Whirlpool EDP-EDN User Manual
Installation, Operation and Maintenance Instructions
P.O. Box 310
Lynnfield, MA 01940
Phone: 781-961-1660
Fax: 781-334-2541
For sales, parts and service, call 781-961-1660
Installation,
Operation and
Maintenance
Instructions for
Endurance
EBP Series Modulating Combination Boiler
(natural or propane gas)
EDP Series Modulating Hydronic Boiler
(natural or propane gas)
EDN Series Modulating Boiler, non ferrous
(natural or propane gas)
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
If the information in this manual is not
W ARNING
followed exactly , a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHA T 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
nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed by a
qualified installer , service agency, or gas
supplier .
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d’incendie ou d’explosion ou
pour éviter tout dommage matériel, toute
blessure ou la mort.
Ne pas entreposer ni utiliser d’essence ni
d’autres vapeurs ou liquides inflammables dans
le voisinage de cet appareil ou de tout autre
appareil.
QUE F AIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
vous trouvez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés p a r
un installateur ou un service d’entretien qualifié ou
par le fournisseur de gaz.
AVERTISSEMENT
30-418D
Page 2
LAARS HEATING SYSTEMS
TABLE OF CONTENTS
SECTION 1.
General Information
1A. Introduction................................................... 3
1B. Codes and Standards ................................... 3
1C. Unpacking the Appliance.............................. 4
1D. Locating the Appliance.................................. 4
1E. Clearances ................................................... 4
SECTION 2.
Venting Options
2A. Direct Vent Kits............................................. 4
2B. Installing Direct Vent Kits.............................. 4
2C. Locating the Vent on an Outside Wall...........4
2D. Stainless Steel Single Pipe Horizontal
and Vertical Vents.........................................7
2E. Air Source for Combustion
(when not direct vented) ............................... 7
2F. Connecting Special Gas Vent
to the Appliance ............................................ 8
2G. Securing Special Gas Vent...........................8
SECTION 3.
Gas Piping
3A. Gas Piping .................................................... 8
3B. Domestic Water Piping (EBP only) ............... 9
SECTION 7.
Maintenance and Component Description
7A. Unit Pump................................................... 19
7B. Gas Valve ...................................................19
7C. Safety Limit Switch ..................................... 19
7D. Operating Control Printed Circuit
Board (PCB) ............................................... 19
7E. Igniter / Flame Sensor Assembly ................ 20
7F. Transformer ................................................ 20
7G. Blower ........................................................ 20
7H. Transfer Tank (EBP only) ........................... 20
7I. Thermostatic Union (EDP/EDN only) .......... 20
7J Cleaning the Boiler Coil ..............................20
SECTION 8.
Servicing
8A. Sequence of Operation ...............................21
8B. Trouble Shooting - Fault Codes .................. 22
8B-1. Fault Code Identification.................... 22
8B-2. Fault Correction................................. 22
8B-3. Resolving Lockouts ...........................22
Fault Trees ................................................. 23
SECTION 9.
Gas Valve Calibration
9A. Gas Valve Calibration ................................. 31
SECTION 4.
Hydronic Heat Piping
4A. Hydronic Piping........................................... 10
4B. Using in a Combined Hot Water
Heating and Chilled Water
Cooling System........................................... 12
4C. Water Quality and Treatment...................... 13
SECTION 5.
Electrical Connections
5A. Electrical Connections ................................ 13
SECTION 6.
Boiler Start-UpP
6A. Common Vent Test..................................... 17
6B. Filling the System ....................................... 18
6C. Firing Burner............................................... 18
6D. Mode and On/Off Buttons Operation .......... 19
SECTION 10.
Symptom Evaluations
10A. Delayed Ignition .......................................... 31
10B. Short Cycling .............................................. 32
10C. Noisy Operation ..........................................32
10D. Insufficient Hot Water (EBP only) ............... 32
10E. High Gas Consumption............................... 33
SECTION 11.
