual supply sensor (S1 = supply A and S2 = supply B).

Shows the actual temperatures measured at the appliance by the dual ue sensor (F1 = Flue A and F2 = Flue B).

Displays the actual temperature measured by the tank or return sensor (HTP 7250P-325). If a mechanical

Indirect

aquastat is used in place of the recommended sensor, it will display “N/C” if the aquastat is open because the DHW tank is satised. If the aquastat is closed it will display ON.

System

This screen displays the system sensor reading. The control will cascade the boilers up to this set point depending on demand. If there is no system sensor this will display “N/C”.

The current outdoor temperature is displayed. If there is no outdoor sensor connected to the boiler, this

Boiler Outdoor

line will display “N/C” in place of the temperature. If the outdoor sensor is shorted, this line will display “ON” in place of the temperature.

Intern Ambient board temperature of BIC928 control, as measured by the on-board Comfort Microprocessor.

Table 23 - Status Screen 1 - Actual Temperatures Table

Actual Temperatures Table

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Statu s Inputs & Out put s

Status Screen 2

Figure 54 - Status Screen 2 - NOTE: For Reference Use ONLY.

Status Screen 2 - Internal

Internal describes the current temperature readings read by the ue, supply, and return sensors, as well as the Delta T setting and the ue and supply lockout temperatures.

Room Thermostat Displays whether the room thermostat is on or o.

Table 24 - Status Screen 2 - Inputs

LWCO / EC04 Displays “Closed/Open” when the target wall (burner door) input is open. Displays “Open/Open” when the external LWCO input is open.

Table 25 - Status Screen 2 - Safeties - NOTE: See below for further detail.

Flue temp limit - NOTE: The Flue ECO

has been replaced with a jumper in the

Internal External

Lock: 205 F

L U E

Supply

90 F

Lock: 210 F

103 F

Inputs

Room Thermostat O FF

CH Enable ON

Ch B oost

0-10V In OFF

Safeties

Water

Block Ven t

Block3

Wat /F lue

LWCO/EC04

Air/Flap

Damper

Alar m

Closed Closed Closed

Closed/Closed

Closed

OFF

Outdoor Temperature

33 F

Supply Temperature

112 F

OFF

Indirect Storage Temperature

Outputs

Gas Valve

Delta T

Return

20 F

83 F

SYSDHWCH

Tapping the PREVIOUS key returns to Status Screen 1

Spa rk

Ionization

---

Pump CH

Pump DHW

Pump Sys

--0-10V (1)

0-10V (2)

Inputs Table

Display Description

CH Enable Displays whether CH Enable is on or o.

CH Boost Displays On or O if CH Boost is engaged.

0-10V In Displays whether 0-10V Input is on or o. Displays ON if 0-10V is enabled.

Safeties Table

Display Description (Normal Operation Displays “Closed”)

Water Displays “Open” when the Water/Flow/Press input is open (e.g. when the ow switch does not detect ow).

Block Vent Displays “Open” when the Blocked Vent Pressure Switch (BVPS) input is open (e.g. ue blockage and high ue pressure).

Wat / Flue

Air / Flap

Displays “Closed/Open” when the ue temp limit input is open. Displays “Open/Open” when either the target wall (Burner door), external LWCO, or water temp limit input is open.

This signal tells the control when the damper vane is in the open or closed position. It is unused but is present for future functionality. It will appear as open or closed.

Damper Displays when the Flue damper is powered on or o. This will appear as “Closed” during normal operation.

Alarm Displays whether the alarm is on or o.

Open Signal I/O 928 Pins Water Block Vent Block 3 Wat/Flue LWCO/ECO4 Air/Flap Damper

ID1 X7-10, X7-20 Closed Closed Closed Closed/Open Closed/Closed Closed Closed

LV harness.

Burner Door ECO ID2 X7-8, X7-18 Closed Closed Closed Open/Open Closed/Open Closed Closed

Man Reset HL ID3 X7-9, X7-19 Closed Closed Closed Open/Open Closed/Closed Closed Closed

Flap closed/APS - NOTE: Unused ID4 X7-6, X7-16 Closed Closed Closed Closed/Closed Closed/Closed Open Closed

BVPS ID5 X6-9, X6-18 Closed Open Closed Closed/Closed Closed/Closed Closed Closed

H/L Gas pressure ID6 X6-8, X6-17 Closed Closed Open Closed/Closed Closed/Closed Closed Closed

Flowswitch ID8 X7-1, X7-11 Open Closed Closed Closed/Closed Closed/Closed Closed Closed

External LWCO ID14 X7-7, X7-17 Closed Closed Closed Open/Open Open/Open Closed Closed

OFF

4.8

OFF OFF

0.0

120 F

Setpoint

Service Mode

HMI Status Screen 2 - Safeties

118 F

Actual Temp.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

History Screen

Outputs Table

Display Description

Gas Valve Displays whether the gas valve is on or o.

Spark Displays whether the spark is on or o.

Ionization Displays the current ame ionization current.

--- ---

Pump CH Displays whether the CH Pump is on or o.

Pump DHW Displays whether the DHW Pump is on or o.

Pump Sys Displays whether the Pump Sys is on or o.

--- ---

0-10V (1) Displays the 0-10V (1) output voltage.

0-10V (2) Displays the 0-10V (2) output voltage.

Table 26 - Status Screen 2 - Outputs

Status Screen 2 - External

External describes the current outdoor temperature and system temperature readings, as well as DHW Temperature setpoint and actual DHW temperature.

B. History Screens

The boiler control also has the ability to review its current history. To access the History screens, tap History in the display Navigation Bar. Tap NEXT or PREVIOUS to swap between the screens. Tap Home in the display Navigation Bar to exit the History screens.

Figure 55 - History Open Screen

History Screen - Internal and External

The History Open Screen displays the current Internal and External temperatures. These are the same as those displayed and described in the Status section.

Internal External

F L U E

Supply

Delta T

Return

Lock: 205 F

90 F

Lock: 210 F

103 F

20 F

83 F

SYSDHWCH

Appliance History

Con trol FW

Safety FW

Para meters FX400BN

Control Serial Number 1438A0001

Production Date 01/11/17

Programming Date 04/30/18

Last Service 04/30/18

Next Maintenance

Power on H ours 193

Hours CH < 5 0% 0

Hours CH > 50% 11

Hours DHW < 50% 0

Hours DHW > 50% 31

Hours C ascade CH

Hours L ast Maint. 0

Total Ignition Attempts 21

Failed Ignition Attempts

Hi Exceed 0

Hours C ascade DHW 0

Maint. I nter val 0

Tapping the NEXT key advances to the next History Screen

ARBA-T 180418

ASAA

-T180824

05/12/18

120 F

Setpoint

Outdoor Temperature

33 F

System Temperature

112 F

Indirect Storage Temp.

Service Mode

118 F

Actual

Temp.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

History Faults and Blocks Screens

Appliance History Table

Display Description

Control Displays control details, including the Comfort and Safety rmware revisions programmed into the control.

Parameters Displays the programmed appliance model number parameter set.

Serial Number Displays the appliance serial number.

Production Date Displays the appliance production date.

Programming Date Displays when the appliance was last programmed.

Last Service Date Displays when the appliance was last serviced.

Next Maintenance Displays the next appliance service date.

Power On Hours Displays the total appliance power on hours.

Hours CH < 50% Displays the total hours that the appliance has met a CH demand at below 50% power.

Hours CH > 50% Displays the total hours that the appliance has met a CH demand at greater than 50% power.

Hours DHW < 50% Displays the total hours that the appliance has met a DHW demand at below 50% power.

Hours DHW > 50% Displays the total hours that the appliance has met a DHW demand at greater than 50% power.

Hours Cascade CH Displays the total hours that the appliance has met a Cascade CH demand.

Hours Last Maint Displays the total hours since the last time the appliance was maintained.

Total Ignition Attempts Displays the total appliance ignition attempts.

Failed Ignition Attempts Displays the total appliance ignition failures.

Hi Exceed Displays the number of times the high limit has been exceeded.

Hours Cascade DHW Displays the total hours that the appliance has met a Cascade DHW demand.

Maint Interval Displays the interval time for the time until the next Maintenance notice.

Table 27 - History Screen - Appliance History Table

History Screen - Faults Screen

Tap NEXT at the History Screen to display the ten (10) most recent lock-out faults along with the date and time when they occurred. There is a list of fault codes as well as their total amount of occurences. Internal temperatures are also provided for troubleshooting purposes.

History Screen - Blocks Screen

Tap Show Blocks at the History Faults Screen to display the ten (10) most recent blocking codes along with the date and time when they occurred. There is a list of fault codes as well as their total amount of occurences. Internal temperatures are also provided for troubleshooting purposes. Tap Show Faults to return to the History Faults Screen. Tap PREVIOUS to return to the History Screen.

Will read “Last 10 Blocks” after tapping “Show Blocks”

InternalInternal

Figure 56 - History Faults and Blocks Screens

L U E

Supply

Delta T

Return

Tapping Show Blocks advances to the Last 10 Blocks screen - Tapping Previous returns to the previous History Screen

Lock: 205 F

90 F

Lock: 210 F

103 F

20 F

83 F

SYSDHWCH

Last 10 Faults

1 F24 Ta rget Wall

2 F02 Supply Sensor interrupted

3 F02 Supply Sensor interrupted

4 F02 Supply Sensor interrupted

5 None -

6 None -

7 None -

8 No ne -

9 None -

None

Show Blocks

02:22:2020 17:34

02:22:2020 12:12

02:22:2020 12:21

02:22:2020 12:25

Fault Codes

CODES

F00 ECO 1 Wat er

F01 ECO 2 Fl ue Temp. 0 1

F02 Supply Sensor 3 4

F03 Return Sensor 0 0

F04 Flue Sensor 0 0

F04 Flue Sensor n.c. 0 0

F05 S upply Maximum 0 0

F06 Return Max imum 0 0

F09 N o Ignition 0 0

F10 Flam e Faul t 0 0

F11 False Flame 0 0

F13 Fan Speed Low 0 0

F14 Fan Speed High 0 0

F15 A ps Stuck O pen 0 0

F16 A ps Stuck Cl osed 0 0

F17 Flue Max imum 0 0

F20 Water Level 1 0 0

F21 Water Level 2 0 0

F22 Ex ternal LWCO 0 0

F24 Burner Door 1 1

F26 G as Pressur e 0 0

F28 B urner Temp. 0 0

F30 B urner Sen sor 0 0

TOTAL

0 0

This table lists all Lockout Fault and Blocking Codes as well as how many

times the codes

have occurred

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Graphics

Graphics Screen

Cascade Screen 1

C. Graphics Screen

Tap Graphics in the display Navigation Bar to open the Graphics function. The Graphics function allows the installer / user to select, record, and view real time system analytics. This function helps the installer / user ne tune system operation and aids in troubleshooting.

