HTP UFT-80W, UFT-100W, UFT-120W, UFT-140W User Manual

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Universal Fire Tube Boiler

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

IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER BOILER.

WHAT TO DO IF YOU SMELL GAS

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

service agency, or the gas supplier.

Wall Mount

INSTALLATION

START-UP

MAINTENANCE

PARTS

WARRANTY

Models

UFT- 80W / 100W / 120W / 140W

Heat Exchanger Bears the ASME “H” Stamp

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

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

LP-542 REV. 7.16.15

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

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

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

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

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

damage.

NOTICE

SAFETY INSTRUCTIONS

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

SAFETY INSTRUCTIONS (or equivalent) signs indicate specific safety related instructions or procedures.

NOTE: Contains additional information important to a procedure.

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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.

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

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.

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

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

NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

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

INSTALLATIONS MUST COMPLY WITH:

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

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

Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in

ANSI Z21.13 – latest edition.

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NOTICE

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

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

sensor is supplied by HTP, Inc. with this appliance.

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

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

 This feature may be over-ridden as described below in specific installations:  The appliance 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.

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this appliance is equipped with a feature that saves energy by reducing the appliance 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 appliance water temperature as the heating load

decreases.

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

NOTICE

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

Certain AHJs, locales, and states will require that commercial boiler installations meet the CSD-1 ASME Code, Section CW-400. To meet this code, HTP, Inc. has integrated a temperature control system into the 926 control provided with this heating boiler. This control system complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature difference between the inlet and the outlet sensor, which is affected by boiler water flow. If this temperature difference exceeds 55°F (typically because of low water flow or very low heat load), the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F, the control will effectively sense there is little or no water flow or heat load and shut the boiler down. The controller will restart automatically once the temperature difference has dropped below 55°F and the minimum off time (anticycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 199°F, the boiler is put into a hard lockout and requires manual reset to restart.

Installers should review the regulations of the AHJ, local and state code authorities, and utility companies which pertain to this type of boiler BEFORE performing installation.

TABLE OF CONTENTS

PART 1 – ITEMS SHIPPED WITH THE BOILER ........................................................................................................................ 7

PART 2 – SAFETY REGULATIONS ........................................................................................................................................... 8

A. OPERATION AND INSTALLATION WARNINGS ....................................................................................................................... 8

B. IMPROPER COMBUSTION ....................................................................................................................................................... 9

C. GAS ............................................................................................................................................................................................ 9

D. WHEN SERVICING THE BOILER............................................................................................................................................ 10

E. BOILER SYSTEM ..................................................................................................................................................................... 10

F. BOILER WATER CHEMISTRY ................................................................................................................................................. 10

G. FREEZE PROTECTION FLUIDS ............................................................................................................................................. 10

PART 3 – TECHNICAL SPECIFICATIONS ............................................................................................................................... 11

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PART 4 – PREPARE BOILER LOCATION ............................................................................................................................... 14

A. UNCRATING THE BOILER ...................................................................................................................................................... 14

B. BEFORE LOCATING THE BOILER ......................................................................................................................................... 15

C. LEVELING ................................................................ ................................ ................................................................................ 16

D. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 16

E. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS .................................................................................... 16

F. EXHAUST VENT AND INTAKE PIPE ....................................................................................................................................... 17

G. PREVENT COMBUSTION AIR CONTAMINATION ................................................................................................................. 17

H. REMOVING A BOILER FROM A COMMON VENT SYSTEM .................................................................................................. 17

I. WALL-MOUNTING THE BOILER .............................................................................................................................................. 18

PART 5 – VENTING ................................................................................................................................................................... 19

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES ................................................................................................................ 19

B. APPROVED VENT MATERIALS .............................................................................................................................................. 21

C. ALLOWED COMBINED VENT LENGTHS ............................................................................................................................... 21

D. TIGHTENING BOILER COLLAR TO EXHAUST VENT AND INTAKE PIPE ............................................................................ 22

E. VENT TERMINATION .............................................................................................................................................................. 23

1. Two Pipe Roof and Sidewall Vent Terminations ..................................................................................................................... 23

2. Direct Vent, Optional Horizontal and Vertical Vent Kits ......................................................................................................... 24

3. Snorkel Venting ......................................................................................................................................................................... 25

4. Screen Installation ..................................................................................................................................................................... 26

PART 6 – INSTALL THE CONDENSATE DRAIN ..................................................................................................................... 26

PART 7 – GAS PIPING .............................................................................................................................................................. 27

A. ADDITIONAL PRECAUTION FOR EXCESS FLOW VALVE (EFV) ......................................................................................... 28

B. GAS PIPE SIZING TABLES ..................................................................................................................................................... 28

1. Gas Pipe Sizing .......................................................................................................................................................................... 28

2. Natural Gas Pipe Sizing ............................................................................................................................................................ 28

3. LP (Liquid Propane) Gas Pipe Sizing ....................................................................................................................................... 28

C. GAS CONNECTION REQUIREMENTS ................................................................................................................................... 29

PART 8 – WATER PIPING ........................................................................................................................................................ 30

A. GENERAL PLUMBING CONNECTION GUIDELINES ................................ ............................................................................. 30

B. BACKFLOW PREVENTER ....................................................................................................................................................... 31

C. CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS ................................................................ ..................... 31

D. CIRCULATOR SIZING ............................................................................................................................................................. 31

E. CH PRESSURE RELIEF VALVE .............................................................................................................................................. 37

F. BUILT-IN LOW WATER CUT-OFF (LWCO) ............................................................................................................................. 37

G. OPTIONAL EXTERNAL UL353 MANUAL RESET LOW WATER CUT-OFF (LWCO) INTERFACE KIT ................................. 37

PART 9 – CONNECT ELECTRICAL POWER / INITIAL STARTUP ......................................................................................... 38

A. GENERAL OPERATING CONDITIONS ................................................................................................................................... 38

B. WIRING INFORMATION .......................................................................................................................................................... 38

