HTP EFTC-140W Installation & Startup Download Page 80

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LP-520 REV. 5.1.17

Figure 62

– Cabinet Replacement Parts – 199W Models

NUMBER

DESCRIPTION

PART

NUMBER

DESCRIPTION

PART

NUMBER

Exhaust Duct Assy

7855P-002

Display Panel

7855P-012

15-1

Exhaust / Intake Duct Clamps

7855P-332

Display Panel Bracket

7855P-413

15-2

Exhaust / Intake Gaskets

7850P-210

Ignition Transformer

7855P-007

15-3

Exhaust Duct

7855P-333

Universal Control Board FT

7855P-268

15-4

Combustion Analyzer Port Plug O-Ring

7855P-334

Terminal Block Bracket

7855P-271

15-5

Combustion Analyzer Port Plug

7855P-335

Manual Power Switch

7855P-014

15-6

Intake / Exhaust Adapter O-Ring

7855P-256

Terminal Block 6P

– Combi

7855P-272

15-7

Exhaust Duct Inner Adapter

7855P-004

Condensate Block APS

7855P-017

15-8

Exhaust Adapter O-Ring

7855P-254

Front Cover

7855P-289

Air Intake Assy

7855P-411

Display Panel Cover

7850P-023

16-1

Air Intake Cap

7855P-337

Exhaust Adapter Gasket

7850P-041

Air Vent

7855P-063

Top Wall Mount Bracket

7850P-068

Air Vent Grommet

7855P-339

Cabinet

7855P-274

PRV Ring

7855P-269

Bottom Wall Mount Bracket

7850P-092

19-1

PRV Rubber Pad

7855P-339

Wire Gland

7855P-348

Air Pressure Switch

7855P-262

CH Pressure Gauge

7855P-135

Control Board Bracket

7855P-412

Table 38

– Cabinet Replacement Parts – 199W Models

Summary of Contents for EFTC-140W

Page 1: ...rsonal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas s...

Page 2: ...2 LP 520 REV 5 1 17 ...

Page 3: ...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 NOTICE is used to address practices not related to personal injury SAFETY INSTRUCTIONS SA...

Page 4: ...OMPLY WITH Local state provincial and national codes laws regulations and ordinances The latest version of the National Fuel Gas Code ANSI Z223 1 from American Gas Association Laboratories 8501 East Pleasant Valley Road Cleveland OH 44131 In Canada CGA No B149 latest version from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 Also Canadian Electrical Code ...

Page 5: ...MATERIALS 25 C ALLOWED COMBINED VENT LENGTHS 25 D TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE 26 E VENT TERMINATION 27 1 Direct Vent Two Pipe Roof and Sidewall Vent Terminations 27 2 Direct Vent Optional Horizontal and Vertical Vent Kits 28 3 Screen Installation 28 4 Power Venting Indoor Combustion Air Installation in Confined or Unconfined Space 29 PART 6 INSTALL THE CONDENSATE DR...

Page 6: ...RE MODE OPTIONAL 59 M 0 10 VOLT INPUT 60 PART 11 START UP PREPARATION 61 A CHECK CONTROL WATER CHEMISTRY 61 B GLYCOL ANTIFREEZE SOLUTIONS 61 C CHECK FOR GAS LEAKS 62 D FILL AND TEST WATER SYSTEM 62 E PURGE AIR FROM CH AND INTERNAL STORAGE TANK 63 F PURGE AIR FROM DHW SYSTEM 63 G CHECK THERMOSTAT CIRCUIT S 64 H CONDENSATE REMOVAL 64 I FINAL CHECKS BEFORE STARTING APPLIANCE 64 J ADJUSTING GAS PRESSU...

Page 7: ...hing CH Line 30 psi 7855P 077 1 Each Vent Screens 3 7855P 085 2 Screens Outdoor Sensor with Screws and Anchors 7855P 084 1 Combi Venting Kit 3 CPVC S7855 002 6 Length X Bell Coupling for Gas Line 140W Model Only 7855P 086 1 Spare Parts Kit Gaskets and O Rings 7855P 258 1 Propane LP Conversion Kit 140W Model 7855P 099 199W Model 7855P 452 1 Anchors and Wall Mounting Bracket 7850P 084 1 Blue Flow Re...

Page 8: ...rd 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 appliance is the user s responsibility Ensure the user carefully reads and understands the User s Informa...