100

212

167

122

25 77

-25 0

-13

Supply Return 32.0 System 32.0 Indirec t 32.0

20 40 60 80 100 120 140 160 180 200

32.0

Boiler Outdoor 32.0 CH Set Alarm 0.0 Fan Speed 0.0

32.0

Roomth 0.0 APS Flap Gas Valve Closed

Igniter O

Ionization

32.0

Pump CH On Pump DH 0.0

O

Pump Sy 0.0

Flue Water Level Condensate System Set

180

181

29 43

Figure 57 - Graphics Screen

D. Cascade Screen

To access Cascade system status and settings, tap Cascade in the display Navigation Bar. Tap NEXT or PREVIOUS to swap between the screens. NOTE: If the boiler is not in Cascade mode, all indicators (ie pumps) will be disabled, and Outdoor temperature and System temperature will be displayed as N/C.

Cascade

Outdoor Temperature

33 F

System Temperature

112 F

System Setpoint

160

Total

60%

175ºF

Tap the corresponding colored box to map real time boiler operation settings

Cascade Mode

DHW Cascade Mode

On/O

Rotation (0-240h)

Entire

Cascade

DHW

On Loop

System Freeze

Protection

Boiler 1 Boiler 2 Boiler 3 Boiler 4 Boiler 5 Boiler 6 Boiler 7 Boiler 8

60%

175ºF

Address

160ºF

Address

160ºF

Address

160ºF

Address

160ºF

Address

160ºF

Address

160ºF

Address

Only

Master

System

Sensor Error

160ºF

Address

SYS

DHW

Demand

Tapping the NEXT key advances to the next Cascade Screen

DHW

Figure 58 - Cascade Screen 1

Cascade Screen 1

Cascade Screen 1 shows the current system supply and outdoor temperature readings, states whether Cascade Mode is On or O, as well as whether DHW Cascade Mode is On or O and the enabled DHW Cascade Mode setting. System Freeze Protection enable and System

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Sensor code are shown here. The Cascade Mode rotation hours are shown here. The operating percentages of connected appliances is shown towards the bottom of the screen, along with whether the SYS, DHW, or CH pumps are enabled and whether the system is meeting a CH or DHW demand. The above screen shows a single boiler system. One boiler is operating at 60% of total modulation capacity.

Cascade Screen 2

Cascade Status

Boiler Present Temp.

Bo iler 1 1 175ºF Bo iler 2 0 - 0% Bo iler 3 0 - 0% Bo iler 4 0 - 0% Bo iler 5 0 - 0% Bo iler 6 0 - 0% Bo iler 7 0 - 0% Bo iler 8 0 - 0%

Actual Temperature

Syste m Supply 85ºF

Indirec t 119ºF

Ou tdoor -3ºF

Ou tdoor Zones -42ºF

System Setpoint

Indirec t S upply 181ºF

Indirec t

Direct Setpoint

Percent.

32ºF

119ºF

Figure 59 - Cascade Screen 2

Input & Output

Thermostat

0-10V In 0.00 V

0-10V Switc h O

CH Enable O

Pump S CH O 

Pump S Ind/dir O

CH Boost 0

Outdoor Temperature

33 F

System Temperature

112 F

Status

Cascade Function

Casca de Demand 0% 32 ºF

Up 80%

Down 40%

Maximum 100%

Mi nimum 30%

O -Timer 0 Se c

On -Timer 0 Sec

Fault OFF

Bus C ontrol Bus Master

Bus C ong Standalone

Tapping the PREVIOUS key returns to the previous Cascade Screen

None

Cascade Screen 2

Cascade Screen 2 replicates many items that can be found on other display screens, including the current Outdoor and System temperatures and Actual Temperature readings. The Cascade Status table oers a text representation of the visual and textual Cascade Status from Cascade Screen 1.

Input and Output Table

Display Description

Thermostat *Displays whether the room thermostat is on or o.

0-10V In Displays current 0-10V voltage input.

0-10V Switch Displays whether 0-10V is On or O.

CH Enable Displays whether CH Enable is on or o.

Pump S CH Displays whether CH Pump is on or o.

Pump S Ind/dir Displays whether DHW Pump is on or o.

CH Boost Displays whether CH Boost is engaged.

Table 29 - Cascade Screen 2 - Input and Output Table - *Will only display if not in Cascade Mode

Status Table

Display Description

Cascade Function This indicates whether the cascade function is turned on.

Cascade Demand Displays the entire percentage of cascaded system demand. Ex: 3 boiler system at max power equals 300%.

Up Power level at which that boiler will switch on the next boiler (Default = 100%).

Down Power level at which the last boiler will switch o (Default = 0%).

Maximum Maximum power allowed per boiler (Default = 100%).

Minimum Minimum power allowed per boiler. Below this setting the boiler will switch o (Default = 30%).

O-Timer Timer to prevent switching o the next boiler (Default = 0 sec).

On-Timer Timer to prevent switching on next boiler (Default = 0 sec).

Fault Indicates ON when boiler is in an Alarm state, OFF when the Alarm is cleared.

Bus Control This displays the bus state of the appliance. The appliance in this example is the bus master.

Bus Cong This displays the bus conguration of the appliance. The appliance in this example is standalone.

Table 28 - Cascade Screen 2 - Status Table

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

Part 13 - Troubleshooting

Unresponsive Screen - Ensure the screen is not installed too tightly into the housing, as the screen may be recording a continuous touch at

the edges. Turn the boiler power o at the main power supply and loosen the screen slightly by backing out the nuts behind the housing. If the problem persists calibrate the screen. See below. Touchscreen Calibration - Turn the power switch o at the boiler. While touching the screen with one nger turn the power back on. The screen will go into calibration mode. Follow the instructions on the screen to complete calibration. NOTE: If any sensor detects an abnormal condition or an internal component fails during the operation of the boiler, the display may show an blocking or fault message and code. IMPORTANT: If you see blocking or fault codes on your display readout, call a technician immediately. The message may indicate a more serious problem will occur soon.

A. Blocking

A Blocking message and code may be the result of a condition that must be manually corrected or by a temporary condition that will resolve itself. The boiler control will be operable. The center pane of the Home Screen will be Orange and the “Blocking” message will display. When the condition is corrected or corrects itself the display will revert to its normal readout and operation. Be sure to observe the operation of the unit for a period of time to ensure correct operation and no reoccurrence of the code. The controller will display a blocking code and message when a blocking condition occurs. These codes, descriptions, and recommended corrective actions are described in Section C.

B. Fault (Lockout)

A Fault (Lockout) message and code is the result of a condition that the control has evaluated as not safe to restart the boiler. In this case, the boiler control will be locked out. The center pane of the Home Screen will be Red and the “Lockout” message will display. The alarm output will also activate. Most fault conditions cause the CH pump to run in an attempt to cool the boiler. The controller will display a fault code and message when a lock-out condition occurs. These fault codes, descriptions, and recommended corrective actions are described in Section C. After the fault condition has been repaired by a qualied technician press and hold RESET on the display for more than 1 second to clear the fault and resume operation. Be sure to observe the operation of the unit for a period of time to assure correct operation and no reoccurrence of fault message.

If overheating occurs or the gas supply fails to shut o, do not turn o electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut o the gas supply to the boiler at the gas service valve. Failure to do so may result in property damage, personal injury, or death.

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

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

• The boiler water is not hot.

• The electrical power is disconnected.

• The gas is shut o.

Failure to make these checks could result in substantial property damage, serious personal injury, or death.

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

NOTE: If system return temperatures are maintained below the dew point, condensation will form on the boiler cabinet and cause some components to rust.

C. User Interface Display

Lockout Codes

Code Message Description Possible Remedy

F00 ECO 1 Water

F00 indicates the water in the boiler has overheated. The boiler will not restart until it cools suciently and a technician determines and repairs the cause of overheating and pushes RESET on the display. This is a serious safety issue as indicated by the illuminated red light and the word LOCKOUT ashing on the display. During this lockout fault, the pump will be on in an eort to cool the boiler down.

1. Check circulator pump operation.

2. If the circulator pump is running, ensure there is water in the system and that the water is moving through the system as intended. Ensure that all correct ball valves and or zone valves are open or closed as intended.

3. Observe the temperature/pressure gauge. If the water is not too hot and this message is displayed, check the wiring to the water ECO sensor and repair if necessary. If the wiring is ok and this code is still present and the water is not excessively hot, replace the ECO sensor.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Code Message Description Possible Remedy

E03

F01

F02

F03

F04

System Supply

Sensor

Flue Temp

ECO

Flue temp /

wat lv

Lockout: F02

Supply

Sensor

Lockout:

Return Sensor

Lockout: F04

Flue Sensor Interrupted

E03 indicates a problem with the system sensor circuit. The circuit could be open or shorted. Possible reasons for this error are:

1. There is no system sensor connected to the Master Boiler.

2. The system sensor is faulty.

3. There is a short circuit in the system sensor wiring; possibly from a staple placed through the wire, or damage to the wire causing both conductors to touch.

4. The system sensor wiring is open due to defect or damage.

The dual ue sensor contains two sensing elements within a single body. F01 indicates that one or both halves of the supply temperature sensor has failed OR the dierence between the dual sensor readings is greater than 18oF. This is a serious safety issue and the boiler will not restart until a qualied service technician replaces the sensor and pushes the RESET button on the display. This situation is indicated by the red center pane of the Home screen. The word LOCKOUT will also be displayed. During this lockout fault, the pump will be on.