C. DIP SWITCHES ....................................................................................................................................................................... 39

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PART 10 – OPERATING SYSTEM INSTRUCTIONS ................................................................................................................ 44

A. CONTROL PANEL ................................................................................................................................................................... 44

B. LCD DISPLAY DESCRIPTIONS .............................................................................................................................................. 44

C. START-UP SEQUENCE .......................................................................................................................................................... 44

D. CHANGING THE CH SET-POINT ............................................................................................................................................ 45

E. CHANGING THE TIME ............................................................................................................................................................. 45

F. STATUS DISPLAY MODE ................................................................................................ ........................................................ 46

G. INSTALLER MODE .................................................................................................................................................................. 47

H. ERROR MODE ......................................................................................................................................................................... 49

I. ERROR TREE ANALYSIS ......................................................................................................................................................... 53

1. FLAME DETECTION ................................................................................................................................................................... 53

2. GAS DETECTION ....................................................................................................................................................................... 53

3. APS / BURNER OVERHEAT LIMIT / CONDENSATE BLOCK SWITCH ................................................................................... 54

4. STORAGE / OP / CH OVERHEAT / EXHAUST OVERHEAT SENSORS .................................................................................. 54

J. OUTDOOR TEMPERATURE MODE (OPTIONAL) ................................................................................................................... 54

K. 0-10 VOLT INPUT .................................................................................................................................................................... 55

PART 11 – START-UP PREPARATION.................................................................................................................................... 56

A. BOILER WATER CHEMISTRY ................................................................................................................................................ 56

B. FREEZE PROTECTION FLUIDS ............................................................................................................................................. 57

C. CHECK FOR GAS LEAKS ....................................................................................................................................................... 57

D. FILL AND TEST WATER SYSTEM .......................................................................................................................................... 57

E. PURGE AIR FROM SYSTEM ................................................................................................................................................... 58

F. CHECK THERMOSTAT CIRCUIT(S) ....................................................................................................................................... 59

G. CONDENSATE REMOVAL ...................................................................................................................................................... 59

H. FINAL CHECKS BEFORE STARTING BOILER ...................................................................................................................... 59

I. ADJUSTING GAS PRESSURE AT THE BOILER ...................................................................................................................... 59

J. SETTING AND VERIFYING THE COMBUSTION SETTING .................................................................................................... 60

PART 12 –INSTALLATION AND START-UP CHECKLIST ...................................................................................................... 61

PART 13 – TROUBLESHOOTING ............................................................................................................................................ 63

PART 14 – ANNUAL MAINTENANCE PROCEDURES ............................................................................................................ 63

REPLACEMENT PARTS ................................................................................................................................................................ 66

UFT Boiler Limited Warranty ........................................................................................................................................................ 70

START-UP REPORT ....................................................................................................................................................................... 72

MAINTENANCE REPORT .............................................................................................................................................................. 73

MAINTENANCE NOTES ................................................................................................................................................................. 76

HTP CUSTOMER INSTALLATION RECORD FORM ..................................................................................................................... 77

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ITEM

DESCRIPTION

QUANTITY

Universal Fire Tube Boiler

UFT-W

H-2 Form, User, and Installation

Manuals

1 Each

Condensate Hose

(Part # 7855P-089)

Anchors and Wall Mounting

Bracket

(Part # 7850P-084)

Outdoor Sensor with Screws and Anchors

(Part # 7855P-084)

Spare Parts Kit

(Gaskets and O-Rings)

(Part # 7855P-383)

30 PSI Pressure Relief Valve

(Part # 7855P-077)

1 ¼” X 1 ¼” X ¾” Tee (steel)

(Part # 7855P-313),

3/4" Street Elbow (steel)

(Part # 7350P-084)

Automatic Air Vent

(Part # 7855P-063)

3” CPVC

(Part # 7855P-101)

6” Length

Vent Screens (3”)

(Part # 7855P-085)

2 Screens

PART 1 – ITEMS SHIPPED WITH THE BOILER

Table 1 – Items Included with the Boiler

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Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death. The boiler has a burner that can come on at any time and ignite vapors. DO NOT use or store flammable liquids around the boiler.

Improper venting can cause a build-up of carbon monoxide. Breathing carbon monoxide can result in brain damage or death. DO NOT operate the boiler unless it is properly vented to the outside and has an adequate fresh air supply for safe operation. Inspect the exterior exhaust gas outlet port and fresh air inlet port on a regular basis to ensure they are functioning properly.

A concentration of carbon monoxide as small as .04% (400 parts per million) in the air can be fatal. When making high fire or low fire adjustments, CO levels must be monitored using a flue gas analyzer such that a CO level of no more than 400 ppm is exceeded at any time during operation.

Adjusting the “low fire offset” on the gas valve in even small increments can result in a significant increase in CO concentration. To avoid serious injury or death, DO NOT make any adjustments to the gas valve without monitoring the exhaust gases with a fully functional and calibrated flue gas analyzer.

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

This boiler must be installed by a licensed plumber, licensed gas fitter, and/or professional service technician. Improper installation and/or operation can cause a potentially hazardous situation, which, if not avoided, could result in serious injury or death, and will void the warranty.

HTP, Inc. cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of the professional service technician.

Proper care of the boiler is the user’s responsibility. Ensure the user carefully reads and understands the User’s Information Manual before operating and maintaining the boiler.

Make sure the user knows the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the boiler is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the boiler checked by a qualified technician before resuming operation.

Do not power up the unit unless the gas and water supply valves are fully opened. Make sure the fresh air intake port and exhaust gas port are open and functional.

No one but a professional service technician should attempt to install, service, or repair this boiler. There are no serviceable parts which can be changed by the user / owner. User / Owner: Contact the original professional service technician if the boiler needs repair or maintenance. If the original technician is unavailable, ask your gas supplier for a list of qualified service providers.

Keep the area around the boiler clean and free of all materials that can burn. DO NOT store or place gasoline, oils, spray paint, or other flammable products near the boiler.