Page 9: ...SE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician The appliance MUST BE replaced if it has been submerged Attempting to operate an appliance that has been submerged could create numerous harmful conditions such as a potential gas leakage causing a fire and or explosion or the release of mold bacteria or other harmful particulates into the air...

Page 10: ... Maximum Allowable Level Total Hardness Residential Use Below 140o F water temperature 200 mg l 12 grains gallon Manganese 0 05 mg l or PPM Total Hardness Commercial Use 140o F and above water temperature 120 mg l 7 grains gallon pH 6 5 8 5 Aluminum 0 05 to 0 2 mg l or PPM Sulfate 205 mg l or PPM Chloride 100 mg l or PPM Total Dissolved Solids TDS 500 mg l or PPM Copper 1 mg l or PPM Zinc 5 mg l o...

Page 11: ...y 120V 60 Hz 6A Maximum Power Consumption 160W Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Ceramic Fiber Infrared Gas Valve System Combination Modulating Current Proportional Internal Pipe Material Copper Dimensions W 17 25 H 34 D 15 5 W 19 7 H 37 16 8 Minimum Flow Rate 0 5 GPM Internal Storage Tank Water Capacity DHW 1 G...

Page 12: ... B Intake Pipe Connection 3 C Exhaust Vent Connection 3 D Relief Valve Adapter NPT E CH Supply Adapter 1 NPT F CH Return Adapter 1 NPT G DHW Outlet Adapter NPT H DHW Inlet Adapter NPT I Gas Connection Adapter NPT 1 2 X Bell Coupling Provided to Upsize Gas Line J Condensate Adapter Table 5 140W Adapter Specifications ...

Page 13: ...M A Automatic Air Vent B Intake Pipe Connection 3 C Exhaust Vent Connection 3 D Relief Valve Adapter NPT E CH Supply Adapter 1 NPT F CH Return Adapter 1 NPT G DHW Outlet Adapter NPT H DHW Inlet Adapter NPT I Gas Connection Adapter NPT J Condensate Adapter NPT Table 6 199W Adapter Specifications ...

Page 14: ...n 11 CH Return Filter 26 Air Pressure Switch 12 CH Pressure Gauge 27 Exhaust Vent Pipe 13 DHW Outlet Adapter 28 Exhaust Vent Adapter 14 Gas Inlet Adapter 29 Relief Valve Adapter 15 DHW Inlet Adapter With Filter and Flow Restrictor Table 7 Component List PART 4 PREPARE APPLIANCE LOCATION A UNCRATING THE APPLIANCE UNCRATING APPLIANCE Any claims for damage or shortage in shipment must be filed immedi...

Page 15: ... systems which draw outdoor air for combustion Such appliances 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 appliance is certified for indoor installations only Do not install the appliance outdoors Failure to install this appliance indoors could result in substantial property damage severe ...

Page 16: ... appliance The appliance cover must be securely fastened to prevent it from drawing air from the appliance room This is particularly important if the appliance is in a room with other appliances 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 Servic...

Page 17: ...f 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 appliance 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 CARBON MONOXIDE...

Page 18: ...cts Table 9 NOTE DAMAGE TO THE APPLIANCE CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY Refer to the limited warranty for complete terms and conditions I REMOVING AN APPLIANCE FROM A COMMON VENT SYSTEM Do not install the appliance into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible substantial property dama...

Page 19: ... to comply with the above and properly mount the appliance 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 appliance could result in substantial property damage severe personal injury or death POSITIONING THE APPLIANCE ON THE WALL 1 At...

Page 20: ... attached to the top of the filter assembly 3 Remove the installed white flow restrictor and replace it with the blue flow restrictor included with the appliance See Figure 7 B 4 Reinstall the DHW inlet filter 5 Reinstall the two pins Figure 7 A Removing the DHW Inlet Filter B Removing the Flow Restrictor Figure 8 Water Pressure vs Flow Through the Restrictors 140W Models ...

Page 21: ...prevent deterioration Pitch the exhaust vent pipe back to the appliance This ensures that condensate in the exhaust vent returns to the appliance and drains properly Failure to follow these instructions could result in property damage severe personal injury or death A INTAKE PIPE AND EXHAUST VENT GUIDELINES 1 Vent system must be installed in accordance with local codes or in absence of local codes...

Page 22: ...nuisance or hazard or cause property damage DO NOT vent where condensate vapor could cause damage or could be detrimental to the operation of regulators relief valve or other equipment DO NOT vent the water heater in a chimney flue serving a separate appliance designed to burn solid fuel The water heater may only be vented in vacant chimneys Maximum Snow Level Determination These installation inst...

Page 23: ...r and properly maintain the heater could result in property damage severe personal injury or death For each floor containing bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms as well as in the room that houses the heater Detectors and alarms shall comply with NFPA 720 latest edition Failure to comply with these requirements could result in produ...

Page 24: ...lator vent outlet Above a regulator within 3 feet 91 cm horizontally of the vertical center line of the regulator vent outlet to a maximum vertical distance of 15 ft 4 5 m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance Direct Vent 1 foot 3 feet 91 cm Power Vent 4 feet below or to side of opening 1 foot above opening K Clearance to a me...

Page 25: ...ess using adapters specifically designed for the purpose by the manufacturer Covering non metallic vent pipe and fittings with thermal insulation is prohibited 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...

Page 26: ...e properly connected supported and the exhaust must be pitched a minimum of 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 Failure to provide a minimum total vent length of 14 equivalent feet could result in property damage and improper ap...

Page 27: ...d Sidewall Vent Terminations All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the appliance to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual insp...

Page 28: ...4 foot intervals on the vent pipe Appliance venting must be readily accessible for visual inspection for the first three feet from the appliance 3 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 ...

Page 29: ...total input rating of all fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space is space with volume less than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning appliances installed in that space Rooms connected directly to ...

Page 30: ...30 LP 520 REV 5 1 17 Figure 17 NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes ...

Page 31: ...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 appliance display if condensate line is blocked The appliance will not operate with a blocked condensate line It is extremely important to have this condition repaired by a qualified service technician NOTE T...

Page 32: ... the appliance is set to operate on the provided gas supply could result in property damage personal injury or death A 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 Pi...

Page 33: ...2370 2200 1950 1570 Table 16 Liquid Propane Delivery Capacity Black Iron Pipe Refer to ANSI Z223 1 National Fuel Gas Code Latest Edition B GAS CONNECTION REQUIREMENTS 1 The gas connection fitting on the appliance is male NPT A X Bell Coupling has been provided with the appliance to aid installation NOTE The pipe size must not be less than 2 The supply line must be sized for the maximum output of t...

Page 34: ...Shut Off Valve Detail Figure 21 Natural Gas Piping Installation NOTE Capacity to be Not Less than Total Capacity of Connected Appliances Figure 22 LP Gas Piping Installation NOTE Capacity to be Not Less than Total Capacity of Connected Appliances ...

Page 35: ...tions are made Do not apply a torch within 12 of the appliance Doing so could damage the appliance Such damages ARE NOT covered by product warranty The size of the hot water pipe should be diameter and the central heating water pipe should be 1 in diameter To ease future maintenance isolation valves are recommended on both the CH and DHW loops All piping should be insulated Figure 23 Operating Des...

Page 36: ...36 LP 520 REV 5 1 17 Figure 24 Piping Legend ...

Page 37: ...h Undersized expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual appliance failure can result due to excessive make up water addition SUCH FAILURE IS NOT COVERED BY WARRANTY 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...

Page 38: ...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 ...

Page 39: ...p must be greater than the appliance 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 Each heating zone of a pump based system has its own circulator with turns on when a zone thermostat calls for heat 10 Unit is e...

Page 40: ...condary loop must be greater than the appliance 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 Each heating zone of a pump based system has its own circulator with turns on when a zone thermostat calls for heat 1...

Page 41: ... 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 Each heating zone of a pump based system has its own circulator with turns on when a zone thermostat calls for heat 10 Unit is equipped with built in primary pump for the heating loop This pump is sized to insure proper flow rate through...

Page 42: ...ef valve is equal to or greater than the maximum input BTU H rating of the combination appliance To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge Dischar...

Page 43: ...operty damage serious personal injury or death 2 The wiring diagrams contained in this manual are to be used for reference purposes only 3 Refer to these diagrams and the wiring diagrams of any external controls used with the installation when wiring the appliance Read understand and follow all wiring instructions supplied with the controls 4 Do not disconnect the power supply when the appliance i...

Page 44: ...S MAXIMUM FLAME DETECTING VOLTAGE 2 5V PRE PURGE TIME Tp 5 seconds SAFETY TIME IGNITING TIME Ts 3 5 seconds IGNITING INTERVAL TIME 10 seconds POST PURGE TIME Tip 2 minutes 1st 1 minute 2nd 1 minute OVER HEATING 1 2 3 PROTECTION DETECTION TIME 3 seconds PUMP 1 POST CIRCULATING TIME T1pv 1 minute PUMP 2 POST CIRCULATING TIME T2pv 1 minute HIGH AND LOW WATER LEVEL DETECTION TIME 6 seconds HIGH AND LO...

Page 45: ...45 LP 520 REV 5 1 17 Figure 32 Electrical Wiring Diagram ...

Page 46: ...46 LP 520 REV 5 1 17 Figure 33 Ladder Diagram ...

Page 47: ...DC CN4 LWD1140 06 1 FAN NOT USED 2 GND SELV 14V DC 3 VDD SELV 14V DC 4 Fan power start coil SELV 8 26 5V AC 5 Fan power end coil 6 Fan speed feedback signal SELV 14V DC CN8 SMW250 04 1 MCU ISP GND SELV 5V DC 2 ISP Reset Port 3 ISP TOOL0 Data Port 4 VCC CN11 LWD1140 16 1 HWL NOT USED SELV 12V AC 8 2 LWL Low Water Level Leakage Sensor 10 3 HD Central Heating Demand SELV 5V DC 11 4 TH Connect to the ...

Page 48: ...ust Temperature Sensor 12 6 ST S NOT USED 13 7 SP S Over Heat Temperature Sensor 14 CN14 SMW250 09 1 DHM GND SELV 14V 2 DHM Stepper Motor Position 3 VDD 4 DHM Stepper Motor Coil X Phase 5 DHM Stepper Motor Coil Y Phase 6 VDD 7 DHM Stepper Motor Coil X Phase 8 DHM Power IWM Stepper Motor Coil Y Phase 9 NOT USED CN3 SMW250 06 4 FLUX1 VCC SELV 5V 5 Water Flow Sensor 6 GND CN5 SMW250 10 1 RPM Fan RPM ...

Page 49: ...49 LP 520 REV 5 1 17 Figure 34 Terminal Block Wiring Detail PART 10 OPERATING SYSTEM INSTRUCTIONS A CONTROL PANEL Figure 35 Appliance Control Panel Detail ...

Page 50: ...mum speed for 1 minute to purge the air and any fumes from the intake and exhaust pipes Display Items Time for Display Remarks LCD Test 1 Sec All segments ON 0 5 Sec All segments OFF Category 140W 199W 1 Sec Pdn 1 Sec 0051 Software Version for Front Panel 1 Sec SPn 1 Sec 00 XX Software Version for Appliance 1 Sec SFn 1 Sec XX XX Hardware Version for Appliance 1 Sec Hdn 1 Sec 00XX Table 21 Start Up...

Page 51: ...s The scald warning letter H high temperature will display High temperature DHW Set Point range is 121 140o F 49 5 60o C Turn the dial counterclockwise to lower and clockwise to raise the DHW set point After changing the temperature press the button to save the set point Hotter water increases the risk of scald injury Scalding may occur within 5 seconds at a setting of 140o F 60o C Water temperatu...

Page 52: ...e appliance will automatically change the target temperature based on the outdoor reset curve When using 0 10V the appliance will automatically change the target temperature based on input voltage NOTE If input voltage is less than 1 5V the 0 10V will be ignored G STORAGE MODE Storage Mode indicates that the appliance is heating stored water in the internal storage tank When Storage Mode is operat...

Page 53: ...utlet temperature H Eh Exhaust temperature Current exhaust temperature I St N A Not Used Default is 0 J oH CH water overheat temperature Current temperature on the overheating sensor L rt 1 PH Burner Operation Time Supply power time L rt display on sub menu Unit 100 hour 2 rh Burner operation time Unit 1 hour 3 rH Burner operation time Unit 1 000 hour 4 It Ignition cycles Cycle 10 times 5 IH Ignit...

Page 54: ...n set the appliance will operate to heat CH water when water temperature falls below a differential setting Example If setpoint is 180o F and differential is 27o F the appliance will turn on when CH water temperature falls below 153o F Range 9 27o F 15 OF 68 F Warm Weather Shutdown Warm weather shut down will shut down CH Mode if the programmed outdoor temperature is exceeded Range 50 110o F 16 cH...

Page 55: ...essure is between 3 5 and 14 WC 2 Check gas valve wire Ensure connection is secure 3 Check flame detection sensor Ensure connections are secure Normal operating settings are more than 2 5DC before ignition less than 2 5DC after ignition 4 Check vent terminations Ensure there are no blockages 5 Assure that the flame is stable when lit 6 If the problem persists replace the main control Er 11 Ignitio...

Page 56: ...istance If resistance is zero replace the sensor 3 Check exhaust vent for blockage 4 If the problem persists replace the main control Er 36 Abnormal Supply Voltage Supply voltage is too low to operate This Error Code will go away when supply voltage returns to normal operating range If Error happens again 1 Ensure appliance is properly wired to a power source meeting the requirements on the rating...

Page 57: ...r 80 Low Water Level Sensor Low Water Level Detected Four 4 Consecutive times This Error Code will go away when the condition is remedied If Error happens again 1 Ensure all valves are open to the appliance and there are no leaks 2 Ensure all air has been purged from the system 3 Check wiring connections to low water level sensor Ensure all are secure 4 Check low water level sensor resistance If r...

Page 58: ...58 LP 520 REV 5 1 17 K ERROR TREE ANALYSIS 1 FLAME DETECTION Figure 44 Flame Detection Error Analysis Tree 2 GAS DETECTION Figure 45 Gas Detection Error Analysis Tree ...

Page 59: ...ior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions NOTE For correct mounting procedures follow instructions provided with the sensor NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires rou...

Page 60: ...agrams this manual Caution should be used to ensure that the 0 10 VOLT connection does not become connected to ground NOTE Ensure that the polarity of the connections from the external modulating appliance controller to the appliance is correct Reversed polarity could lead to erratic and or no response from the appliance controller NOTE Outdoor Temperature Mode Icon on the display will flash if an...

Page 61: ...n pH 6 5 8 5 Aluminum 0 05 to 0 2 mg l or PPM Sulfate 205 mg l or PPM Chloride 100 mg l or PPM Total Dissolved Solids TDS 500 mg l or PPM Copper 1 mg l or PPM Zinc 5 mg l or PPM Iron 0 3 mg l or PPM Dissolved Carbon Dioxide CO2 15 mg l or PPM Table 26 Water Chemistry Specifications Clean system to remove sediment 1 You must thoroughly flush the system without the appliance connected to remove sedi...

Page 62: ...h your gas supplier call the fire department Turn off gas shutoff valve located outside of the appliance so that the handle is crosswise to the gas pipe If the handle will not turn by hand don t try to force or repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 4 Do not use this appliance if any part has been under water Immediately call a qua...

Page 63: ...n purging the circuits h Disconnect the wires that are connected to the THERMOSTAT terminals of the terminal block Apply power to the appliance After the control goes through the start up sequence the display will turn off i Press and hold the button for five seconds Then scroll to 29 AP by turning the dial Press the button AP cP will show on the display Press the button to change the test time Th...

Page 64: ...o a local drain It is very important that the minimum condensate line is sloped downward away from the appliance to a suitable inside drain If the condensate outlet on the appliance is lower than the drain you must use a condensate removal pump available from HTP 554200 This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a c...

Page 65: ...y or death If the readings obtained are lower or higher than the combustion readings in Table 27 use a 4mm Allen key to adjust the offset screw in a clockwise positive or counterclockwise negative direction approximately 1 4 turn See Figure 50 Check your combustion values Repeat this procedure until the values obtained on the combustion analyzer agree with those stated in Table 27 NOTE If the appl...

Page 66: ...appliance front cover 7 Use a Phillips Head screwdriver to reinstall the appliance top cover In order to increase CO2 values on high fire the gas orifice size can be increased to achieve the maximum CO2 value listed in Table 27 Contact the factory for recommended orifice sizes to achieve the desired setting ...

Page 67: ...anual supply line no less than in diameter length and diameter adequate to deliver the required BTUs union and shut off valve installed etc Does the gas type match the type indicated on the appliance rating plate Has gas supply line pressure been measured between 3 5 and 14 WC Has the gas supply line been leak tested per locally approved methods 5 Pressure Relief Valves Have you installed approved...

Page 68: ...99200 5 48440 5 22152 5 74229 14 38045 14 17408 14 56090 23 30107 23 13782 23 42790 32 23998 32 10990 32 32930 41 19261 41 8824 41 25550 50 15562 50 7131 50 19990 59 12655 59 5800 59 15760 68 10353 68 4747 68 12510 77 8520 77 3906 77 10000 86 7051 86 3233 86 8050 95 5867 95 2690 95 6520 104 4908 104 2250 104 5310 113 4125 113 1891 113 4350 122 3485 122 1598 122 3590 131 2957 131 1356 140 2520 140 ...

Page 69: ...this manual It takes a long time before hot water flows from the faucet Is the faucet some distance from the appliance a Allow time for the cold water already in the pipes to flow from the faucet b Have recirculation valves and or plumbing return line s installed and program the unit for recirculation mode The water is not hot enough Is the water temperature set too low Adjust the temperature sett...

Page 70: ... owner to assure maximum efficiency and reliability Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could damage the appliance or system components resulting in substantial property damage severe personal injury or death Check the Surrounding Area To prevent the potential of substantial property d...

Page 71: ...sure relief valve and discharge pipe for signs of weeping or leakage If the pressure relief valve often weeps the expansion tank may not be operating properly Immediately contact a qualified service technician to inspect the appliance and system Check Vent Condensate Drain System While the appliance is running check the discharge end of the condensate drain tubing Ensure no flue gas is leaking fro...

Page 72: ...service technician It is recommended to flush the heat exchanger annually if water hardness exceeds 12 grains per gallon considered extremely hard water If water hardness falls below 12 grains per gallon it is recommended to flush the heat exchanger every two to three years NOTE Improper maintenance WILL VOID appliance warranty 1 Disconnect electrical power to the appliance 2 Close the shutoff val...

Page 73: ...he circulation pump Operate the pump and allow the cleaning solution to circulate through the appliance for at least 1 hour at a rate of 4 gallons per minute 7 Rinse the cleaning solution from the heat exchanger as follows a Remove the free end of drain hose D1 from the bucket b Close service valve V4 and open shutoff valve V2 c Do not open shutoff valve V1 d Allow water to flow through the applia...

Page 74: ...e make sure the condensate collector cap is replaced securely Failure to do so will cause venting issues that will result in serious injury or death 1 Ensure the appliance is powered off and has had time to cool 2 Remove the hose clamp attaching the condensate trap to the condensate hose from the heat exchanger Remove the clear plastic hose from the hose barb Remove the condensate hose clamp to de...

Page 75: ...er to the appliance It is very important that the condensate piping be no smaller than To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched 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 ...

Page 76: ... 335 26 Terminal Block 7855P 015 15 6 Intake Exhaust Adapter O Ring 85 Φ 7855P 256 27 Condensate Block APS 7855P 017 15 7 Exhaust Duct Inner Adapter 7855P 004 28 Front Cover 7855P 218 15 8 Exhaust Adapter O Ring 75 Φ 7855P 254 29 Display Panel Cover 7850P 023 16 Air Intake Cap assembly 7855P 003 30 CH Pressure Gauge 7855P 135 16 1 Air Intake Cap 7855P 337 31 Wire Gland 7855P 348 16 2 Air Intake In...

Page 77: ... DHW Outlet Adapter 7855P 225 53 Filter for CH Return Block 7855P 265 39 DHW Temperature Sensor 7855P 094 54 CH Filter Clip 7855P 286 40 DHW Inlet Pipe 7855P 241 55 CH Return Pipe 7855P 243 41 DHW Flow Sensor 7855P 083 55 1 3 4 Pipe Gasket 7855P 073 42 Mixing Valve 7855P 043 56 CH Return Temperature Sensor 7855P 097 42 1 P15 O ring 7855P 044 57 3 Way Valve Assembly 7855P 247 42 2 P16 O ring 7855P ...

Page 78: ... Body Assembly 7855P 354 70 CH Supply Temperature Sensor 7855P 030 64 2 Burner Overheat Switch 7855P 066 71 Water Level Detection Sensor Low water Cutoff 7855P 029 64 3 Burner Body 7855P 067 72 Flame sensor bracket 7855P 356 64 4 Burner Gasket 7855P 266 73 Flame sensor 7855P 031 64 5 Ceramic Fiber Burner 7855P 069 74 Condensate Trap Assembly 7855P 053 64 6 Burner plate O Ring 7855P 249 74 1 Burner...

Page 79: ...Outlet Adapter 7855P 232 81 Air Intake hose top clamp Φ60 7855P 372 87 2 Gas Valve O ring 7855P 076 82 Air Intake Hose 7855P 071 87 3 Gas valve 7855P 034 83 APS Hose Fitting 7855P 375 87 4 Gas valve inlet adapter 7855P 033 84 Fan Assembly 7855P 457 87 5 Gas Valve Bracket 7855P 234 84 1 Fan 7855P 025 88 Gas Inlet Pipe 7855P 235 84 2 Air intake Chanel Orifice 7855P 458 89 Gas Inlet Adapter 1 2 7855P...

Page 80: ...nual Power Switch 7855P 014 15 6 Intake Exhaust Adapter O Ring 7855P 256 28 Terminal Block 6P Combi 7855P 272 15 7 Exhaust Duct Inner Adapter 7855P 004 29 Condensate Block APS 7855P 017 15 8 Exhaust Adapter O Ring 7855P 254 30 Front Cover 7855P 289 16 Air Intake Assy 7855P 411 31 Display Panel Cover 7850P 023 16 1 Air Intake Cap 7855P 337 32 Exhaust Adapter Gasket 7850P 041 17 Air Vent 7855P 063 3...

Page 81: ... 7855P 225 55 CH Return Adapter 7855P 227 41 DHW Temperature Sensor 7855P 094 56 Filter for CH Return Block 7855P 265 42 DHW Inlet Pipe 7855P 241 57 CH Filter Clip 7855P 286 43 DHW Flow Sensor 7855P 083 58 CH Return Pipe 7855P 287 44 Mixing Valve 7855P 043 58 1 3 4 Pipe Gasket 7855P 073 44 1 Flow Sensor Clip 7855P 278 59 CH Return Temperature Sensor 7855P 097 44 2 P15 O Ring 7855P 044 60 3 Way Val...

Page 82: ...nk Clamp 7855P 291 76 4 Ceramic Fiber Burner 7855P 420 68 Storage Tank Bracket 7855P 292 76 5 Ignition Rod 7855P 607 69 CH Supply Pipe 7855P 293 76 6 Igniter Gasket 7855P 252 69 1 3 4 CH Supply Pipe Gasket 7855P 073 76 7 Burner Overheat Switch 7855P 066 69 2 1 CH Supply Pipe Gasket 7855P 074 76 8 Heat Exchanger Top 7855P 619 70 Storage Tank 7855P 294 76 9 Burner Refractory 7855P 612 71 CH Supply T...

Page 83: ...Chanel Gasket 7855P 426 88 2 Gas Valve O Ring 7855P 076 83 Fan and Mixer Assembly 7855P 427 88 3 Gas Valve 7855P 034 83 1 Fan 7855P 025 88 4 Gas Valve Bracket 7855P 436 83 2 Fan O Ring 7855P 371 89 1 2 Gas Pipe Gasket 7855P 221 83 3 Air Gas Mixer Inner Part 7855P 609 90 Gas Orifice NG 8 3 mm 7855P 610 83 4 Air Gas Mixer Gasket 7855P 428 Gas Orifice LP 6 3 mm 7855P 435 83 5 Air Gas Mixer Outer Part...

Page 84: ...hirty 30 days after the date of manufacture of the appliance and NOT the date of installation of the appliance F This warranty extends only to appliances utilized in heating applications that have been properly installed by qualified professionals based upon the manufacturer s installation instructions G It is expressly agreed between HTP and the original consumer purchaser that repair replacement...

Page 85: ...r For questions about the coverage of this warranty please contact HTP at the following address or phone number HTP 272 Duchaine Blvd New Bedford MA 02745 Attention Warranty Service Department 1 800 323 9651 SERVICE LABOR AND SHIPPING COSTS This limited warranty does not extend to any shipping charges delivery expenses or administrative fees incurred by the owner in repairing or replacing the appl...

Page 86: ...priate locations on the appliance If applicable have all dip switches been set and verified to match system requirements Verify combustion settings after gas conversion Carbon Dioxide ____ CO2 High Fire ____ CO2 Low Fire Verify combustion settings after gas conversion Carbon Monoxide ____ppm CO High Fire ____ppm CO Low Fire What is the drop on light off No more than 1 W C ____ in w c Dynamic 4 Ven...

Page 87: ...on appliance or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker Switch and Plug Verify ON OFF switch and co...

Page 88: ...88 LP 520 REV 5 1 17 MAINTENANCE NOTES ...

Page 89: ...of Installation Installer s Code Name Product Serial Number s Combustion Setting at Time of Installation Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If yo...

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