Indicates possible low voltage harness error.

The dual supply sensor contains two sensing elements within a single body. F02 indicates that one or both halves of the supply temperature sensor has failed OR the dierence between the dual sensor readings is greater than 18oF. This is a serious safety issue and the boiler will not restart until the sensor is replaced by a technician and he pushes the RESET button on the display. This situation is indicated by the red center pane of the Home screen and the displayed phrase Lockout: F02 Supply Sensor. During this lockout fault, the pump will be on.

F03 indicates the return temperature sensor of the boiler has failed. The boiler will not restart until a technician replaces the sensor and pushes RESET on the display. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F03 Return Sensor. During this lockout fault, the pump will be on.

F04 indicates that the ue temperature sensor of the boiler has failed. The boiler will not restart until a technician replaces the sensor and pushes RESET on the display. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F04 Flue Sensor Interrupted. During this lockout fault, the pump will be on.

Disconnect the system sensor from the wiring and measure its resistance. Compare the measured resistance to the table in this manual to see if it corresponds to the temperature of the sensor. If the resistance does not agree with the table, replace the sensor. If the sensor is OK, disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter. Repair or replace as necessary. If this error is present, the boilers in the cascaded group will run and ignite simultaneously when there is a heat demand. Each boiler will modulate to maintain set point temperature on its own supply sensor. This code automatically resets when repair is complete. This code will not display if system setting function ERROR SYSTEM SENS is set to OFF.

1. Check the electrical connections to each half of the thermistor on the outlet manifold. Verify 3.3 VDC by checking in Molex connector. If there is not 3.3 VDC, check the harness. If harness and sensors are OK, replace the control. NOTE: The boiler will reset automatically. Verify thermistor resistance values of each half of the dual sensor by referencing the chart in this manual.

2. Replace the thermistor if necessary.

1. Conrm the jumper from X7-10 to X-20 in the low voltage harness is intact.

2. Visually inspect and test the low voltage harness for continuity.

1. Check the electrical connections to each half of the thermistor on the outlet manifold. Verify 3.3 VDC by checking in Molex connector. If there is not 3.3 VDC, check the harness. If harness and sensors are OK, replace control. NOTE: The boiler will reset automatically. Verify thermistor resistance values of each half of the dual sensor by referencing chart in this manual.

2. Replace thermistor if necessary.

1. Check circulator pump operation.

2. Ensure adequate ow through the boiler by accessing the status menu and determining there is less than a 50oF rise from the return thermistor to the supply thermistor.

3. Troubleshoot thermistor by following the steps in F02.

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

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Code Message Description Possible Remedy

F05 indicates the boiler supply temperature is excessive. When accompanied by the red center pane of the Home screen and the displayed phrase Lockout: F05 Supply Maximum, this code indicates the supply sensor temperature has exceeded 210oF and a serious safety issue exists. The boiler will not restart until a technician determines and repairs the cause of excessive temperature and pushes RESET on the display. If the center pane of the Home screen is orange, and the displayed phrase Blocking: Supply Temperature High, the supply temperature of the boiler is at or above 199oF. The message will clear automatically when the temperature drops below 194oF. During the time that this fault is displayed, the pump will be on.

This display indicates that the boiler return temperature is excessive. This code indicates that the return sensor temperature has exceeded 210oF and a serious safety issue exists when accompanied by the red center pane of the Home screen and displayed phrase Lockout: F06 Return Maximum. The boiler will not restart until a technician determines and repairs the cause of excessive temperature and pushes RESET on the display. If the center pane of the Home screen is orange and the word Blocking is displayed, the supply temperature of the boiler is at or above 199oF. The message will clear automatically when the temperature drops below 194oF. During the time that this message or lockout fault is displayed, the pump will be on.

The boiler tried to ignite four times during one heat call and failed. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F09 No Ignition. The boiler will reset automatically after an hour. The boiler may also be restarted after a technician determines and repairs the cause of ignition failure and pushes RESET on the display. During this lockout fault, the pump will remain on.

The ame was lost 3 times while the boiler was ring during one (1) demand call. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F10 Flame Fault. The boiler will reset automatically after an hour. The boiler may also be restarted after a technician determines and repairs the cause of ignition failure and pushes RESET on the display. During this lockout fault, the pump will be on.

1. Check circulator pump operation.

2. Ensure adequate ow through the boiler by accessing the status menu and determining there is less than a 50°F rise from the return thermistor to the supply thermistor.

3. Check the direction of ow o the boiler circulator. (See Piping Details in this manual.)

4. Troubleshoot the dual supply thermistor by following steps in F02.

1. Check circulator pump operation.

2. Ensure adequate ow through the boiler by accessing the status menu and determining there is less than a 50°F rise from the return thermistor to the supply thermistor.

3. Check the direction of ow on boiler circulator. (See Piping Details in this manual.)

4. Troubleshoot thermistor by following steps in F02.

1. Watch the igniter through the observation window.

2. If there is no spark, check the spark electrode for the proper 1/4” gap between the burner.

3. Remove any corrosion from the spark electrode.

4. If there is a spark but no ame, check the gas supply to the boiler.

5. If there is a ame, check the ame current.

6. Check any ue blockage or condensate blocks.

7. Replace the ignitor.

1. Monitor gas pressure to the unit while in operation.

2. Assure the ame is stable when lit.

3. Check if the display readout changes from “GAS VALVE ON” to “RUN” within a few seconds of boiler ignition.

4. Check the FLAME signal on the display. It should be above 1.2uA when the boiler is ring.

5. If the signal reads less than 1.2uA, clean the spark probe.

6. If the problem persists and the ‘FLAME” signal is still less than

2.5uA, replace the spark igniter probe.

7. The ame signal should be steady after the boiler has been ring for 1 minute and is normally at 5.0 to 9.0. If the ame signal is not steady, disassemble the burner door and check the burner and its sealing gaskets.

F05

F06

F09

F10

Blocking:

Supply

Temperature

High

Lockout:

F05 Supply

Maximum

Blocking:

Return

Temperature

High

Lockout:

F06 Return

Maximum

Lockout: F09

No Ignition

Lockout: F10

Flame Fault

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Code Message Description Possible Remedy

1. Look into window. If there is ame, turn the gas o to the unit at the service valve and replace the gas valve.

2. If the ame signal on the status menu is greater than 1.2uA when the burner is not lit, replace the spark ignitor.

3. If the ame signal is not present after turning o the gas supply, check the gas valve electrical connection.

4. Check for condensate backup. Repair condensate system as necessary. If condensate has partially lled the combustion chamber, the refractory wall may be damaged and should be replaced.

5. Turn the gas on at the service valve after corrective action is taken.

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

1. Check the combustion fan wiring.

2. Measure DC voltage from the red fan wire (POS) to the light blue wire (ground) while it is connected to the fan. It should be 24V +/- 1v volts. If it is lower than 23 volts, check for excessive external loads connected to the boiler sensor terminals

3. Disconnect the 5 pin plug from the fan and check the voltage on the red wire again. If it is now 24 volts, replace the fan. If it is still below 23 volts replace the boiler control board.

1. Check the combustion fan wiring.

3. Disconnect the 5 pin plug from the fan and check the voltage on the red wire again. If it is now 24 volts, replace the fan. If it is still below 23 volts replace the boiler control board.

1. Check condensate lines for obstructions.

2. Check oat switch in condensate reservoir.

3. Check wiring from condensate reservoir to 928 control and repair as necessary.

1. Check boiler feed water system to be sure it is supplying make-up water to the boiler system.

2. Ensure all air is bled from the system.

3. Check for leaks in the boiler and system piping and repair as necessary.

4. Inspect low water cuto probe and wiring for damage and repair and replace as necessary.

IF EXT LWCO is installed:

1. Check boiler feed water system. Ensure it is supplying make-up water to the boiler system.

2. Be sure all air is bled from the system.

3. Check for leaks in the boiler and system piping and repair as necessary.

4. Inspect low water cuto wiring for damage and repair as necessary.

5. Ensure EXT LWCO has power applied to the power input terminals.

6. Press Reset button on LWCO. If code reoccurs, replace EXT LWCO. IF EXT LWCO is NOT installed: Inspect the jumper from terminals 20 and 21 on the Field Connection Board for damage or loose connections.

F11

F13

F14

F20

F21

F22

Lockout: F11 Flame Signal

in Standby/

Purge

Lockout: F13

Fan Speed

Low

Lockout: F14

Fan Speed

High

Lockout: F20 Water Level 1 (Condensate)

Lockout: F21 Water Level 2

(Internal

LWCO Fault)

Lockout:

F22 External

LWCO

(EXT LWCO

Fault)

There is ame during a call for heat, but prior to the ignition sequence. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F11 Flame Signal in Standby/Purge. The boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display. During this lockout fault, the pump will be on.

The fan is not running at the speed determined by the control. Fan speed has been more than 30% slower than the commanded speed for more than 10 seconds. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F13 Fan Speed Low. This boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display. During this lockout fault, the pump will be on.

The fan is not running at the speed determined by the control. Fan speed has been more than 30% faster than the commanded speed for more than 10 seconds. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F14 Fan Speed High. This boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display. During this lockout fault, the pump will be on.

The condensate trap is full. This is a serious safety issue as indicated by the red center pane of the Home screen and the phrase Lockout: F20 Water Level 1. The boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display. During this lockout fault, the pump will be o.

This fault indicates the water level in the boiler is low. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F21 Water Level 2. To test LWCO function, enter the Service Mode. If the LWCO is Ready, tap Test. Tap Reset to clear the code.

This code is generated when the External Low Water Cuto is installed and the water level in the boiler is low. This is a serious safety issue as indicated by the red center pane of the Home screen and the displayed phrase Lockout: F22 External LWCO. When this code is displayed, the boiler will not respond to a demand for heat. The pump icons on the lower left corner of the display indicate the status of the pumps. The pump will remain on when this code is displayed.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Code Message Description Possible Remedy

1. Use an ohmmeter to check the burner door switch for continuity. First disconnect the switch and determine if it has tripped. If the switch has no continuity it has tripped:

a. Check bolts on hx door. If door is not tight, a minor combustion leak will cause elevated door temperatures. b. Check for warm spots on the heat exchanger with an infrared thermal sensor. c. Check for a cracked / damaged refractory. d. Investigate the ue for blockages. e. Repair / replace components as necessary.