DO NOT use spray paint, hair spray, or any other flammable spray near the boiler or near the exterior fresh air intake port. DO NOT place any items in or around the exterior exhaust gas outlet port and/or fresh air inlet port that could restrict or block the flow in or out of the vent system.

OPTIONAL EQUIPMENT

Below is a list of optional equipment available from HTP. These additional options may be purchased through your HTP distributor:

 System Sensor (Part # 7250P-324)  Indirect Tank Sensor (Part # 7250P-325)  2" PVC Concentric Vent Kit (Part # KGAVT0501CVT)  3" PVC Concentric Vent Kit (Part # KGAVT0601CVT)  2” Stainless Steel Outside Termination Vent Kit (Part # V500)  3” Stainless Steel Outside Termination Vent Kit (Part # V1000)  4” Stainless Steel Outside Termination Vent Kit (Part # V2000)  6” Stainless Steel Outside Termination Vent Kit (Part # V3000)  3” Polypro Vent Kit (Part # 8400P-001)  3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)  Condensate Neutralizer (Part # 7450P-212)  Condensate Removal Pump (Part # 554200)  Communication Cable (Part # 7850P-093)  2” Vent Screens (Two Screens) (Part # 7850P-088)

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

PART 2 – SAFETY REGULATIONS

A. OPERATION AND INSTALLATION WARNINGS

To avoid serious injury or death, read, understand, and follow all the precautions listed here.

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DO NOT store or place newspapers, laundry, or other combustible items near the boiler or the exterior exhaust gas outlet and/or fresh air inlet port.

The owner should inspect the system monthly for damage, water stains, signs of rust, corrosion, and exhaust vent and air intake blockage. If inspection of the unit shows signs of damage, the boiler should be shut off until the problem is repaired by a qualified technician.

After installation, all boiler safety devices should be tested.

This boiler is certified for indoor installations only. The boiler consists of gas ignition system components which must be protected from water (dripping, spraying, etc.) during operation and service. Carefully consider installation location and the placement of critical components (circulators, condensate neutralizers, etc.) before installing the boiler.

DO NOT allow children to operate this unit. DO NOT use this unit if it does not appear to be operating correctly. A qualified technician should service and inspect the boiler annually.

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

1. FIRE

2. DAMAGE

3. WATER

This boiler is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug.

DO NOT alter or modify the boiler or boiler controls. This can be dangerous and WILL VOID the warranty.

Failure to follow these statements could result in property damage, severe personal injury, or death.

NOTICE

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

This boiler provides a overheat shutdown limit. In the event the boiler water exceeds the set point of the control limit, the cutoff will trip and the boiler will shut down. Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit provided with the boiler. Contact a qualified service technician for additional overheat controls.

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified 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 fire 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 flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Be sure to disconnect electrical power before opening boiler cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the boiler. Wiring errors can cause improper or dangerous operation. Failure to do so could result in an electrical shock, improper boiler operation, property damage, serious personal injury, or death.

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

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

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

B. IMPROPER COMBUSTION

C. GAS

Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the boiler.

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ACIDITY

6 to 8 pH

CONDUCTIVITY

Less than 400 uS/cm at 25oC

CHLORIDE

Less than 100 ppm

IRON

Less than 0.5 mg/L

COPPER

Less than 0.1 mg/L

SODIUM

Less than 20 mg/L

HARDNESS

Less than 7 Grains

NEVER use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems, with this boiler. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Consider boiler piping and installation when determining boiler location.

D. WHEN SERVICING THE BOILER

 To avoid electric shock, disconnect electrical supply before performing

maintenance.

 To avoid severe burns, allow boiler to cool.  Do not use petroleum-based cleaning or sealing compounds in a boiler

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

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

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

 Always verify proper operation after servicing the boiler.

E. BOILER SYSTEM

 Thoroughly flush the system (without boiler connected) to remove

sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment. HTP recommends a suction strainer in all systems.

 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.

F. BOILER WATER CHEMISTRY

 Sodium less than 20mGL.  Water pH between 6 and 8

o Maintain water pH between 6 and 8. Check with litmus paper or have it chemically analyzed by water treatment

company.

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

 Hardness less than 7 grains

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

 Chlorine concentration less than 100 ppm

o Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm. o Do not connect the boiler to directly heat swimming pool or spa water. o Do not fill boiler or operate with water containing chlorine in excess of 100 ppm.

NOTE: It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup. To clean the heat exchanger, follow the maintenance procedure in Part 13, Section B of this manual.

Table 2 – Water Quality Requirements

G. FREEZE PROTECTION FLUIDS

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

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MODEL

UFT-80W

UFT-100W

UFT-120W

UFT-140W

Installation

Indoor, Wall Hung, Fully Condensing

Minimum / Maximum Input

(Btu/Hr)

8,000 / 80,000

10,000 / 100,000

12,000 / 120,000

14,000 / 140,000

Flue System

Sealed Combustion Direct Vent

Vent Run

2” (50 feet), 3” (100 feet), Schedule 40 PVC, CPVC, PP

Weight (lbs)

100

Gas Supply

Pressure

3.5” to 14” WC

Power Supply

Main Supply

120V 60 Hz / 6a

Maximum

Power

Consumption

160W

General Operating Conditions

Temperature

 Ambient Temperature Range: 33 – 104oF (0.6 – 40oC)  Operating Relative Humidity: Up to 90% at 140oF (40oC)  Shipping and Storage Temperature Range: -4 – 176oF (-20 – 80oC)

Input Ratings

 Power Supply and Communication (CN4): 14V DC

Ignition System

Direct Electronic Ignition / Automatic Flame Sensing

Burner System

Premixed Fuel Modulation Metal Fiber Infrared

Gas Valve System

Combination Modulating (Current Proportional)

Internal Pipe Material

Copper

Dimensions

W 17.5” – H 34” – D 15.4”