Parts Identification.......................................... 34
Endurance
Page 3
SECTION 1.
General Information
1A. Introduction
EBP - This appliance is a low pressure, direct
vent, hot water boiler that provides priority domestic
hot water on demand as well as hydronic space heating
system. The unit has a twenty gallon tank which holds
boiler water (and is not domestic water storage).
The boiler water is kept hot at all times to
provide immediate response to call for heat or
domestic water. Domestic water is heated by the boiler
water through a stainless steel plate heat exchanger.
EDP/EDN - This appliance is a low pressure,
direct vent, cold start hot water boiler that provides
heat for hydronic space heating.
Both appliances incorporate a circulating pump
and a bypass loop, and provide circulation for the
heating system and adequate flow for its own needs.
It may be necessary to install a system circulator to
achieve the required flow rate through the system.
Both appliances feature a forced draft, premixed
combustion system. All air for combustion is supplied
with the gas to the burner (flame holder). Both the
intake air and the gas are metered through separate
orifices before entering the combustion air blower.
The blower forces the air/fuel mixture through the
flame holder and into the combustion chamber. The
mixture is ignited from the hot surface ignitor and
burns. Hot gases are forced out between the passes of
the heat exchanger into the flue collector. Flue gases
are discharged into the outside atmosphere through the
vent terminal.
The appliance can operate with a concentric vent
system that will provide outside air for combustion.
Other venting arrangements can be provided for the
appliance to include an alternative 50 equivalent feet
maximum horizontal or condensate trapped vertical
vent.
1B. Codes and Standards
The Endurance may be a direct vent or Category
IV Boiler. All installations must be made in
accordance with:
1. The National Fuel Gas Code, ANSI Z223.1 latest
edition, or.
2. CAN/CGA B149 “Installation Codes for Gas
Burning appliances and Equipment” and with the
requirements of the local utility or other
authorities having jurisdiction. Such application
requirements take precedence over the general
instructions contained herein.
All electrical wiring is to be done in accordance with:.
1. The National Electrical Code ANSI / NFPA70
latest edition or
Figure 1. Combo Heating/Domestic Water (Model EBP).
Figure 2. Heating Unit (Model EDP/EDN).
Page 4
LAARS HEATING SYSTEMS
2. The CSA standard C22.1 “Canadian Electrical
Code - Part 1” and local codes.
All vent installations must be made in accordance with:
1. Part 7, Venting of Equipment of the National Fuel
Gas Code, ANSI 223.1 latest edition, or applicable
provisions of the local building codes or
2. CAN/CGA B149.
When required by the jurisdiction authority, the
installations must conform to the American Society of
Mechanical Engineers' Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, No.
CSD-1.
1C. Unpacking the Appliance
Remove all packing and tie down materials.
Make immediate claims (to the carrier) if the
appliance and its packaging are damaged.
1D. Locating the Appliance
The appliance is designed for installation on
combustible flooring, in alcoves, basements, closets,
or utility rooms. It must not be installed on carpeting.
IF INSTALLED IN A FINISHED AREA,
PROVISION SHOULD BE MADE FOR DRAINAGE
OF ANY ACCIDENTAL SPILLAGE OR LEAKAGE.
The location for the unit should be chosen with
regard to venting dimensions, convenient access to
piping, and accessibility for service and cleaning.
The boiler shall be installed so that the gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
SECTION 2.
Venting Options
2A. Direct Vent Kits
When using a direct vent kit, the appliance is a
sealed combustion unit. All of its air is drawn in from
the outside through the 5" outer pipe. Flue gases are
vented through the 3" vent pipe positioned inside the
5" intake pipe. The hot flue gases are surrounded by
the intake flow of cooler outdoor air. This vent system
may be installed through, and be in contact with,
combustible materials. Except for roof vent kit (max 7'
vertical) all venting should pitch away (down) from
unit.