2. If switch has not tripped, push RESET on the boiler. If the boiler tries to ignite or ignites and only runs for a short time and an error code returns, measure temperature surface with an infrared thermal sensor. If the temperatures are low (below 300 F) and the sensor has not tripped then it is most likely a loose wire connection. Check all wires and terminations for loose or broken connections.

3. If the door is cool and the switch continues to trip the switch is faulty and needs to be replaced.

1. If an indicator light is illuminated, investigate the source of the code for that particular switch.

2. With boiler in service mode, measure the gas pressure in the supply line with a gas pressure meter. Monitor the gas pressure during both low and high re conditions for correct pressure range.

3. If there are no optional switches or none of the indicator lights is illuminated on the optional switches, use an ohmmeter to test each of the switches one at a time. Turn the power o to the boiler and disconnect the switch to be tested from the boiler to determine which has tripped. When you nd the tripped switch investigate the cause of the fault based on the purpose of the switch.

The control must be reprogrammed. If programming does not solve the problem, the control must be replaced.

1. Inspect the ground wires for damage or loose connections.

2. Inspect the condensate wiring for damage and repair as necessary.

3. Ensure no high voltage wires are routed in parallel with the condensate low voltage wiring.

4. Replace control.

1. Inspect the ground wires for damage or loose connections.

2. Inspect the LWCO wiring for damage and repair as necessary.

3. Ensure no high voltage wires are routed in parallel with the LWCO low voltage wiring.

4. Replace control.

Ensure the connections to the ue and supply sensors are intact. If wires are intact, check sensor resistance. If the problem persists or the sensors are out of normal resistance range, replace the sensors.

1. Check outdoor sensor connections and wiring. Ensure the sensor and wiring are intact and that the sensor is connected to the boiler.

2. Check the outdoor sensor resistance with an ohmmeter. See table in this manual for correct outdoor sensor resistance.

3. Replace the outdoor sensor.

F24 Burner Door

F26 Gas Pressure

F31

F41

F42

F43 AD Saft Fault

FOU

Program

Error

Hard Fault

Cond

Hard Fault

LWCO

Outdoor

Sensor

This code indicates that the burner door switch has tripped. The burner door switch trips if there is excessive heat on the heat exchanger.

The following switches are optional equipment that may be installed on boiler. These devices have indicator lights that illuminate if tripped. High gas pressure switch – Trips if there is excessive gas pressure on the outlet side of the gas valve and must be manually reset. Low gas pressure switch – Trips if there is low gas pressure on the inlet side of the gas valve and must be manually reset.

There was a code while programming the control and the memory is corrupt. The boiler control will not function in this state and the pump will be o as indicated on the bottom line. This code only occurs if a technician is programming the control and the programming function fails. The only way to recover from this code is to reprogram the control. If this code occurs at any time other than when a technician is servicing the boiler, the control has failed and must be replaced by a qualied technician.

This code indicates there is an internal fault in the circuit within the control connected to the condensate switch.

This code indicates there is an internal fault in the LWCO circuit.

The temperature of either the ue or supply sensors has risen nine degrees in 100 milliseconds and not returned to normal within 1 second.

There is an issue with the outdoor sensor. It is shorted, damaged, or disconnected from the boiler.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

The following blocking codes will block operation until the control determines the situation safe for boiler operation.

1. Ensure boiler contains water and all valves are open.

2. Check the boiler circulator and ensure it is in good operating condition (operating, wiring intact, etc.).

Blocking: Tap

E07

FLU

WARNING: Do not use jumper to remedy an FLU code. Faulty switch MUST be replaced. Failure to follow this instruction could result in serious

personal injury or death.

E07

Table 30 - Boiler Blocking and Fault Codes

Block

Blocking:

Flue Temp

Blocking:

Supply

Temperature

Blocking:

Supply

Temperature

Blocking:

Blocked Vent

Flue Temp

High

Common

Flue Block

This indicates the ow switch is not activated.

This display indicates that the ue sensor temperature is above 210oF. When this code is displayed, the boiler will not respond to a demand for heat. When the ue temperature decreases below 194oF, the display will return to normal and allow the boiler to respond to a heat demand. The bottom line indicates the status of the pump. The pump will remain on when this code is displayed.

TT indicates there is a demand for heat on the boiler, the pump is powered on, and the supply sensor temperature is too high for the boiler to ignite. This occurs because the water temperature measured by the supply sensor is higher than the tank temperature – CH di setting.

This screen indicates a demand for heat from the DHW circuit. The pump is powered on and the supply sensor temperature is too high for the boiler to ignite. This occurs because the water temperature measured by the supply sensor is higher than the tank temperature – DHW di setting.

Blocking: Blocked Vent indicates excessive ue pressure. This code resets automatically after the high pressure condition is resolved.

E07 indicates the ue sensor temperature is excessive and above 204oF. When Blocking: Burner Temp is displayed the boiler will begin to modulate down on vent temp rather than supply temp. When the ue temperature decreases below 194oF, the display will return to normal and allow the boiler to modulate back up to 100% if required.

Common Flue Block indicates an error with Installer Menu 23.

3. Inspect the wiring to the ow switch for damage and repair as necessary.

4. Disconnect one wire from the ow switch and test for continuity across the switch while ow is conrmed to be present.

5. Remove ow switch and inspect switch paddle for proper operation.

Check the ue for obstructions or any sign of damage, especially signs of excessive heat. Repair as necessary. Run the boiler and check the ue temperature with an external thermometer. If the ue temperature on the thermometer does not agree with the ue temperature displayed in the status menu, inspect the wiring to the ue temperature sensor in the boiler and repair as necessary. If the wiring is intact, replace the ue sensor. If the ue temperature is excessive on the status menu and the test thermometer reads the same, check and adjust combustion controls on the boiler.

This message will stay present until the water temperature measured by the supply sensor is less than the tank temperature – CH di setting.

This message will stay present until the water temperature measured by the supply sensor is less than the BOILER SUPPLY – boiler supply dierential (5oF) or DHW SETPOINT is satised and no longer calls for heat.

1. Assure the ue is not blocked.

2. Check the switch wiring by applying a jumper in place of the switch. If the code clears with the jumper in place, REPLACE the ue switch and connect the wires to the new switch BEFORE running boiler.

1. Check the ue for obstructions and any sign of damage, especially signs of excessive heat. Repair as necessary.

2. Run the boiler and check the ue temperature with an external thermometer. If the ue temperature on the thermometer does not agree with the ue temperature displayed in the status menu, inspect the wiring to the ue temperature sensor in the boiler and repair as necessary. If the wiring is intact replace the ue sensor.

3. If the ue temperature is excessive on the status menu and the test thermometer reads the same, check and adjust combustion controls on the boiler.

1. Navigate to Installer Menu 23.

2. Select 0 if boiler is operating alone. Choose 1 to establish a cascaded system. NOTE: DO NOT USE NUMBERS 2 - 8. Doing so will result in an error code. Always select 0 if boiler is operating alone or with Vision 3 panel.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

WARNING

Outdoor Sensor (7250P-319) Return Sensor (7100P-004)

Temperature (oF) Resistance (ohms) Temperature (oF) Resistance (ohms)

-22 171800 32 32624

-13 129800 41 25381

-4 98930 50 19897

5 76020 59 15711

14 58880 68 12493

23 45950 77 10000

32 36130 86 8056

41 28600 95 6530

50 22800 104 5324

59 18300 113 4365

68 14770 122 3599

77 12000 131 2982

86 9804 140 2483

95 8054 149 2079

104 6652 158 1748

113 5522 167 1476

176 1252

185 1066

194 912

203 782

212 674

Table 31 - Sensor Temperature Resistance

Indirect Sensor

(7350P-325)

Supply Sensor (7700P-073)

Flue Temp. Sensor

(7550P-147)

Part 14 - Maintenance

A. Procedures

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

The combustion chamber insulation in this product contains ceramic ber material. Ceramic bers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”

• Avoid breathing dust and contact with skin and eyes.

• Use a NIOSH certied dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on job site conditions. Current NIOSH recommendations can be found on the NIOSH website: http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose tting clothing, gloves, and eye protection.

• Apply enough water to the combustion chamber lining to prevent dust.

• Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

• Eye: Irrigate immediately.

• Breathing: Fresh air.

BEFORE EACH HEATING SEASON a trained and qualied service technician should perform the inspections as per the boiler inspection and maintenance schedule in this manual. Failure to do so could result in death or serious injury.

B. Combustion Chamber Coil Cleaning Instructions

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

• a nylon, stainless steel, or brass brush (not steel)

• an FDA approved liquid lime scale remover in a spray bottle

• gloves and eye protection

1. Shut down the boiler by using the following steps: a. Shut the power o to the boiler at the circuit breaker. b. Close the gas valve external to the unit. Shut down the unit, and wait for it to be cool to the touch. c. Open the condensate trap cleanout outside the boiler, so ow from condensate reservoir can be observed.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

WARNING

d. Disconnect electrical connections from the gas valve, spark electrode, ame rectication probe, and combustion blower. Make note of connections.

e. Disconnect the incoming ex line to the gas valve. f.

i. For 400 - 1000 Models: Remove the six (6) 10MM bolts from the burner plate assembly. ii. For 1500 - 2000 Models: Remove the eight (8) 10MM bolts from the burner plate assembly with a 12mm Allen key.

d. Reconnect all wiring connections. e. Use pipe dope or tape to reconnect the ex line to the gas valve. (IMPORTANT: CHECK FOR GAS LEAKS!) f. Reinstall the air intake. g. Restore gas and power to the boiler. h. Turn boiler power on and create a heat demand. When boiler is lit observe condensate ow from the boiler. Be sure the boiler is operating properly. i. Reinstall the condensate trap cleanout trap.

Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe boiler operation, substantial property damage, severe personal injury, or death.

Figure 60 - 400 - 1000 Model Heat Exchanger Detail - Burner Door Torque Sequence

i. For 400 - 500 Models: Loosen the band clamp from the air intake assembly. Then pull the entire combustion assembly towards you, while removing or pushing aside any wiring to allow removal of the assembly. Set aside in a safe location for eventual reinstallation. ii. For 650 - 1000 Models: Pull the entire combustion assembly towards you and then down to disconnect from the air intake assembly. Then remove or push aside any wiring to allow removal of the assembly. Set aside in a safe location for eventual reinstallation.

3. Scrub coils of any buildup with a nylon, stainless steel, or brass brush. Do not use a steel brush. Vacuum the debris from the coils.

4. Spray the coils again with clear tap water. Conne the spray to the area being cleaned. Flush the combustion chamber with fresh water until it runs clear from the condensate reservoir. At this point, the boiler should be ready to be reassembled.

a. Inspect gaskets. b. Reinstall the combustion assembly. c. Reinstall and tighten the bolts to the burner plate using staggered tightening sequence. See Figure 60 and Table 32.

400 - 1000 Models Torque Ratings

Location # of Screws Screw Size Torque

Burner Door 6 M10 X 20 36.88 ft.lb [50 N.m.]

Ignition Electrode 2 M4 X 10 1.84 ft.lb [2.5 N.m.]

Ionization Electrode 2 M4 X 10 1.84 ft.lb [2.5 N.m.]

1500 - 2000 Models Torque Ratings

Location # of Screws Screw Size Torque

Burner Door 8 M14 X 20 36.88 ft.lb [50 N.m.]

Ignition Electrode 2 M4 X 10 1.84 ft.lb [2.5 N.m.]

Ionization Electrode 2 M4 X 10 1.84 ft.lb [2.5 N.m.]

Table 32 - Torque Ratings for Specic Components by Model

Figure 61 - 1500 - 2000 Model Heat Exchanger Detail - Sliding Out the Combustion Assembly

iii. For 1500 - 2000 Models: First, remove the ve (5) screws attaching the cabinet post to the left side of the boiler cabinet assembly. Then remove the post. Then remove the three (3) screws attaching the air intake assembly. The heat exchanger features a hinged sliding device to ease service.

First remove the pin located to the left of the door. This locks the hinge in place. After the pin is removed the door will swing at the hinge, providing better access to the inside of the heat exchanger. BE CAREFUL NOT TO DAMAGE THE COMBUSTION ASSEMBLY, WHICH IS MOUNTED TO THE DOOR, WHEN OPENING AT THE HINGE. After the pin is removed: (1) Lift the air intake pipe. (2) Spin air intake pipe while sliding the combustion assembly out. (3) Swing the assembly open to allow access to the combustion chamber. (4) Slide the assembly back toward the heat exchanger and use the removed pin to secure in the open position while performing maintenance. See Figure 61.

2. Spray the coils liberally with the FDA approved liquid lime scale remover. Conne the spray to the area being cleaned. Avoid getting the ceramic target wall wet. If the condensate system is blocked, use a vacuum to clear it.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

3. Scrub coils of any buildup with a nylon, stainless steel, or brass brush. Do not use a steel brush. Vacuum the debris from the coils.

a. Inspect gaskets. b. Reinstall the combustion assembly. c. Reinstall and tighten the bolts to the burner plate using staggered tightening sequence. See Figure 60 and Table 32. d. Reconnect all wiring connections. e. Use pipe dope or tape to reconnect the ex line to the gas valve. (IMPORTANT: CHECK FOR GAS LEAKS!) f. Reinstall the air intake. g. Restore gas and power to the boiler. h. Turn boiler power on and create a heat demand. When boiler is lit observe condensate ow from the boiler. Be sure the boiler is operating properly. i. Reinstall the condensate trap cleanout trap.

400 - 1000 Model Igniter Detail (Gap from Burner Wall)

0.31”

Burner Wall

1500 - 2000 Model

0.31”

Burner Wall

Figure 64 - 1500 - 2000 Model Igniter Gap Details

Igniter Detail

Figure 62 - 400 - 1000 Model Igniter Gap Details

Figure 63 - 400 - 1000 Model Flame Probe Gap from Burner Wall Details

lp-666 Rev. 003 Rel. 004 Date 9.3.20

CAUTION

C. Cleaning the Water Side of the Heat Exchanger

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

• Part number 7550P-606 - Flush Kit

• an FDA approved liquid lime scale remover (approved for use with stainless steel heat exchangers)

• bucket

• circulation pump

• three (3) hoses

• gloves and eye protection

Flushing the heat exchanger is a complicated procedure that should only be performed by a qualied installer / service technician. NOTE: Improper maintenance WILL VOID warranty.

1. Disconnect electrical power to the appliance.

2. Close the shuto valves on both the return and supply lines to isolate the appliance.

3. Open the drain valve on the appliance. Drain the appliance. Keep the drain valve open.

4. Remove the ow switch from the appliance. See Figure 65.

5. Install the gasket and brass adapter for the hose connection (included with part # 7550P-606) onto the ow switch tting. See Figure 65-A.

6. Connect one hose to the drain valve (Figure 65-B) and place the free end in a bucket. Connect one of the hoses to the circulation pump outlet and the hose connection adapter installed on the ow switch tting. Connect the other hose to the circulation pump inlet and place the free end in the bucket.

7. Pour the heat exchanger cleaning solution into the bucket. Ensure the cleaning solution is approved for potable water systems.

8. Turn on the pump. Operate the pump and allow the cleaning solution to circulate through the appliance for at least 1 hour at a rate of 4 gallons per minute. This will remove any possible harmful scale deposits.

9. Rinse the cleaning solution from the appliance as follows: a. Remove the free end of drain hoses from the bucket. b. Properly dispose of the cleaning solution. c. Fill the bucket with clean water. d. Place the removed hoses back in the bucket. e. Turn on the pump. f. Allow water to ow through the water heater for 5 minutes.

10. Disconnect all hoses.

11. Remove the gasket and brass adapter from the appliance.

12. Close the drain valve.

13. Reinstall the ow switch on the appliance.

14. Connect electrical power to the appliance.

15. Open the shuto valves.

16. Initiate a call for heat and observe appliance operation. Check for leaks and ensure the appliance is operating properly. Repair leaks as necessary.

Part 15 - Shutdown

A. Shutdown Procedure

If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70oF and wait for the burner to shut o. Continue to wait for the combustion blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 40 to 90 seconds. NOTE: If the boiler is to be shut down for an extended period of time in freezing conditions, it is recommended to drain the heating system of water. When water freezes it expands, which could degrade the heating system components or cause the heat exchanger to leak.

Freeze related damages are not covered by product warranty.

B. Failure to Operate

Should the burner fail to light, the control will perform two more ignition trials prior to entering a lockout state. Note that each subsequent ignition trial will not occur immediately. After a failed ignition trial, the blower must run for approximately 10 seconds to purge the system. Therefore, a time period of approximately 40 to 90 seconds will expire between each ignition trial. If the burner lights during any one of these three ignition trails, normal operation will resume. If the burner lights, but goes o in about 4 seconds, check the polarity of the wiring. See electrical connection section. If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout state indicates that a problem exists with the boiler, the controls, or the gas supply. Under such circumstances, a qualied service technician should be contacted immediately to properly service the boiler and correct the problem. If a technician is not available, pressing and holding RESET on the display for more than 1 second will remove the lockout state so additional trials for ignition can be performed. The unit will try to re-light once every 6 minutes.

Figure 65 - Drain Kit Details

lp-666 Rev. 003 Rel. 004 Date 9.3.20

AIR/GAS MIXER W/ LABELS - 400 NG AIR/GAS MIXER W/ LABELS - 400 LP AIR/GAS MIXER W/ LABELS - 500 NG AIR/GAS MIXER W/ LABELS - 500 LP AIR/GAS MIXER W/ LABELS - 650 NG

AIR/GAS MIXER W/ LABELS - 800NG AIR/GAS MIXER W/ LABELS - 800LP AIR/GAS MIXER W/ LABELS - 1000NG AIR/GAS MIXER W/ LABELS - 1000 LP

TOP PANEL (includes Mohawk)(400, 500)

Part 16 - Replacement Parts

ELX-400, 500 ONLY

ITEM#

* INDICATES FINISHED GOOD REVISION

LP-666-U 08/27/20

PART#

7550P-215

7550P-209 7550P-210

7250P-478

7550P-268

7550P-313

7550P-211 6300P-009

7350P-079

7350P-099

8600P-044

6300P-072

7350P-089

7700P-073 DUAL TEMPERATURE SENSOR - HIGH LIMIT

SEE TABLE

7550P-054

6300P-037

7550P-337

7550P-285

7350P-230

7550P-221 7550P-220

7700P-038

7550P-050

COMBUSTION BLOWER w/GASKET, SCREWS (400) COMBUSTION BLOWER w/GASKET, SCREWS (500) COMBUSTION BLOWER w/GASKET, SCREWS (650-1000)

SCREWS (400/500)- COMBUSTION BLOWER SCREWS (650-1000) - COMBUSTION BLOWER

GAS VALVE w/CABLE (400, 500) GAS VALVE (650) GAS VALVE (800/1000)

GAS SHUT-OFF VALVE (400/500) GAS SHUT-OFF VALVE (650/800/1000)

GASKET - VALVE TO AIR MIXER (400,500) GASKET - FLANGE TO VENTURI (650-1000)

LOW WATER CUT-OFF PROBE

INTEGRATED BOILER CONTROL LOW VOLTAGE BOARD FUSES - 2 AMP HIGH VOLTAGE CUSTOMER CONNECTION BOARD FUSES - 15A CAT5 PLUG PRESSURE SWITCH INTAKE PRESSURE SWITCH (400, 500)

INTAKE PRESSURE SWITCH (650-1000) DISPLAY - 7"

DESCRIPTION

Figure 66 - 400 - 1000 Model Replacement Parts

ITEM#

PART#

7550P-447

7550P-060

7500P-087

7550P-219 7550P-200

7550P-201 7550P-202 7550P-203 7550P-204

7550P-205 7550P-206 7550P-207 7550P-314 7550P-208

7550P-327

7550P-127 7550P-993

7550P-991 7550P-994

7550P-990

7550P-992

7550P-287 7550P-216 7550P-214

GASKET - DISPLAY - 7" TOUCH SCREEN BRACKET POWER SWITCH SWIVEL CASTERS

AIR/GAS MIXER W/ LABELS - 650 LP

BACK PANEL (400 - 1000) BACK PANEL (400 - 1000)

TOP PANEL (includes Mohawk)(650, 800, 1000) SIDE PANEL (400, 500)

SIDE PANEL (650, 800, 1000) FRONT PANEL (400 - 1000)

PART #

OTHER ITEMS NOT SHOWN

LEAD - SPARK EXTERNAL SPARK TRANSFORMER DISPLAY CABLE

DESCRIPTION

REV 000 - 002 REV 003 +

DESCRIPTION

lp-666 Rev. 003 Rel. 004 Date 9.3.20

* INDICATES FINISHED GOOD REVISION

PART#

PRESSURE RELIEF VALVE - 50 PSI TEMPERATURE/PRESSURE GAUGE DRAIN VALVE FLUE TEMPERATURE SENSOR RUBBER GROMMETT CONDENSATE ASSEMBLY HOSE - CONDENSATE HOSE CLAMP (2) SCREWS - #10 X 1/2" SELF TAPPING GAS PIPING ASSY - 1" (400, 500) GAS PIPING ASSY - 1" (650) GAS PIPING ASSY - 1-1/4" (800) GAS PIPING ASSY - 1-1/4" (1000) 2" WATER RETURN PIPE 2" WATER SUPPLY PIPE (400) 2" WATER SUPPLY PIPE (500) 2" WATER SUPPLY PIPE (650) 2" WATER SUPPLY PIPE (800) 2" WATER SUPPLY PIPE (1000) SCREW - 1/4-20" X 3/4" LONG

HEAT EXCHANGER (400) HEAT EXCHANGER (500) HEAT EXCHANGER (650) HEAT EXCHANGER (800) HEAT EXCHANGER (1000) SCREW - 3/8-16" X 3/4" LONG

SERRATED/FLANGED NUT - 3/8-16" SERRATED/FLANGED METAL INTAKE ADAPTER - 6" PLASTIC INTAKE ADAPTER - 6" METAL INTAKE ADAPTER - 4" PLASTIC INTAKE ADAPTER - 4" METAL FLUE ADAPTER - 6" PLASTIC INTAKE ADAPTER - 6" METAL FLUE ADAPTER - 4" PLASTIC INTAKE ADAPTER - 4" SCREW - 1/4-20 X 3/4" LONG CPVC PIPE - 4" DIA (400/500) REV 000 - 002 CPVC PIPE - 6" DIA (650-1000) PVC TUBING (w/HOSE CLAMPS) HOSE CLAMP FLOW SWITCH

DESCRIPTION

ITEM#

7550P-218

7250P-211

6070P-009

7550P-147

7550P-148

7550P-226

7550P-222

7250P-210

7350P-063 7550P-225 7550P-224

7550P-223 7550P-263

7550P-227 7550P-228 7550P-229 7550P-230

7550P-231 7550P-232

7550P-189

7100P-004 RETURN SENSOR 7550P-001 7550P-002 7550P-003

7550P-004 7550P-005

7550P-275

7550P-276

7550P-235

7550P-291

7550P-237

7550P-290

7550P-236

7550P-291

7550P-239

7550P-290

7550P-189

7550P-257

7550P-279

7550P-186

7550P-168

7550P-063

LP-666-U 12/06/19

REV 000 - 002

REV 003 +

REV 000 - 002

REV 003 +

REV 000 - 002

REV 003 +

REV 000 - 002

REV 003 +

REV 000 - 002

Figure 67 - 400 - 1000 Heat Exchanger Replacement Parts

lp-666 Rev. 003 Rel. 004 Date 9.3.20

PART#

LP-666-U2 10/10/19

ITEM#

DESCRIPTION

7550P-372 CLAMP - VENT ADAPTER 4"

CLAMP - VENT ADAPTER 6"7550P-373

7550P-374 GASKET - VENT ADAPTER 4"

7550P-375 GASKET - VENT ADAPTER 6"

7550P-376 CERAMIC REFRACTORY (w/CLIP, SCREW) BACK OF MODULE

7550P-377 CERAMIC REFRACTORY KIT, BURNER DOOR (w/SCREW & CLIP)

7550P-378 BURNER DOOR (w/SCREWS, WASHERS, GASKET)

7550P-379 SCREW, WASHERS - BURNER DOOR M10

7550P-380

SIGHT GLASS ASSEMBLY

7550P-381 SPARK ELECTRODE (w/GASKET, SCREWS)

7550P-382 FLAME RECTIFICATION PROBE (w/GASKET, SCREWS)

7550P-383 FLAPPER VALVE (w/SCREW, BRACKET) (400/500)

7550P-384 FLAPPER VALVE (w/SCREW, BRACKET) (650/1000)

7550P-385 BURNER (w

7550P-386 BURNER (w/GASKET) (500)

7550P-387 BURNER (w/GASKET) (650)

7550P-389 BURNER (w/GASKET) (800)

7550P-390 BURNER (w/GASKET) (1000)

7550P-391 GASKET - BURNER

7550P-392 AIR CHANNEL (w/GASKET, SCREWS, WASHERS) (400/500)

7550P-393 AIR CHANNEL (w/GASKET, SCREWS, WASHERS) (650/1000)

7550P-394 SCREWS, WASHER - AIR CHANNEL

7550P-395 GASKET -COMBUSTION BLOWER (650/1000)

7550P-396 GASKET - AIR CHANNEL (400/500)

7550P-397

7550P-398

7350P-274

/GASKET) (400)

ADAPTER - AIR CHANNEL (400-500)

SCREWS - AIR CHANNEL ADAPTER (400-500)

GASKET - COMBUSTION BLOWER (400/500)

Figure 68 - 400 - 1000 Heat Exchanger Replacement Parts

lp-666 Rev. 003 Rel. 004 Date 9.3.20

LP-666-U 08/27/20

ITEM#

1 2 3 4

PART# 7550P-060 7550P-050 7550P-447 7550P-054

SEE CHART

7550P-053 7550P-337

7550P-998

7550P-140 7550P-554

7550P-076

7550P-501

7550P-077 7550P-502

6300P-017

7550P-246

TOUCH SCREEN BRACKET TOUCH SCREEN DISPLAY GASKET - LCD DISPLAY LOW VOLTAGE BOARD

CONTROL BOARD HIGH VOLTAGE BOARD 2 (2000)

HIGH VOLTAGE CUSTOMER CONNECTION BOARD (1500)

HTP LINK WI-FI DONGLE KIT

SCREW- HEX HEAD M8X16, 6 PER (2000) SCREW- HEX HEAD M8X14, 6 PER (1500)

LEFT BASE PANEL (2000) LEFT BASE PANEL (1500)

RIGHT BASE PANEL (2000) RIGHT BASE PANEL (1500)

GAS BALL VALVE 1-1/4"

GAS VALVE W/1-1/4" ADAPTER

DESCRIPTION

ITEM#

PART#

7550P-079 7550P-509

7550P-065 7550P-535

7550P-221 7550P-129

7550P-542 7550P-125

7550P-309 7550P-310 7550P-442

6300P-072

7550P-162 7550P-503

7550P-214

BASE SKIRTS WITH BOLTS (2000) BASE SKIRTS WITH BOLTS (1500)

BLOWER (2000) BLOWER (1500)

PRESSURE SWITCH (BLOCKED VENT) TOP MOHAWK WITH GASKETS (2000)

TOP MOHWAK WITH GASKETS (1500) BEZEL WITH GASKET (LESS CONTROLS)

AIR/GAS MIXER W/ LABELS - 1500NG AIR/GAS MIXER W/ LABELS - 1500LP AIR/GAS MIXER W/ LABELS - 2000NG

GASKET - FLANGE TO VENTURI

SIDE PANEL (2000) SIDE PANEL (1500)

DISPLAY CABLE (NOT SHOWN)

DESCRIPTION

Figure 69 - 1500 - 2000 Model Replacement Parts

lp-666 Rev. 003 Rel. 004 Date 9.3.20

LP-666-U 12/17/19

ITEM# PART# DESCRIPTION

1 7550P-531 8" INTAKE ADAPTER 2 7550P-137 SCREW - 10-32 X 1/2" LONG 3 7550P-072 VENT ADAPTER 4 7550P-052 HIGH VOLTAGE BOARD 1 5 8800P-108 CONTACTOR 6 7550P-119 COVER - HIGH VOLTAGE BOX 7 7550P-216 EXTERNAL SPARK TRANSFORMER 8 7550P-541 SPARK LEAD (NOT SHOWN) 9 7550P-085 BACK PANEL

7550P-150

7550P-504 11 7550P-163 FRONT DOOR (NOT SHOWN) 12 7550P-120 LOWER BACK PANEL

TOP COVER (LESS CONTROLS)(2000) TOP COVER (LESS CONTROLS) (1500)

Figure 70 - 1500 - 2000 Model Replacement Parts (Looking from Rear)

lp-666 Rev. 003 Rel. 004 Date 9.3.20

LP-666-U 04/14/20

ITEM#

3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19 20 21

PART#

7550P-192

7550P-197 7550P-532

7550P-199 7350P-089 7550P-063 7700P-073 7100P-004 7550P-175 7250P-211 6070P-009 7550P-147 7550P-148 7550P-007 7550P-196 7550P-276 7550P-062 7550P-051 7550P-173 7550P-174 7550P-168 7350P-063

DESCRIPTION GAS PIPE ASSEMBLY WATER SUPPLY ASSEMBLY (2000)

WATER SUPPLY ASSEMBLY (1500) WATER RETURN ASSEMBLY LOW WATER CUT-OFF PROBE HIGH TURNDOWN FLOW SWITCH DUAL TEMPERATURE SENSOR - HIGH LIMIT HIGH TEMPERATURE SENSOR PRESSURE RELIEF VALVE, 1-1/4", 50 PSI TEMPERATURE/PRESSURE GAUGE 60 PSI DRAIN VALVE FLUE TEMPERATURE SENSOR RUBBER GROMMET MODULE HEX HEAD BOLTS - 3/8-16" X 1-1/4"(4 PER) LOCKNUT - 3/8-16" SERRATED (4 PER) 2-1/2" GROOVE LOCK FITTING CONDENSATE ASSY HOSE CLAMP - 1-1/2" HOSE CLAMP - 1-3/4" HOSE CLAMP - 3/4" SCREWS #10 X 1/2"