Boiler Heat Exchanger Capacity

3 Gallons

Main Controller / Control Panel

NGTB-900C / P-950EH

Water Pressure

Min 15 – Max 30 PSI

Connection

Sizes

Space Heating

Supply /

Return

1 ¼” NPT

Gas Inlet

¾” NPT

Materials

Cabinet

Painted Cold Rolled Carbon Steel

Heat

Exchanger

Heat Exchanger: Stainless Steel

Safety Devices

Optical Flame Sensor, Burner Plate High Limit (392oF), Water Temperature High Limit Sensor

(200oF), Gas Leak Detection Sensor (Detects Natural Gas or Propane), Freeze Protection (Three

Stage Operation - Activates at 46oF – See Freeze Protection in Installer Menu for Details),

Exhaust Temperature High Limit Sensor (190oF), Blocked Flue Switch, Condensate Switch, Built-

In Low Water Cut-Off Probe

PART 3 – TECHNICAL SPECIFICATIONS

Table 3 – Technical Specifications

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DESCRIPTION

DIAMETER

CH Supply Adapter

1 ¼”

CH Return Adapter

1 ¼”

Gas Inlet Adapter

¾”

Condensate Adapter

½”

Intake Pipe Connection

3”

Exhaust Vent Connection

3”

MODEL

G H I J K L M N O P Q R S T U V W

80W

100W

17.5

28.75

4.7

7.3

9.1

2.4

5.8

11.7

14.9

9.6

2.8

2.1

2.7

10.7

14.1

2.1

15.4

120W 140W

Figure 1 – UFT Specifications and Dimensions

Table 4 – UFT Specifications

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NUMBER

COMPONENT DESCRIPTION

NUMBER

COMPONENT DESCRIPTION

Intake Pipe Adapter

CH Bottom Return Adapter

CH Top Supply Adapter

Condensate Trap

Air / Gas Mixing Pipe

Condensate Adapter

Internal Gas Piping

Condensate Air Pressure Switch

Gas Valve

Low Voltage Terminal Block

Exhaust Duct

CH Return Pipe

Main PCB

Heat Exchanger

Optical Flame Detection Sensor

Ignition Transformer

Control Panel CH Supply Pipe

Flame viewing window

Internal Gas Piping

Burner Overheat Switch

Manual ON/OFF Power Switch

Ignitor rod

High Voltage Terminal Block

BLDC Fan

CH Supply Pipe

Air Pressure Switch

Gas Inlet Adapter

CH Supply Adapter

CH Bottom Supply Adapter

Exhaust Vent Adapter

CH Pressure Gauge

Automatic Air Vent

Figure 2 – UFT Components (All Models)

Table 5 – UFT Component List How the Boiler Operates

UFT condensing technology intelligently delivers hydronic heating while maximizing efficiency. Outlined below are the features of the system and how they operate:

Stainless Steel Heat Exchanger - The highly efficient 316L stainless steel fire tube heat exchanger with internal aluminum is designed to extract all available heat from the combustion process and pass it into heat transfer fluid. The stainless steel construction provides protection for longer service life. The heat exchanger offers greater water content, providing lower system pressure and greater overall system efficiency.

10 to 1 Modulating Combustion System - The combustion system is specially designed to provide very high turn down. This combustion system will modulate the burner output to very low levels to match the system demand and achieve better overall control of the heating system for maximum efficiency and reliability.

Control – The integrated control system monitors the system and responds to internal and external signals to regulate fan speed and control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more.

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

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

The control can be set up to monitor outdoor temperature through an outdoor sensor to regulate boiler set point temperature, increasing overall system efficiency while providing great comfort. 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 by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating output from the connected boilers. Through the use of multiple UFT boilers cascaded systems offer greater system turndown and redundancy.

Electronic LCD Display – The high resolution display allows the user to monitor boiler functions. The display also provides the means to program the system parameters to maximize the efficiency of the system design.

Combustion System (Blower – Gas Valve – Mixer – Burner – Spark Ignition) – The highly efficient spark ignition combustion system uses a variable speed blower to adjust combustion as the system requires more or less energy. The negative regulated gas valve provides only the amount of fuel required to ensure clean combustion. The mixer accurately regulates the combination of gas and air throughout the modulating range to ensure high reliability. The burner is constructed of durable ceramic metal fiber for long service life.

Boiler Sensors (Return – Supply – Flue - Outdoor) - Sensors provide highly accurate temperature monitoring to assure accurate system control. These sensor inputs can be monitored through the boiler control system and display.

Pressure Gauge – Allows the user to monitor system pressure. System Safeties – The boiler is provided with many safety features to ensure reliable and safe operation. Each safety is connected to

the boiler control. The boiler will alert the user if an unsafe condition occurs and needs to be addressed. The following are provided safeties: Flue Pressure Switch (monitors flue pressure), Burner High Limit (monitors burner plate temperature), High Limit Water Switch (monitors boiler water temperature), Low Water Sensor (monitors water level in the heat exchanger), optic flame sensor (monitors flame quality), Flue Sensor (monitors flue temperature), Condensate Pressure Switch (monitors pressure to ensure condensation does not back up into boiler).

Manual Air Vent – Each boiler is equipped with an air vent to discharge air from the system during start–up. Intake and Exhaust Adapters – The boiler is equipped with adapters to ease connection to the vent system. The adapters are

provided with clamps and seals to secure field supplied piping, and test ports to ease monitoring of the combustion system. Each boiler is supplied with a 6 inch piece of CPVC that must be connected into the exhaust vent adapter.

Boiler 1 ¼” Inlet and 1 ¼” Outlet Connection – Boilers are equipped with both top and bottom piping connections for greater installation flexibility.

Gas Connection – The boiler is equipped with a ¾” gas connection to connect the incoming gas supply. Field Wiring and Power Switch – Each boiler is supplied with a power switch to cut off power. The boiler is also equipped with two

front mounted terminal strips. These terminal strips are separated into low and line voltage to ease system wiring. Condensate Trap and Hose Assembly – Each boiler has a built-in condensate trap to control the discharge of condensate produced

by the boiler during normal operation. A corrugated condensate hose is also provided to ensure proper drainage of condensate into the pump or drain.

Low Water Cut Off Probe – LWCO is provide with each boiler to assure the boiler has adequate water level to eliminate overheating and even damaging the boiler heat exchanger .

Pump Service Mode – Allows manual operation of pumps to commission system and check pump operation.

PART 4 – PREPARE BOILER LOCATION

A. UNCRATING THE BOILER

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

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the boiler installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.

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

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

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

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 floors of the building. The boiler should be located near a floor drain, or installed in an adequately drained drain pan. HTP WILL NOT be held liable for leakage damages.

To conserve water and energy, insulate all water piping, especially the hot and recirculation water lines.

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

Remove all sides of the shipping crate to allow the boiler to be lifted into its installation location.

B. BEFORE LOCATING THE BOILER

1. Installation Area (Mechanical Room) Operating Conditions

 Ensure ambient temperatures are higher than 32oF/0oC and lower than 104oF/40oC.  Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual.  Avoid continuously high levels of humidity  Never close existing ventilation openings

2. Check for nearby connections to:

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

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

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

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

MINIMUM CLEARANCES

Installation Clearances from Non-

Combustibles / Combustibles

Recommended Service and Proper

Operation Clearances

Top

18 in. (45.7 cm)

Back

0 in. (0 cm)

Bottom

12 in. (30.45 cm)

Front

24 in. (60.9 cm)

Right Side

3 in. (7.6 cm)

Left Side

Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.

Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage, closet, or alcove. 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.

In order for the condensate to properly flow out of the collection system, the boiler must be installed level. Failure to ensure the boiler is installed level will result in improper boiler operation.

Figure 3 – Minimum Service Clearances

6. Clean and flush system when reinstalling an boiler. NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to

make note of the boiler model and serial number.

C. LEVELING

D. CLEARANCES FOR SERVICE ACCESS

See Figure 3 and Table 6 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the boiler without removing it from the space.

Table 6 – Minimum Installation and Service Clearances NOTE: For closet installations, a combustible door or removable panel is acceptable

front clearance. A 3” minimum clearance must be provided from the boiler front cover to the removable panel or combustible door. MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS

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

E. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS

PRECAUTIONS

If the boiler is located in a residential garage, it should be installed per the latest edition of the National Fuel Gas Code, ANSI Z223.1, and CGA-B149 Installation Code in Canada.

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

well off the floor.

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

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For closet or alcove installations, a two pipe venting system must be used. Failure to follow this warning could result in substantial property damage, severe personal injury, or death.

The space must be provided with correctly sized combustion/ventilation air openings for all other boilers located in the space with the boiler. 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.

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

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

Ensure that the intake air will not contain any of the contaminants below. For example, do not pipe intake near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death.

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

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

(Refer to the limited warranty for complete terms and conditions).

Do not install the boiler into a common vent with any other boiler. This will cause flue gas spillage or boiler malfunction, resulting in possible 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.

You must also install air intake piping from outdoors to the boiler flue adaptor. The resultant installation is categorized as direct vent (sealed combustion).

NOTE: To prevent combustion air contamination, see Table 7 in this section when considering exhaust vent and intake pipe termination.

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

G. PREVENT COMBUSTION AIR CONTAMINATION

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

Table 7

H. REMOVING A BOILER FROM A COMMON VENT SYSTEM

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

The boiler must be installed on a wall that can bear its weight (more than 110 lbs. when fully plumbed and full of water). Installing the boiler on a wall which cannot support its weight could result in property damage, personal injury, or death.

This boiler is too heavy for one person to lift. It is highly recommended to install the boiler with two people. Use caution as to not drop the boiler, which could damage the boiler and cause property damage and/or severe personal injury. Verify that the boiler is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

Figure 4 - CO Warning Label

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

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

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

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

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

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

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

7. Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

I. WALL-MOUNTING THE BOILER

The boiler may be installed on any suitable internal wall (suitable sound-proofing may be required when installing onto a stud partition wall).

POSITIONING THE BOILER ON THE WALL

1. Attach the wall bracket on the location where you want to install the boiler. Ensure it is level and on stud (16” centers) before proceeding.

2. Mark the four drill holes with a pencil or marker. Remove the wall bracket.

3. Drill four (4) holes using a 5/32 drill bit at the marked hole locations.

4. Mount the wall bracket to the wall with the four (4) included anchor bolts. Ensure the mounted bracket is level. See Figure 5A.

5. Align the boiler bracket grooves on the back of the boiler with the tongues on the wall bracket and hang the boiler on the bracket. See Figure 5B.

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Vent this boiler in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death.

DO NOT mix vent systems or materials unless specifically told to do so in this manual.

DO NOT thermally insulate the exhaust vent or intake pipes.

DO NOT use an electric damper, vent damper, or draft hood with this boiler.

DO NOT locate the exhaust vent or intake pipe terminations where exposed to prevailing winds.

Moisture will be produced by the exhaust vent. Take precautions when determining exhaust vent termination. Moisture may fall from the vent termination to the ground and turn to ice in freezing conditions. Moisture or ice can produce a hazardous condition.

Exhaust condensate is acidic, and could deteriorate the surface below the exhaust vent termination. Ensure this surface is in good repair (sealed, painted, etc.) to prevent deterioration.

Pitch the exhaust vent pipe ¼” back to the boiler. This ensures that condensate in the exhaust vent returns to the boiler and drains properly.

For closet and alcove installations: CPVC, polypropylene, or stainless steel venting material MUST BE USED. Failure to follow this statement could result in product damage, severe personal injury, or death.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

Figure 5 – Wall Mounting the Boiler

PART 5 – VENTING

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES

1. Vent system must be installed in accordance with local codes, or, in absence of local codes, the National Fuel Gas Code, ANSI Z223.1 / NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

2. For installation in Canada, installer supplied plastic vent piping must comply with CAN/CGA B149.1 and be certified to the Standard for Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products. Clean and dry all applicable surfaces before applying cement.

3. This boiler is designed to be installed as a direct vent (sealed combustion) type. Combustion air must be supplied directly from the outdoors to the burner, and the flue (exhaust) gases should be vented directly to the outdoors through the wall or roof.

4. This boiler uses 2” or 3” diameter pipe for exhaust vent and intake pipe. It is important to ensure an airtight seal from the boiler collar to the vent terminations. See Table 9 for a list of Approved Vent Materials.

5. Do not install venting system components on the exterior of the building except as specifically required by these instructions.

 Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.  Maintain the correct clearance and orientation between the exhaust vent and intake pipe terminals.  The exhaust vent and air intake terminals must be at the same height and their center lines must be spaced apart 1 foot

minimum.

 The bottom of the exhaust vent and intake pipe terminals must be at least 1 foot above the normal snow accumulation level. In

no case should these terminals be installed less than 1 foot above normal snow accumulation level.

 Do not install the exhaust vent terminals directly above windows or doors.  Intake pipe terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming

pools.

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DESCRIPTION

CANADA

Clearance above grade, veranda, porch, deck, or balcony

1 foot

Clearance to window or door that may be opened

1 foot

3 feet

Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

terminal within a horizontal distance of 2 feet from the center

line of the terminal

Clearance to unventilated soffit

Clearance to outside corner

* G Clearance to inside corner

Clearance to each side of center line extended above meter

/ regulator assembly

3 feet with a height 15 feet

above meter / regulator

assembly

Clearance to service regulator vent outlet

3 feet

Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other boiler

1 foot

3 feet

Clearance to a mechanical air supply inlet

3 feet above if within 10 feet

horizontally

6 feet

Clearance above paved sidewalk or driveway located

7 feet

Clearance under veranda, porch, deck, or balcony

1 foot

 For sidewall venting, the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot. It is

recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces.

 For roof venting, minimum horizontal distance between any adjacent exhaust vent termination is 1 foot.  If the exhaust vent is to be terminated in a walled off 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 flue gas does not get trapped and possibly recirculated into the intake air pipe, which could contaminate the combustion air.

Figure 6 – Vent Termination Detail

Table 8 – Vent Termination Clearances *NOTE: For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA-B 149.1, please use clearances in accordance with local

installation codes and the requirements of the gas supplier.

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NOTICE

Consult Table 9 or the most recent edition of ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 as well as all applicable local codes and regulations when selecting vent pipe materials.

APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or Intake

pipe and fittings

CPVC schedule 40

ASTM-D2846

PP, CPVC, and PVC venting must be

ULC-S636 Certified. IPEX is an approved

manufacturer in Canada, supplying vent

material listed to ULC-S636.

PVC schedule 40

ANSI/ASTM D1785

Polypropylene

UL-1738

Stainless Steel AL29-4C

Certified for Category IV and

direct vent boiler venting

Certified for Category IV and direct vent

boiler venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements & Primers

CPVC

ANSI/ASTM F493

 The exhaust and intake components installed with this boiler must be used for near boiler piping BEFORE transitioning to the

approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.  DO NOT use Foam Core Pipe (CPVC cellular core, Radel, etc.) in any portion of the exhaust piping from this boiler.  DO NOT connect PVC/CPVC to PP without an approved vent connector.  When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the boiler vent connection, and at the termination

when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

 DO NOT insulate non-metallic exhaust vent pipe or fittings.  DO NOT obstruct the flow of combustion or ventilation air.  When using Pipe Cement/Primer, follow the instructions included with the Cement/Primer closely. Clean and dry all applicable

surfaces before applying.

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

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 must be pitched a minimum of ¼” 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.

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.

2” COMBINED VENT LENGTH

3” COMBINED VENT LENGTH

MAXIMUM

50’ (15M)

100’ (30M)

B. APPROVED VENT MATERIALS

Table 9 – Approved Venting Materials

C. ALLOWED COMBINED VENT LENGTHS

Table 10 – Approved Vent Lengths NOTE: When using more than 1 elbow, reduce maximum allowable length:

 5 feet (1.5M) for each additional 3” 90o elbow  2.5 feet (.75M) for each additional 3” 45o elbow  8 feet (2.4M) for each additional 2” 90o elbow  4 feet (1.2M) for each additional 2” 45o elbow

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Failure to properly install the included 6” length of 3” CPVC pipe BEFORE venting the boiler could result in product damage, severe personal injury, or death.

D. TIGHTENING BOILER COLLAR TO EXHAUST VENT AND INTAKE PIPE

NOTE: The included 6” length of 3” CPVC pipe MUST BE INSTALLED in the exhaust vent connection BEFORE venting the boiler.

This boiler uses 3” diameter adapters for exhaust vent and intake pipe. In order to use 2” pipe, it is required to reduce pipe size in a vertical length of pipe with a reducing coupling (not included). Follow the steps below to install 3” pipe into the boiler adapter. See Figure 7 for details.

1. Clean and dry the boiler connection. DO NOT use primer or cement on the boiler connection.

2. Push the included 6” length of CPVC pipe into the connection until it touches the bottom of the fitting.

3. Tighten the clamps using a screwdriver.

4. Ensure the pipe is secure before continuing installation.

5. For 2” installations, install a reducing coupling in a vertical section of pipe. See Figure 8.

Figure 7 – Installing the 6” Length of CPVC into the Exhaust Vent Connection

Figure 8 – Transitioning from 3” to 2” Vent Pipe

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

E. VENT TERMINATION

1. Two Pipe Roof and Sidewall Vent Terminations

Figure 9 – Direct Vent, Roof and Sidewall Vent Terminations

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2. Direct Vent, Optional Horizontal and Vertical Vent Kits

Figure 10 – Direct Vent, Vent Terminations (With Optional Kits)

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3. Snorkel Venting

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

NOTES:

A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake.

C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D. Minimum 12” between vents when installing multiple vents. E. 12” minimum beyond air intake.

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SAFETY INSTRUCTIONS

Do not connect any other boiler vents to the boiler exhaust vent or intake pipes.

Figure 13 – Internal Condensate Trap

Figure 12 - Screen Installation

4. Screen Installation

After connecting the intake air and exhaust vent pipes, it is required to install the included screens into the exhaust vent and intake pipe terminations to prevent damages to the unit due to blockages. Clean the vent terminations and cement the screens into the terminations. See Figure 12 for installation detail.

PART 6 – INSTALL THE CONDENSATE DRAIN

1. Due to its efficient design, the boiler produces condensate (water) as a normal by-product. This condensate is acidic, with a pH level between 3 and 4. This condensate must be drained away from the boiler and disposed in accordance with all local regulations.

2. Use corrosion-resistant materials approved by the Authority Having Jurisdiction (AHJ) to drain condensate. In the absence of an AHJ, the included flexible plastic hose, or field supplied ½” PVC and CPVC drain pipe complying with ASTM D1785, F441, or D2665 may be used. Cement and primer must comply with ASTM D2564 or F493. For Canadian applications, use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

3. Local building codes may require an in-line neutralizer to be installed (not included) to treat the condensate. Follow all the installation instructions included with the neutralizer. If a neutralizer is installed, periodic replacement of the limestone (or neutralizing agent) will be required. The rate of depletion of the limestone varies with usage of the boiler. During the first year of boiler operation, check the neutralizer every few months for depletion.

4. Route the drain line to a nearby floor drain, laundry tub, or condensate pump. NOTE: If a nearby laundry tub is used as a disposal for waste water from the washing machine, draining

the condensate into this tub allows the soapy water discharge to neutralize the acidic condensate.

5. An error will appear on the boiler display if condensate line is blocked. The boiler will not operate with a blocked condensate line. It is extremely important to have this condition repaired by a qualified service technician.

NOTE: This boiler has an internal condensate trap that must be cleaned and maintained. See Maintenance section of this manual for instructions on maintaining the trap.

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

It is very important that the condensate piping be no smaller than ¾”. To prevent sagging and maintain pitch, condensate piping should be supported with pipe supports, and pitched ¼” per foot to allow for proper drainage.

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate freezes in the line, or if line is obstructed in any other manner, condensate can exit from the tee, resulting in potential water damage to property.

FIRE AND/OR EXPLOSION HAZARD

To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional.

Always match the boiler with the type of gas supplied to the unit (natural gas or LP gas). Propane ready boilers have the suffix “LP” after the model serial number.

Make sure the gas line pressures are within normal limits. Pressures outside normal limits can result in poor performance and hazardous operating conditions.

Failure to follow these guidelines could result in property damage, personal injury, or death.

Figure 14 – Condensate Piping with Condensate Neutralizer / Condensate Piping with Condensate Neutralizer and Pump

NOTES:

1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line.

2. Plastic pipe should be the only material used for the condensate line. Steel, brass, copper, or other materials will be subject to corrosion or deterioration.

3. NEVER install condensate lines outside. It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.

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

PART 7 – GAS PIPING

LP-542 REV. 7.16.15

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Maximum Natural Gas Delivery Capacity – Length of Corrugated Stainless Steel Pipe in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

¾”

192

137

112

1”

383

269

218

188

168

153

132

118

1 ¼”

639

456

374

325

292

267

232

208

171

148

1 ½”

1260

888

723

625

559

509

440

393

320

277

2”

2930

2080

1700

1470

1320

1200

1040

933

762

661

Maximum Natural Gas Delivery Capacity – Length of Black Iron Pipe (Sch. 40 Metallic) in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

¾”

360

247

199

170

151

137

117

104

1”

678

466

374

320

284

257

220

195

157

134

1 ¼”

1390

957

768

657

583

528

452

400

322

275

1 ½”

2090

1430

1150

985

873

791

677

600

482

412

2”

4020

2760

2220

1900

1680

1520

1300

1160

928

794

Maximum Liquid Propane Delivery Capacity – Length of Corrugated Stainless Steel Pipe in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

¾”

303

216

177

153

137

126

109

1”

605

425

344

297

265

241

208

186

143

129

1 ¼”

971

661

528

449

397

359

307

270

217

183

1 ½”

1990

1400

1140

988

884

805

696

621

506

438

2”

4640

3290

2680

2330

2080

1900

1650

1480

1210

1050

Maximum Liquid Propane Delivery Capacity – Length of Black Iron Pipe (Sch. 40 Metallic) in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

¾”

608

418

336

287

255

231

212

197

175

140

1”

1150

787

632

541

480

434

400

372

330

265

1 ¼”

2350

1620

1300

1110

985

892

821

763

677

543

1 ½”

3520

2420

1940

1660

1480

1340

1230

1140

1010

814

2”

6790

4660

3750

3210

2840

2570

2370

2200

1950

1570

Figure 15 – Excess Flow Valve (EFV)

A. ADDITIONAL PRECAUTION FOR EXCESS FLOW VALVE (EFV)

If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and

maximum flow capacity ratings. An improperly sized EFV will not allow for a full flow of gas to the boiler and will cause the boiler to malfunction.

B. GAS PIPE SIZING TABLES

1. Gas Pipe Sizing

This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard for Natural Gas is 1100 BTU/ft3. Contact the local gas supplier for actual BTU/ft3 rating.

2. Natural Gas Pipe Sizing

The following tables list maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 0.5 psi or less and a pressure drop of 0.5 inches water column, based on a

0.60 specific gravity for natural gas.

Table 11 – Natural Gas Delivery Capacity – Corrugated Stainless Steel Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

Table 12 – Natural Gas Delivery Capacity – Black Iron Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

3. LP (Liquid Propane) Gas Pipe Sizing

The following is intended for use for piping between a Single or Second Stage (Low Pressure) Regulator and the boiler. The following tables list maximum capacity of pipe in cubic feet of gas per hour for an inlet pressure of 11 inches water column and specific pressure drop of 0.5 inches water column based on 1.5 specific gravity for liquid propane.

Table 13 – Liquid Propane Delivery Capacity – Corrugated Stainless Steel Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

Table 14 – Liquid Propane Delivery Capacity – Black Iron Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

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C. GAS CONNECTION REQUIREMENTS

1. The gas connection fitting on the boiler is ¾” male NPT. NOTE: The pipe size must not be less than ½”.

2. The supply line must be sized for the maximum output of the boiler being installed. If there are additional gas boilers from the main supply line, measure the size of the supply line according to the COMBINED total maximum BTUH draw for the boilers as if they were operating at the same time.

3. Measure the length of the gas supply line from the gas meter to the boiler. Boiler must be installed downstream of the gas meter to ensure adequate gas supply. Use the tables in this manual or refer to the gas line manufacturer’s sizing information to determine the correct supply pipe size.

4. A manual gas shut-off valve should be installed in the gas supply line close to the boiler. See Figure 16 for detail.

5. To facilitate any future maintenance, it is also recommended that an approved gas union fitting be installed in the supply line between the shut-off valve and the connection on the boiler.

6. Test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the boiler.

7. Leak test the gas line pipe before placing the boiler in operation. Only use approved leak detector liquid solutions to check for leaks.

8. Do not operate the boiler until all connections have been completed and the heat exchanger is filled with water.

10. When using flexible gas lines, ensure that the pipe’s inner diameter and connector is sufficient to supply the required BTUs. Also, ensure that the flexible line has no crimps or tight bends in it, as this will restrict gas flows.

Figure 16 – Gas Line with Shut-Off Valve Detail

Figure 17 – Natural Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Boilers

Figure 18 – LP Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Boilers

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Use at least the MINIMUM pipe size for all boiler loop piping (connecting the boiler to and from the primary / secondary connection). Failure to follow these guidelines could result in system problems, increased installation cost, and possible boiler failure. SUCH COSTS AND FAILURES ARE NOT COVERED BY WARRANTY.

PART 8 – WATER PIPING

A. GENERAL PLUMBING CONNECTION GUIDELINES

 Pipe material must be suitable to meet local codes and industry standards.  The pipe must be cleaned and without blemish before any connections are made.  Do not apply a torch within 12” of the boiler. Doing so could damage the boiler. Such damages ARE NOT covered by product

warranty.

 The size of the central heating pipe should be 1” diameter.  To ease future maintenance isolation valves are recommended on both the CH and DHW loops.  All piping should be insulated.

Figure 19 – Piping Legend

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To control thermal expansion, a thermal expansion tank suitable for potable water should be installed in systems with an installed backflow preventer. DO NOT use a closed type expansion tank. Follow expansion tank manufacturer’s specifications to properly size an expansion tank to the installation. Failure to properly accommodate thermal expansion could result in property damage, severe personal injury, or death.

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

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.

B. BACKFLOW PREVENTER

It may be recommended to use a back flow preventer – check local codes. If a back flow preventer or a no return valve is used, a thermal expansion tank must be installed on the cold water supply between the boiler and valve.

C. CENTRAL HEATING PIPING SYSTEM WATER PIPING METHODS

EXPANSION TANK AND MAKE-UP WATER

1. Ensure that the expansion tank is designed and sized to correctly handle system water volume and temperature. Check technical specifications for water content of this boiler.

2. The expansion tank must be located following recognized design methods. See expansion tank manufacturer’s instructions for details.

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

DIAPHRAGM (OR BLADDER) EXPANSION TANK

Always install an automatic air vent on top of the air separator to remove residual air from the system. Use both thread tape and pipe dope to connect to the 1 ¼” heating water outlet and inlet.

D. CIRCULATOR SIZING

The heat exchanger has a pressure drop that must be considered in your system design. Refer to Table 15 for pressure drop through the heat exchanger.

Table 15 – Pressure Drop through the Heat Exchanger

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SYSTEM TEMPERATURE RISE CHART

MODEL

20oF ∆T

30oF ∆T

40oF ∆T

Flow Rate (GPM)

Head (FT)

Flow Rate (GPM)

Head (FT)

Flow Rate (GPM)

Head (FT)

UFT-80W

7.6

3.1

5.1

1.8

3.8

1.2

UFT-100W

9.5

4.7

6.3

2.3

4.8

1.7

UFT-120W

11.4

5.4

7.6

2.5

5.7

1.6

UFT-140W

13.3

7.3

8.9

3.5

6.7

2.1

The chart below represents the various system design temperature rise through the boiler along with their respective flows and friction loss, which will aid in circulator selection.

Table 16 – Boiler Flow Rates

Figure 20 – Zoning with Zone Valves and Indirect Water Heating – Direct Piping NOTES:

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

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

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

4. The minimum pipe size of CH piping should be 1” in diameter.

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

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

7. VERY IMPORTANT – Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.

8. In a valve-based system, each heating zone has a zone valve which opens when that zone calls for heat. Each zone thermostat is wired to its corresponding zone valve. Contacts in the zone valves provide a signal to the boiler to operate when there is a call for heat.

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Figure 21 – Zoning with Pumps and Indirect Fired Water Heater – Direct Piping NOTES:

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

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

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

4. The minimum pipe size of DHW piping should be ¾” diameter and CH piping should be 1” in diameter.

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

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

7. VERY IMPORTANT – Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.

8. Each heating zone of a pump-based system has its own circulator with turns on when a zone thermostat calls for heat.

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Figure 22 – Zoning with Zone Valves and Indirect Water Heating – Primary / Secondary Shown NOTES:

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

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

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

4. The minimum pipe size of CH piping should be 1” in diameter.

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

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

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

8. VERY IMPORTANT – Minimum flow rates outlined in this manual must be maintained through the heat exchanger to minimize short cycling.

9. In a valve-based system, each heating zone has a zone valve which opens when that zone calls for heat. Each zone thermostat is wired to its corresponding zone valve. Contacts in the zone valves provide a signal to the boiler to operate when there is a call for heat.

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Figure 23 – Zoning with Pumps and Indirect Fired Water Heater – Primary/Secondary Shown NOTES: