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

...

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.

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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.

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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.

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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

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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

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