Figure 71 - 1500 - 2000 Model Replacement Parts (Looking from Front)

lp-666 Rev. 003 Rel. 004 Date 9.3.20

12/09/19

ITEM#

PART # DESCRIPTION

7550P-410 GASKET - VENT ADAPTER

7550P-411 CERAMIC REFRACTORY - BACK OF MODULE

7550P-412 CERAMIC REFRACTORY KIT - BURNER DOOR

7550P-413 SIGHT GLASS (w/SCREWS)

7550P-414 BURNER DOOR (w/SCREWS, WASHERS)

7550P-415 SCREWS, WASHERS - BURNER DOOR

7550P-416 SPARK ELECTRODE (w/SCREWS, GASKET)

7550P-417 FLAME RECTIFICATION PROBE (w/SCREWS, GASKET)

7550P-580 BURNER (w/SCREWS, GASKET) (1500)

7550P-418 BURNER (w/SCREWS, GASKET) (2000)

7550P-419 SCREW - BURNER

7550P-420 GASKET - BURNER

7550P-421 AIR CHANNEL (w/GASKET, SCREWS, WASHERS)

7550P-422 SCREWS, WASHERS - AIR CHANNEL

7550P-423 GASKET - AIR CHANNEL

LP-666-U3

Figure 72 - 2000 Model Heat Exchanger Replacement Parts

Model Control Board Part Numbers Model Control Board Part Numbers

400 NG 7550P-2104 800 NG 7550P-2116

400 LP 7550P-2105 800 LP 7550P-2117

500 NG 7550P-2108 1000 NG 7550P-2120

500 LP 7550P-2109 1000 LP 7550P-2121

650 NG 7550P-2112 1500 NG 7550P-2124

650 LP 7550P-2113 2000 NG 7550P-2128

Table 33 - Control Board Replacement Part Numbers

Model Part Description Control Board Part Numbers

400 - 500 Low Voltage Harness 7550P-311

400 - 500 High Voltage Harness 7550P-312

650 - 1000 Low Voltage Harness 7550P-513

650 - 1000 High Voltage Harness 7550P-514

1500 Low Voltage Harness 7550P-510

1500 High Voltage Harness 7550P-511

2000 Low Voltage Harness 7550P-101

2000 High Voltage Harness 7550P-102

Table 34 - Wire Harness Replacement Part Numbers

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Part 17 - Installation Checklist

WARNING

CAUTION

Light O Activities Date Completed:

Check all piping and gas connections. Verify all are tight.

1. Fill the Heating System

2. Check Gas Pipe

3. Check Combustion

4. Check Electrical Connections

5. Verify System Operation Turn up thermostat to verify wiring connections.

6. Record Ionization Current

7. System Setting Verify system settings. CH Setpoint CH Dierential

8. Indirect Water Heater

Notes:

Pressurize system (12 - 15 psi). PSI

Add water to prime condensate cup.

Verify near boiler piping is properly supported.

Percentage of glycol in system (0 - 50%)

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

Check incoming gas pressure. Static WC

Check the “drop” on light o (less than 1” WC). Dynamic WC

Check and adjust (if necessary) carbon dioxide content.

Check and adjust (if necessary) carbon monoxide content.

Ensure all electrical connections of line voltage (pumps, etc.) and low voltage circuits (system sensor, outdoor sensor, etc.) are properly wired.

Check uA reading in the status menu (see StartUp section, this manual).

Verify safety and operation of the indirect water heater. Record settings.

%CO2 High Fire %CO2 Low Fire

ppm CO High Fire ppm CO Low Fire

uA High Fire uA Low Fire

DHW Setpoint DHW Dierential

Table 35 - Installation Checklist

Part 18 - Maintenance Report

In unusually dirty or dusty conditions, care must be taken to keep boiler cabinet door in place at all times. Failure to do so VOIDS the warranty.

Allowing the boiler to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in boiler failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

The boiler requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended. Periodic maintenance should be performed once a year by a qualied service technician to assure that all the equipment is operating safely and eciently. The owner should make necessary arrangements with a qualied heating contractor for periodic maintenance of the boiler. Installer must also inform the owner that the lack of proper care and maintenance of the boiler may result in a hazardous condition.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Inspection Activities Date Last Completed

Piping

Near boiler piping

Vent

System

Visual Do a full visual inspection of all system components.

Functional Test all functions of the system (Heat, Safeties).

Temperatures

Glycol (If Applicable)

Electrical

Connections Check wire connections. Make sure connections are tight.

Smoke and CO Detector

Circuit Breakers Check to see that the circuit breaker is clearly labeled. Exercise circuit

Switch and Plug Verify ON/OFF switch and convenience plug are both functional.

Chamber / Burner

Combustion Chamber

Spark Electrode Clean. Set gap as described in Figures 62 - 64. Clean probe with plumbers

Combination Ignitor and Flame Probe

Condensate

Neutralizer Check condensate neutralizer. Replace if necessary.

Condensate Pipe Disconnect condensate pipe. Clean out dirt. Fill with water to level of

Gas

Pressure Measure incoming gas pressure.

Pressure Drop Measure drop in pressure on light o (no more than 1” WC).

Check Gas Pipe for Leaks

Combustion

CO / CO2 Levels Check CO and CO2 levels in exhaust. See Start-Up Procedures for ranges.

Safeties

ECO (Energy Cut Out)

Sensors Check wiring. Verify through ohms reading.

Final Inspection

Check List Verify that you have completed entire check list. WARNING: FAILURE TO

Homeowner Review what you have done with the homeowner.

Table 36 - *Continue annual maintenance beyond the 4th year as required.

Check boiler and system piping for any sign of leakage; make sure pipes are properly supported.

Check condition of all vent pipes and joints. Ensure the vent piping terminations are free of obstructions and blockages.

Verify safe settings on boiler or anti-scald valve.

Verify programmed temperature settings.

Check glycol for the correct concentration, pH, and inhibitor level.

Verify devices are installed and working properly. Change batteries if necessary.

breaker.

Check burner tube and combustion chamber coils. Clean according to maintenance section of manual. Vacuum combustion chamber. Replace any gaskets that show signs of damage.

cloth to remove oxides.

Check ionization in uA (d7 in Status Menu in Start-Up Procedures). Record high re and low re. Clean probe with plumbers cloth to remove oxides.

outlet and reinstall. (NOTE: Verify the ow of condensate, making sure that the hose is properly connected during nal inspection.)

Check gas piping. Test for leaks and signs of aging. Make sure all pipes are properly supported.

Record at high and low re.

Check continuity on ue and water ECO. Replace if corroded.

DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

1st Year 2nd Year 3rd Year 4th Year*

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Ten year warranty to assure your complete satisfaction.

HTP warrants this boiler and its components to be free from defects in material and workmanship according to the following terms, conditions, and time periods. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original

consumer purchaser (herinafter “Owner”) of this boiler, and is non-transferable.

Coverage Coverage Period Coverage Rate Components Covered Additional Terms and Conditions

Basic

Extended

Year 1 100% All Components

Years 1 - 5 100% Pressure Vessel Only

Year 1 100% All Components

Years 1 - 5 100% Pressure Vessel Only

Years 6 - 10 20% Pressure Vessel Only

Basic Coverage Explanation

Installations Not Registered Online within Six (6) Months of Installation

A. During the rst year after the date of manufacture, HTP warrants that it will repair or replace, at its option and at 100% coverage, any defective or malfunctioning component of the boiler that is found to have failed due to manufacturer’s defect. B. During the rst ve years after the date of manufacture, HTP warrants that it will repair or replace, at its option and at 100% coverage, any defective or malfunctioning pressure vessel that is found to have failed due to manufacturer’s defect.

Extended Coverage Explanation

Installations Registered Online within Six (6) Months of Installation

A. During the rst year after the date of installation, HTP warrants that it will repair or replace, at its option and at 100% coverage, any defective or malfunctioning component of the boiler that is found to have failed due to manufacturer’s defect. B. During the rst ve years after the date of installation, HTP warrants that it will repair or replace, at its option and at 100% coverage, any defective or malfunctioning pressure vessel that is found to have failed due to manufacturer’s defect. C. During the sixth through tenth year after the date of installation, should a defect or malfunction result in a leakage of water from the pressure vessel due to defective material or workmanship, malfunction, or failure to comply with the above warranty, with such defect or malfunction having been veried by an authorized HTP representative, HTP will repair or replace, at its option and at a reduced 20% coverage, the defective or malfunctioning pressure vessel.

Coverage Terms and Conditions

1. This warranty applies only to the components (including the pressure vessel) of the boiler, and does not apply to any boiler installation.

2. Replacement components will be of the nearest comparable model available at the time of replacement.

3. Replacement components (other than the pressure vessel) will be warranted for ninety (90) days. A replacement pressure vessel will be warranted for the unexpired portion of the applicable warranty period of the original pressure vessel.

4. In the event of a leakage of water from a replacement pressure vessel due to defective material or workmanship, malfunction, or failure to comply with the above warranty, HTP reserves the right to refund to the Owner the published wholesale price available at the date of manufacture of the original pressure vessel, at the applicable coverage rate detailed in the Basic or Extended

Coverage sections above.

5. If government regulations, industry certication, or similar standards require the replacement component(s) to have features not found in the defective component(s), the Owner will be charged the dierence in price represented by those required features. If the Owner pays the price dierence for those required features and/or to upgrade the size and/or other features available on new replacement component(s), the Owner will also receive a complete new

limited warranty for that replacement component(s).

6. This warranty extends only to boilers utilized in heating applications that have been properly installed by qualied professionals based upon the

manufacturer’s installation instructions.

7. It is expressly agreed between HTP and the Owner that repair, replacement, or refund are the exclusive remedies of the Owner.