2B. Installing Direct Vent Kits
The direct vent appliance is certified with a
maximum of 15 linear feet (4.6m) of vent pipe and
three sets of elbows. There are two basic vent kits
available, together with various additional elbow and
extension kits if required (see Figures 3 and 4).
Detailed installation instructions are provided in the kits.
For additional length and/or fittings, the
following components are available:
3" and 5" elbow set Part Number 2400-330
5" x 1' extensions Part Number 2400-332
5" x 2' extensions Part Number 2400-334
5" x 2' to 4' adjustable
extensions Part Number 2400-336
3" x 1' extensions Part Number 2400-338
3" x 2' extensions Part Number 2400-340
3" x 2' to 4' adjustable
extensions Part Number 2400-342
1E. Clearances
The dimension and criteria in Table 1 should be
followed when choosing the location for the unit.
2C. Locating the Vent on an Outside Wall
The center line of the vent opening must be at
least 16½" (419mm) above grade, outside, and at least
13½" (343mm) from any other building opening, such
as doors, windows, etc. Vent opening should be well
away from shrubbery or other obstructions that would
A B
AGA/CGA AGA CGA
in.
Left Side 1 25 6 152 24 610
Right Side 1 25 12 305 24 610
Top Side 1 25 14 356 24 406
Back 1 25 9 229 12 305
Front 1 25 24 610 24 610
mm
in.
mm
in.
mm
prevent free air flow to and from vent terminal. Do not
terminate vent under decks, stairways, or car ports.
NOTE: Should it be impossible to locate
opening center line 16½" (419mm) above grade, use
optional vent terminal extension (p/n 2400-278).
Vent terminals must also be at least 3' (0.9m)
above any forced air inlet located within 10' (3.0m),
and at least 7' (2.1m) above grade when located
adjacent to a public walkway, and cannot terminate in
Vent: Direct Vent 0 0 0 0
Vent: Category IV 3 76 3 76
A. Minimum clearance from combustible construction to
meet AGA/CGA requirements.
B. Recommended clearance for accessibility and venting.
Table 1. Clearances
a location where condensate or vapor may be a
nuisance, hazard, or could be a detriment to other
equipment. Vent terminals must have a minimum
clearance of 4' (1.2m) (6' (1.8m) in Canada)
horizontally from, and in no case above or below
electrical meters, gas meters, regulators, and relief
equipment unless a 4' (1.2m) horizontal distance is
maintained.
Endurance
Page 5
Figure 3. Part number 2400-500 provides all of the required venting materials for appliance installations adjacent to an
outside wall and for installation of wall mounted units. Requires minimum above unit clearance of 13" (330mm) and
provides maximum horizontal length of 24" from unit center line to outside wall face.
Figure 4. Part number 2400-326 for vent installations which require adjustable height and horizontal run. This kit
provides vertical and horizontal lengths of pipe from 2' to 3½' (0.6 to 1.1m). To adapt 2400-278 (vent terminal
extension) remove 3" screen section of telescoping piece. Companion section will directly fit extension.
Page 6
Figure 5. Part number 2400-328 provides all of the required venting materials for appliance installations that require
adjustable horizontal run, but a short vertical run. It requires minimum above unit clearance of 13" (330mm) and
provides for an adjustable horizontal run of 2' to 3-1/2' (0.6 to 1.1m).
LAARS HEATING SYSTEMS
Figure 6. Part number 2400-360 provides the required venting materials for concentric through-the-roof vents. It allows
for a vertical vent, straight off the top of the unit, from 2 to 7 feet (0.6 to 2.1m).
Endurance
Figure 7. For Appliances Certified as Direct Vent.
Figure 8. Typical vent installation with 18" or less
overhead clearance to outside.
Page 7
2D. Stainless Steel Single Pipe Horizontal
and Vertical Vents - Category IV
Stainless steel special gas Vent listed to U.L.
Standard 1738 and U.L.C. Standard 636 may be used
Minimum clearance from
combustibles (vent) 3" 76mm
Max. flue gas temp. 325°F 163°C
Max. vent pressure 1.5" WC 0.4kPa
Max. equivalent ft. of venting 3" 76mm
(any combination of horizontal diameter diameter
or vertical) 50 equiv. ft. 15.2m
Max. equivalent ft. of venting 100 equiv. ft. 30.5m
(any combination of horizontal
or vertical) 4" diameter 102mm dia.
Table 2. Appliance Venting Design Data.
to vent all models. Vent pipe and fittings are
manufactured to these standards by HeatFab, Inc.
under the trade name of Saf-T Vent
under the trade name of Z-Vent. Follow the Special
Gas Vent manufacturer's instructions regarding design,
location and assembly of the vent system.
The appliance may be vented with any number of
elbows or fittings provided that the maximum
equivalent feet of venting is not exceeded. Elbows
(90°) in the vent system shall be considered to be 5
equivalent feet (1.5m). When vented with special gas
vent, the appliance must not be common vented with
any other appliance.
For applications requiring vertical venting
through a roof, the above limitations apply. Vertical
vents greater than 7' (2.1m) in length must offset a
condensate trap tee p/n 2400-358 adjacent to the
appliance. Utilize vent cap p/n 2400-370 to terminate
vertical venting.
®
and by Z-Flex
™
Figure 9. Multiple Concentric Vent Clearances.
When appliances are used, the concentric vent
terminals must be at least 12" apart, edge-to-edge (see
Figure "term").
Do not locate the vent terminal where blockage
by snow is a possibility, or where flue products could
strike against building materials and cause
degradation. If the vent terminal location chosen is
less than 18" below an overhang, the 3" vent pipe
must extend to the outside edge of the overhang (see
Figure 6).
2E. Air Source For Combustion
(when not direct vented)
When using Category IV venting methods the
appliance draws all combustion air through its top and
from the adjacent space. When locating the appliance
in unconfined spaces in buildings, infiltration may be
adequate to provide air for combustion and ventilation.
However, in buildings of unusually tight construction,
or when locating the appliance in a confined space,
additional air should be provided and the following
guidelines must be followed.
1. If the space is in a building of unusually tight
construction, air should be obtained from
outdoors, or from spaces which freely connect
with outdoors.
2. For boilers in confined rooms, two permanent
openings shall be provided - one within 12"
(305mm) of the ceiling, and one within 12"
(305mm) of the floor of each room. Each
opening shall be at least one square inch
Page 8
Figure 10. Special Gas Vent Connection.
Figure 11. Non-Concentric Combustion Air Source.
(6.5 sq. cm) per 1,000 BTU/hr (293W) boiler
input, but not be less than 100 square inches
(645.2 sq. cm). These openings shall freely
connect with areas having adequate infiltration
from outside.
3. When all air is provided from outdoors, the
confined space shall be provided with one
opening within 12" of the ceiling. This opening
shall connect directly, or by ducts, with outdoors
or spaces (crawl or attic) that freely connect
with the outdoors, and shall have a minimum free
area of:
a. 1 sq. in. per 3000 BTU/hr (7 cm
2
/kw) of the
total input rating of all equipment located
in the enclosure, and
b. Not less than the sum of the areas of all
vent connectors in the confined space.
2F. Connecting Special Gas Vent
to the Appliance
Part number 2400-372 is used with a vent
terminal (p/n 2400-277) to secure the 3 inch special
LAARS HEATING SYSTEMS
gas vent to the flue outlet of the appliance. Heat-Fab
pipe or fittings (p/n 2400-350 or 2400-352) or the male
end of Z-Vent pipe (Z-Vent # 02 SVEPXX030) may
be installed over the flue outlet of the Appliance (see
Figure 10).
2G. Securing Special Gas Vent
Attach p/n 2400-277 with sheet metal screws to
the 5" collar on the appliance with a short piece of 5"
pipe or to the end of the 5" combustion air duct.
Attach p/n 2400-372 bracket and tighten clamp. Form
the tabs on the bracket onto the special gas vent pipe
and secure the tabs with the 3" clamp. After the clamp
has been tightened, fold the end of the tabs down over
the clamp (see Figure 10).
DO NOT use screws in any portion of the 3"
special gas vent.
When providing combustion air from another
location, the connection of the 5" duct to the appliance
must be secured with sheet metal screws.
Each 5" joint in the 5" duct must be secured with
sheet metal screws.
In this type of installation, p/n 2400-372 must be
used to secure the special gas vent at the point where it
exits the duct. The combustion air supply should be
protected from debris entering the duct with an
appliance vent terminal, p/n 2400-277, as shown in
Figure 8 or with a large mesh screen.
Follow the special gas vent manufacturer's
instructions for cleaning and sealing all parts before
assembling.
Apply ¼" bead of silicone sealer (GE108 or
Novagard 400) to the 3" flue outlet of the appliance
approximately 1" from the end.
Slide 3" inner vent pipe or 1-880 adapter, when
using outer 3" telescoping section, over the appliance
flue outlet and push down to stop (do not force pipe
beyond stop).
Apply another bead of silicone around this joint
and smooth out.
Apply ¼" bead of silicone to subsequent 3" joints.
An alternate, nonconcentric combustion air
source may be installed (as shown in Figure 11),
provided that the minimum 4" diameter combustion air
duct does not exceed 15' (4.6m). Termination should
include an air screen and be located in a qualified air
space (see Section 2E) or outside.
SECTION 3.
3A. Gas Piping
The appliance requires an inlet gas pressure of at
least 4" w.c. (1.0kPa) and no greater than 13" WC
(3.2kPa). Check with your local gas utility or supplier
for availability of this pressure range.
Refer to Table 3 to size the supply piping to
minimize pressure drop between meter or regulator
and unit.
Endurance
Page 9
Length
ft.
10
20
30
40
50
75
100
150
of Pipe
m
3
6.1
9.1
12.2
15.2
22.9
30.5
45.7
MBTU/h
1/2" 3/4" 1" 1-1/4"
MBTU/h
278
190
152
130
115
93
79
64
Additional length to be added for each tee or bend
ft
1.7
132
92
73
63
ft
1.3
kW
38.7
27
21.4
18.5
m
0.4
1. Run gas supply line in accordance with all
applicable codes.
2. Locate and install manual shutoff valves in
accordance with state and local requirements.
3. Install drip leg, ground joint union and drip cap
to trap sediment and for test gauge access.
4. Support all piping with proper hangers.
5. All threaded joints should be coated with piping
compound resistant to the action of liquefied
petroleum gas.
6. The boiler and its individual shutoff valve must
be disconnected from the gas supply piping
system during any pressure testing of that system
at test pressures in excess of ½ psig (3.5kPa).
7. The boiler must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the
gas supply piping system at test pressures equal
to or less than ½ psig (3.5kPa)
8. The boiler and its gas connection must be leak
tested before placing the boiler in operation.
9. Purge all air from gas lines.
Capacity of Pipe
Table 3.
kW
81.5
55.7
44.5
38.1
33.7
27.2
23.1
18.8
m
0.5
MBTU/h
520
350
285
245
215
175
150
120
ft
2.2
kW
152.4
102.6
83.5
71.8
63
51.3
44
35.2
m
0.7
MBTU/h
1050
730
590
500
440
360
305
250
ft
2.7
be no higher than 120°F mixed delivery
temperature or as local codes dictate.
RECOMMENDS ANTI-SCALD TEMPERING
(MIXING) VALVES (see Figure 12).
2. Connect gate or shutoff valve 13 to tempering
(mixing) valve 12 “MIX” port, and cold
water inlet.
3. Install supplied flow restrictor 14 ahead of
tempering (mixing) valve tee.
4. Connect pressure relief valve 1 (if required by
codes), maximum 150 PSI as close to the unit as
possible. No other valves or restrictions may be
installed between the Endurance and the relief
valve.
DO NOT USE A TEMPERATURE/PRESSURE
RELIEF VALVE AS THIS IS NOT A STORAGE
HOT WATER HEATER.
Note: Installations with water containing 10
or more grains of hardness, must be installed with
appropriate water treatment.
kW
307.7
213.9
172.9
146.5
128.9
105.5
89.4
73.3
m
0.8
LAARS
3B. Domestic Water Piping (EBP only)
1. Connect tempering (mixing) valve 12 “Hot” port
to hot water outlet from unit. This valve should
Figure 12. Domestic Water Piping. Figure 13. Domestic Water Piping With Storage Tank.
Page 10
Figure 14. EBP Domestic Water Piping with Recirculating Loop.
LAARS HEATING SYSTEMS
WARNING
Failure to install a hot water tempering (mixing)
valve (12) creates a scalding hazard with potential for
serious bodily injury. Some brands of tempering
(mixing) valves are not designed as anti-scald valves.
Where domestic water is supplying multiple
apartments or large whirlpool tubs, additional storage
tank may be connected as shown in Figure 13. The
bronze circulator shown must be connected to tank
aquastat and must not run continuously. If the
circulator is wired to run continuously, unit's domestic
water flow switch will keep the unit in domestic water
priority, and no water will be allowed to be sent to the
heating system.
SECTION 4.
Hydronic Heat Piping
4A. Hydronic Piping
The appliance incorporates its own circulating
pump and bypass loop and is capable of providing
flow through heating zones, in addition to what it
needs for itself. Model size 110 is capable of
providing flow for two heating zones (up to 67 feet of
¾" baseboard each), and model 175 is capable of
providing flow for four heating zones (up to 67 feet of
¾" baseboard, each).
EDP/EDN boilers installed in radiant (in floor)
systems and other low mass boilers should be provided
with a buffer/blender tank to assure a controlled
supply temperature, and to prevent short cycling. In
radiant systems utilizing 3-way tempering valves, a
bypass pipe must be installed between supply and
return piping.
1. EBP ONLY: Connect system supply to 1¼"
supply connection marked “SUPPLY”.
2. EDP/EDN ONLY: Connect 1¼" thermostatic
union to system supply connection in direction
designated with union.
3. Pipe the discharge of the relief valve, full size, to
a drain or in a manner to prevent injury in the
event of pressure relief.
4. Install an air purger in flow supply line as shown
in Figures 15, 16 or 17.
5. Install automatic float type air vent on air scoops.
6. Install a diaphragm expansion tank in boiler
outlet piping. To ensure sufficient expansion
volume for the hydronic system water, due to
heat-up and cool-down during normal operation,
a #30 or larger expansion tank must be used on
EBP combo units.
NOTE: Never install expansion tank and auto
fill valve on return.
7. If necessary, install a properly sized circulator
with optional isolation valves in supply beyond
expansion tank.
Caution
All hot water pipes must be installed with a minimum
1" (25mm) clearance from combustible materials.
8. Connect boiler feed water supply with shut off
valve to inlet connection of automatic fill valve.
Locate in boiler outlet piping.
9. If codes require, install suitable back flow
preventer between automatic fill valve and city
main.
10. The appliance may be installed in single and
multiple zone systems (using either zone valves
Endurance
Figure 15. Hydronic Piping EDP/EBP with Zone Valves.
Page 11
Figure 16. Piping, Single EDP/EBP Boiler for Multiple Temperature Systems.
Figure 17. Piping, Model “EDP/EDN” for Radiant Floor.
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