Basic Coverage applies to boiler installations not registered at http://www. htproducts.com/Warranty-Wizard.html within six (6) months of installation and commences on the date of manufacture.

Extended Coverage applies to boiler installations registered at http://www. htproducts.com/Warranty-Wizard.html within six (6) months of installation and commences on the date of installation.

Owner Responsibilities

The Owner or Qualied Installer / Service Technician must:

1. Have a relief valve bearing the listing marks of the American Society of Mechanical Engineers (ASME) installed with the boiler assembly in accordance with federal, state, and local codes.

2. Maintain the boiler in accordance with the maintenance procedure listed in the manufacturer’s provided instructions. Preventive maintenance can help avoid any unnecessary breakdown of the boiler and keep it running at optimum eciency.

3. Maintain all related system components in good operating condition.

4. Check all condensate lines to conrm that all condensate drains properly from the boiler.

5. Use the boiler with a properly sized and installed thermal expansion tank.

6. Use the boiler at water pressures not exceeding the working pressure shown on the rating plate.

7. Keep the boiler free of damaging scale deposits.

8. Make provisions so if the boiler or any component or connection thereto should leak, the resulting ow of water will not cause damage to the area in which it is installed.

Warranty Exclusions

This limited warranty will not cover:

1. Any boiler purchased from an unauthorized dealer.

2. Any boiler not installed by a qualied heating installer/service technician, or installations that do not conform to ANSI, CSA, and/or UL standards, as well as

any applicable national or local building codes.

3. Service trips to teach the Owner how to install, use, maintain, or bring the boiler installation into compliance with local building codes and regulations.

4. The workmanship of any installer. The manufacturer disclaims and does not assume any liability of any nature caused by improper installation, repair, or maintenance.

5. Electricity or fuel costs, or increased or unrealized savings for same, for any reason whatsoever.

6. Any water damage arising, directly or indirectly, from any defect in the boiler or component(s) or from its use.

7. Any incidental, consequential, special, or contingent damages or expenses arising, directly or indirectly, from any defect in the boiler or the use of the

boiler.

8. Failure to locate the boiler in an area where leakage of the boiler or water

line connections and the relief valve will not result in damage to the area adjacent to the boiler or lower oors of the structure, as well as failure to install the boiler with properly designed containment measures.

9. Any failed components of the system not manufactured by HTP as part of the boiler.

10. Boilers repaired or altered without the prior written approval of HTP.

11. Damages, malfunctions, or failures resulting from failure to install the boiler in accordance with applicable building codes/ordinances or good plumbing and electrical trade practices.

12. Damages, malfunctions, or failures resulting from improper installation, failure to operate the boiler at ring rates or pressures not exceeding those on the rating plate, or failure to operate and maintain the boiler in accordance with the manufacturer’s provided instructions.

13. Failure to operate the boiler with a properly sized and installed thermal expansion tank.

14. Failure or performance problems caused by improper sizing of the boiler, expansion device, piping, or the gas supply line, the venting connection,

combustion air openings, electric service voltage, wiring or fusing.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

ELX Boiler Limited Warranty

15. Damages, malfunctions, or failures caused by improper conversion from natural gas to LP gas or LP gas to natural gas.

16. Damages, malfunctions, or failures caused by operating the boiler on Natural Gas or LP gas with average sulfur rates greater than 30 mg/m3.

17. Damages, malfunctions, or failures caused by operating the boiler with modied, altered, or unapproved components, or any component / attachment not supplied by HTP.

18. Damages, malfunctions, or failures caused by abuse, accident, re, ood, freeze, lightning, electrochemical reaction, acts of God and the like.

19. Failures (leaks) caused by operating the boiler in a corrosive or contaminated atmosphere.

20. Damages, malfunctions, or failures caused by operating an empty or partially empty boiler (“dry ring”), or failures caused by operating the boiler when it is not supplied with water, free to circulate at all times.

21. Any damage or failure of the boiler due to the accumulation of solid materials or lime deposits.

22. Any damage or failure resulting from improper water chemistry. See installation manual for full water chemistry requirements.

23. Any damages, malfunctions, or failures resulting from the use of dielectric unions.

24. Boilers replaced for cosmetic reasons.

25. Components of the boiler that are not defective, but must be replaced during the warranty period as a result of reasonable wear and tear.

26. Components of the boiler that are subject to warranties, if any, given by their manufacturers; HTP does not adopt these warranties.

27. Damages, malfunctions, or failures resulting from the use of any attachment(s) not supplied by HTP.

28. Boilers installed outside the fty states (and the District of Columbia) of the United States of America and Canada.

29. Boilers moved from the original installation location.

30. Boilers that have had their rating labels removed.

Extended Limited Warranty Registration

To register for the Extended Limited Warranty, complete the registration form located on the HTP website at http://www.htproducts.com/Warranty-Wizard. html within six (6) months of installation. The form must be completed in full with owner name, email address, and phone number, the address where the unit is installed and installation date, and unit model and serial numbers. Proof of purchase is required, and may be an invoice for the product, or a bill from an installing contractor that clearly documents the installation of the unit. To be valid, proof of purchase must also include the unit serial number. Proof of purchase may be typed or hand written. Submit the proof of purchase to HTP

via the directions provided on the website. NOTE: When registration is complete, retain proof of the Extended Limited Warranty registration. Proof of Extended Limited Warranty registration must be presented when making a warranty claim in order for the Extended Limited

Warranty to be valid.

Procedures for Warranty Service Requests

1. Any claim for warranty assistance must be made immediately upon nding the issue. Contact your installing contractor or service provider. DO NOT CALL HTP. If your contractor or qualed service technician requires further help, they will contact HTP directly.

NOTE: HTP cannot provide technical assistance unless you are a licensed and trained qualied service technician.

2. If the contractor or qualied service technician determines that the issue may be covered by warranty, consult the HTP Warranty Wizard (http://www. htproducts.com/Warranty-Wizard.html) to check warranty eligibility. You may also contact HTP Technical Support at 1-800-323-9651 for questions or assistance. Warranty coverage requires review and approval of the issue with HTP Technical Support or through the Warranty Wizard prior to a full unit replacement. Any claim for warranty reimbursement will be rejected if prior approval from HTP is not obtained in advance of a full unit replacement. Final determination will be made as part of the warranty claim process.

3. When submitting a warranty claim the following items are required: a. Proof of purchase or installation of the product – Typically a copy of

the invoice from the installing contractor, the receipt of the purchase of the product, or an original certicate of occupancy for a new home.

b. Clear pictures (or video) of the following:

i. Serial number tag (sticker) ii. The product iii. The product issue / failure whenever possible iv. A picture of the piping near the product v. For gas red products, a picture of the venting, including how it exits

the building All claims will be reviewed by HTP within three (3) business days. If additional information is required and requested by the HTP Claims Department you will have thirty (30) days to provide it. When all requested information is provided HTP will respond within three (3) business days. The claim will be automatically closed if requested information is not provided within thirty (30) days. Claims will not be reopened without HTP Warranty Supervisor approval. During the claims process a product that must be replaced will be given a designation of either a) eld scrap, or b) return to HTP. If the product must be returned to HTP, the returned product must arrive at HTP within thirty (30) days of the date of our request to return the product. After receipt of the returned product HTP may require as many as thirty (30) additional days for product testing.

NOTE: Any components or heaters returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied.

4. HTP will replace or credit components under warranty only. Credits are issued to the authorized wholesaler at their cost, so do not purchase replacement component(s) from suppliers with hopes of receiving 100% credit.

5. Take care to maintain records of all regular maintenance and combustion eciency test results (showing appropriate adjustment settings), as these will be required for any warranty claim.

6. If you have questions about the coverage of this warranty, please contact

HTP at the following address or phone number: HTP, 272 Duchaine Blvd., New Bedford, MA, 02745, Attention: Warranty Service Department, 1(800) 323-9651.

Service, Labor, and Shipping Costs

Except when specically prohibited by the applicable state law, the Owner, and not the Manufacturer, shall be liable for and shall pay for all charges for labor or other expenses incurred in the removal, repair, or replacement of any component(s) claimed to be defective or any expense incurred to remedy any defect in the product. Such charges include, but are not necessarily limited to:

1. All freight, shipping, handling, and delivery costs of forwarding replacement component(s) to the owner.

2. All costs necessary or incidental in removing the defective component(s) and installing replacement component(s).

3. All administrative fees incurred by the Owner, as well as material required to complete, and/or permits required for, installation of replacement component(s), and

4. All costs necessary or incidental in returning the defective component(s) to a location designated by the manufacturer.

LIMITATIONS OF THIS HTP WARRANTY AND REMEDIES

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED TO THE FURTHEST EXTENT UNDER APPLICABLE LAW IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM HTP’S NEGLIGENCE, ACTUAL OR IMPUTED. THE REMEDIES OF THE OWNER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL DAMAGES, SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, PROPERTY DAMAGE, LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF HTP TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE. NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES, REMEDIES OR THIS LIMITATION WILL BE BINDING UPON HTP. UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF HTP. THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL

OWNER ONLY.

NO OTHER EXPRESS WARRANTIES

This warranty gives the Owner specic legal rights. The Owner may also have other rights that vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to the Owner. These are the only written warranties applicable to this boiler manufactured and sold by HTP. HTP neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said boilers. HTP reserves the right to change specications or discontinue models without

notice.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Maintenance Notes

lp-666 Rev. 003 Rel. 004 Date 9.3.20

Customer Installation Record Form

The following form should be completed by the qualied installer / service technician for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.

Customer’s Name

Date of Installation

Installation Address

Product Name / Serial Number(s)

Comments

Installer’s Code / Name

Installers Phone Number

Signed by Installer

Signed by Customer

Installation Notes

IMPORTANT

Customer: Please only sign after the qualied installer / service technician has fully reviewed the installation, safety, proper operation, and maintenance of the system. If the system has any problems please call the qualied installer / service technician. If you are unable to make contact, please call your sales representative. Distributor / Dealer: Please insert contact details.

lp-666 Rev. 003 Rel. 004 Date 9.3.20

HTP ELX-400, ELX-500, ELX-650, ELX-800, ELX-1000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual