HTP Elite Ultra ELU-150WBN Installation, Start-Up, Maintenance, Parts, Warranty Download Page 3

Page: 3 / 89

LP-719 Rev. 000 Rel. 000 Date 6.25.20

SPECIAL ATTENTION BOXES

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 serious personal injury or death.

WARNING

indicates a potentially hazardous situation which, if not

avoided, could result in personal injury or death.

CAUTION

indicates a potentially hazardous situation which, if not

avoided, may result in moderate or minor personal injury.

CAUTION

CAUTION used without the safety alert symbol

indicates a

potentially hazardous situation which, if not avoided, may result

in property damage.

NOTICE

is used to address practices not related to personal injury.

Foreword

This manual is intended to be used in conjunction with other

literature provided with the boiler. This includes all related control

information. It is important that this manual, all other documents

included in this system, and additional publications including the

National Fuel Gas Code - ANSI Z223.1

in the United States and the

Natural Gas and Propane Installation Code - B149.1

in Canada (latest

versions), be reviewed in their entirety before beginning any work.

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 by local codes and utility company requirements. In the

absence of local codes, preference should be given to the

National Fuel

Gas Code - ANSI Z223.1

in the United States and the

Natural Gas and

Propane Installation Code - B149.1

in Canada (latest versions).

Installations Must Comply With:

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

ordinances.
In the United States - 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.
The latest version of the

National Electrical Code, NFPA No. 70

In Canada - The latest versions of the

Natural Gas and Propane

Installation Code, CSA B149.1

, and the

Canadian Electrical Code, C22.1

from CSA Group, 178 Rexdale Blvd, Toronto, Ontario, Canada M9W 1R3.

NOTE:

The gas manifold and controls met safe lighting and other

performance criteria when undergoing tests specified in

ANSI Z21.13

- latest edition.

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 AHJ may be a federal, state,

provincial, 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:

The manufacturer reserves the right to modify product technical

specifications and components without prior notice.

Summary of Contents for Elite Ultra ELU-150WBN

Page 1: ...ld liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 272 Duchaine Blvd New Bedford MA 02745 www htproducts com LP 719 Rev 000 Rel 000 Date 6 25 20 WARNING Improper installation adjustment alteration service or maintenance could void product warranty and cause property damage severe personal injury or death California Proposition 65 War...

Page 2: ...iance 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 Improper installation adjustment alteration service or mai...

Page 3: ...lity company requirements In the absence of local codes preference should be given to the National Fuel Gas Code ANSI Z223 1 in the United States and the Natural Gas and Propane Installation Code B149 1 in Canada latest versions Installations Must Comply With Local state provincial and national codes laws regulations and ordinances In the United States The latest version of the National Fuel Gas C...

Page 4: ...ing load decreases These features include A modulating combustion system that adjusts firing rate based on heat demand Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor The outdoor sensor is supplied with this boiler This boiler does not include a standing pilot This boiler is designed and shipped to assure the highest efficiency operation possible Such ...

Page 5: ...vels must be monitored using a calibrated combustion analyzer such that a CO level of no more than 150 ppm is exceeded at any time during operation G Exhaust Vent and Intake Pipe Installation 33 H Applications 35 1 Direct Vent Installation of Exhaust and Intake 35 2 Venting Through an Existing System 41 3 Power Venting Indoor Combustion Air in Confined or Unconfined Space 42 Part 6 Installing the ...

Page 6: ...ntil the problem is repaired by a qualified technician After installation all appliance safety devices should be tested The 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 circ...

Page 7: ...ness Specifications Contaminant Maximum Allowable Level Total Hardness Below 140o F water temperature 200 mg l 12 grains gallon Total Hardness Above 140o F water temperature 120 mg l 7 grains gallon CH and DHW Loop Water Quality Specifications Contaminant Maximum Allowable Level Aluminum 0 05 to 0 2 mg l or PPM Chloride 100 mg l or PPM Copper 1 mg l or PPM Iron 0 3 mg l or PPM Manganese 0 05 mg l ...

Page 8: ...k the valve motor in central heating mode and ensure freeze protection operates properly Failure to disconnect the valve may disable boiler freeze protection and result in property damage Approximate Time Temperature Relationships in Scalds 120oF More than 5 minutes 125oF 1 1 2 to 2 minutes 130oF About 30 seconds 135oF About 10 seconds 140oF Less than 5 seconds 145oF Less than 3 seconds 150oF Abou...

Page 9: ... maximum flow and control heat exchanger flow rate Text Display and Operational Display Icons The display allows the user to change system parameters and monitor system outputs Gas Valve Senses suction from the blower allowing gas to flow only if powered and combustion air is flowing Integrated Venturi Controls air and gas flow into the burner Burner The high grade stainless steel burner uses prem...

Page 10: ...r death 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 WARNING This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32 o F Precautions should be taken to protect the condensate trap and drain lines fro...

Page 11: ...but are not limited to a properly sized drain pan installed beneath the boiler and piped to an open drain line or installing the boiler on a concrete floor pitched to a free flowing drain Failure to provide containment measures is the sole responsibility of the owner and or installer Leakage damages ARE NOT covered by warranty In addition water leak detection devices and automatic water shutoff va...

Page 12: ... Mounting to a Wood Studded Wall CAUTION If the boiler is not installed upright vertically plumb and level improper and unsatisfactory operation may occur causing excessive condensation build up nuisance fault codes and unnecessary maintenance 1 Position the upper wall mounting bracket on the wall Ensure the bracket is level and the drilling holes are on stud Then use the bracket as a template to ...

Page 13: ...t the supply of combustion air to the boiler If the boiler is installed in areas where indoor air is contaminated see Table 6 it is imperative that the boiler be installed as direct vent so that all combustion air is taken directly from the outdoors into the boiler intake connection Unconfined space is space with volume greater than 50 cubic feet per 1 000 BTU hr 4 8 cubic meters per kW of the tot...

Page 14: ...gure 6 CO Warning Label J Removing a Boiler from a Common Vent System WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death DANGER Do not install the boiler into a common vent with any other appliance Thiswillcausefluegasspillageorappliancemalfunction resulting in possible substantial property damage severe ...

Page 15: ...ust Vent Materials3 PVC CPVC PP Stainless Steel Shipping Weight lbs 115 125 130 Gas Supply Pressure NG 3 5 to 10 5 WC LP 8 to 13 WC Power Supply 120V 60 Hz less than 12A General Operating Conditions Ambient Temperature Range 33 104o F 0 6 40o C Product Approvals and Requirements ANSI Z21 13 CSA 4 9 Ignition System Direct Electronic Spark Ignition Flame Rectification Burner System Premixed Fuel Mod...

Page 16: ... Water Heater 3 4 NPT B Domestic Hot Water Outlet 3 4 NPT C Gas Inlet 3 4 NPT C Gas Inlet 3 4 NPT D N A D Domestic Hot Water Inlet 3 4 NPT E Central Heating Return 1 1 4 NPT E Central Heating Return 1 1 4 NPT F Pressure Relief Valve 3 4 NPT F Pressure Relief Valve 3 4 NPT Table 8 Boiler Connection Sizes 34 1 8 19 3 4 2 1 4 3 2 5 8 2 5 8 3 3 5 8 2 3 4 3 3 4 9 3 4 6 3 8 38 1 4 1 7 8 A B C D E F 18 1...

Page 17: ...e gas temperature sensor 6 Main heat exchanger 7 Flame detection electrode 8 Silencer 9 Junction box 10 DHW Heat Exchanger Combi Models Only 11 Condensate trap 12 Gas valve 13 Control panel 15 Circulation Pump 16 DHW Flow Sensor Combi Models Only 17 Water pressure switch 18 Modulating Fan 19 Boiler inlet temperature sensor 20 Frame 21 Ignition electrode 22 Spark generator 23 Combustion Analysis Te...

Page 18: ...anger Combi Models Only 11 Condensate trap 12 Gas valve 15 Circulation Pump 16 DHW Flow Sensor Combi Models Only 17 Water pressure switch 18 Modulating Fan 19 Boiler inlet temperature sensor 21 Ignition electrode 24 Air intake connection 25 Exhaust vent connection 26 Diverter valve 27 By pass 29 Pressure gauge Combi Models Boiler Models CAPTION A Central Heating Supply D DHW Cold Inlet B DHW Hot o...

Page 19: ... to the adapter before fitting adapter to the water connections on the boiler Damages due to improper installation practices ARE NOT covered by warranty B Backflow Preventer Use a backflow preventer specifically designed for hydronic boiler installations This valve should be installed on the cold water fill supply line per local codes C Expansion Tank Expansion Tank and Make Up Water 1 Ensure that...

Page 20: ...Supply 1 1 4 B DHW Outlet 3 4 C Gas Inlet 3 4 D DHW Inlet 3 4 E CH Return 1 1 4 F Condensate discharge A CH Supply 1 1 4 B Supply to Indirect Water Heater 3 4 Cap if not in use C Gas Inlet 3 4 D N A E CH Return 1 1 4 F Condensate Discharge Combi Models Boiler Models A B D E F C ...

Page 21: ...rating greater than 150 psi the maximum allowable operating pressure of the boiler s DHW circuit After installing the relief valves and filling and pressurizing the system test the operation of the valves by lifting the levers Make sure the valves discharge freely If a valve fails to operate correctly replace it with a new relief valve The relief valve capacity must exceed the BTU H input capacity...

Page 22: ...e loops Figure 12 Low Water Cut Off Basic Installation G Air Elimination Device A micro bubble air elimination device must be installed in every boiler installation Automatic air vents alone are not an acceptable substitute for a micro bubble air elimination device Here are a few examples of acceptable devices Spirovent TACO 4900 Series Caleffi Discal H Low Water Cut Off Field Supplied Thisboileri...

Page 23: ...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 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT Minimum flow rates outlined in this manual 2 gpm must b...

Page 24: ...to operate when there is a call for heat 7 Unit is equipped with built in primary pump for the heating loop This pump is sized to ensure proper flow rate through the boiler heat exchanger and related piping 8 IWH Applications a mixing valve is recommended if the DHW temperature is set above 119oF 9 For direct not primary secondary piping applications it is required to install the expansion vessel ...

Page 25: ...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 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 VERY IMPORTANT Minimum flow rates outlined in this manual 2 gpm must be maintained through the heat exchanger to minimize short cycling 9 In a ...

Page 26: ...es 2 Primary Secondary Loop 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 diameter and CH piping should be 1 in diameter 5 Circulators are shown with isolation flanges The alternative is standard f...

Page 27: ...imum flow rates outlined in this manual 2 gpm must be maintained through the heat exchanger to minimize short cycling 6 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 7 Unit is equippe...

Page 28: ...r all equipment and detailing required by local codes 2 Primary Secondary Loop 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 diameter and CH piping should be 1 in diameter 5 Circulators are shown w...

Page 29: ... to 18 Example 1 Parameter 2 7 5 131 F increasing phase from 77 F to 131 F 6 days stays at 131 F for 6 days decreasing phase from 131 F to 77 F 6 days Example 2 Parameter 2 7 5 140 F increasing phase from 77 F to 140 F 7 days stays at 140 F for 4 days decreasing phase from 140 F to 77 F 7 days 3 0 10 20 30 40 50 60 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Jours Fonction chauffage 7 jours Durcissement ch...

Page 30: ... injury or death DANGER Due to the extreme flammability of most glues cements solvents and primers used to join plastic exhaust vent and intake pipes explosive solvent vapors must be cleared from all vent piping before start up Avoid using excess cement or primer as this may pool in the vent pipes Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connecte...

Page 31: ... venting systems is prohibited Covering non metallic vent pipe and fittings with thermal insulation is prohibited The boiler s vent and air intake connections are designed to accept 3 PVC CPVC and Polypropylene directly DO NOT insert PVC piping into the boiler s exhaust connection When venting with PVC insert the factory supplied 5 length of CPVC before transitioning to PVC When installing AL29 4C...

Page 32: ...at may be opened Direct Vent 1 foot 3 feet 91 cm Power Vent 4 ft below or to side of opening 1 ft above opening C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Cle...

Page 33: ...ance Collar When venting with PVC first install the included 5 length of 3 CPVC into the boiler s exhaust connection then adapt to PVC using approved CPVC to PVC transition cement Installing PVC pipe into the boiler s exhaust connection is strictly prohibited the strain of the gear clamp combined with heat can deform PVC over time and result in flue gas leakage causing property damage severe perso...

Page 34: ... b In the absence of specific ordinances snow levels shall be calculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service s 10 year statistics for the installation location geographical area In addition Total length of vent piping shall not exceed the limits specified in this manual The vent piping for this direct vented appliance is approved...

Page 35: ...as a venting material prior to use 7 IPEX Concentric kits can be shortened to fit the requirements of the installation See instructions included with the kit for more details Table 16 Optional Vent Termination Kits Take extra precaution to adequately support the weight of vent pipes terminating through the roof Failure to properly support roof terminated piping could result in property damage seri...

Page 36: ...aust must terminate a minimum of 18 above the air intake termination See Figure 27 for more details WARNING 3 IPEX Low Profile Termination illustrated See Figure 28 for more details WARNING Concentric Termination 3 IPEX Low Profile Termination illustrated See Figure 29 for more details WARNING 3 Duravent Innoflue Concentric Termination illustrated See Figure 30 for more details WARNING Figure 25 S...

Page 37: ...rminationkitforcomplete installation instructions WARNING Concentric Termination Refer to documentation included with termination kit for complete installation instructions WARNING Refer to documentation included with termination kit for complete installation instructions WARNING Figure 29 Sidewall Concentric Termination with Optional IPEX kit Figure 30 Sidewall Concentric Termination with Optiona...

Page 38: ... 5 mm plus snow allowance above grade Air Inlet Figure 32 Venting Below Grade For installations that exit the wall below grade 1 Excavate the site to a point where the pipes are to exit as shown in Figure 32 2 Ensure the wall is fully sealed where the pipes penetrate 3 The exhaust vent air intake piping MUST be secured to the side of the building above grade as shown to provide rigidity 4 Ensure t...

Page 39: ...ke Exhaust must terminate a minimum of 18 above the air intake termination See Figure 38 for more details WARNING Exhaust must terminate a minimum of 12 above snow level See Figure 39 for more details WARNING Concentric Termination 3 Polypro Innoflue Concentric Termination illustrated See Figure 40 for more details WARNING 3 IPEX Concentric Termination illustrated See Figure 41 for more details WA...

Page 40: ...n Figure illustrates two options for exhaust termination only Neither vent pipe illustrated is intended for combustion air intake WARNING Concentric Termination Refer to documentation included with termination kit for complete installation instructions WARNING Refer to documentation included with termination kit for complete installation instructions WARNING Figure 40 Sidewall Concentric Terminati...

Page 41: ...des before installing through an existing opening could result in property damage and add significantly to installation costs CAUTION If an existing venting system is converted for use with this boiler the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the boiler Failure to do so could result in property damage and boiler f...

Page 42: ...rom the outdoors into the boiler intake connection Unconfined space is space with volume greater 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 this space through openings not furnished with doors are considered part of the space Confined space is space with volume less than ...

Page 43: ...blockage In installations that may encounter sustained freezing conditions the use of heat tape is recommended to avoid freezing of the condensate line Longer condensate runs are more prone to freezing 7 Support of the condensate line may be necessary to avoid blockage of the condensate flow 8 Local building codes may require an in line neutralizer to be installed not included to treat the condens...

Page 44: ... grounding prong from the boiler plug 2 Do not attach the ground wire to either the gas or water piping 3 The wiring diagrams in this manual are to be used for reference purposes only 4 Refer to these diagrams and the wiring diagrams of any external controls used with the installation when wiring the boiler Read understand and follow all wiring instructions supplied with the controls 5 Do not disc...

Page 45: ...TE WHEN CONNECTING THE BOILER TO EXTERNAL CONTROLS DO NOT RUN 120V CABLES AND CABLES FOR CONTROL CIRCUITS WHICH ARE LOWVOLTAGE TOGETHER USE SEPARATE CABLESTO PREVENT INDUCEDVOLTAGE ONTHE LOW VOLTAGE CIRCUITS 5 Aquastat Default and Tank Sensor Optional Connections non Combi Models The boiler is designed for managing the production of domestic hot water via an indirect water heater IWH in one of two...

Page 46: ...20V 120V 120V N G L 120 V AC GATEWAY WIFI Bk Bl Bl Rd Wh Bl Bl Rd Rd Br Br Bl Gry Bl Bk Bk Bk Rd Rd Wh Br Br Br Bk Bk Br Wh Br Bl Br Detection electrode EBUS 2 TT2 TT1 System sensor Tank sensor Outdoor sensor Boiler Pump Igniter Gas valve Fan Diverter valve Water pressure switch D H W temperature sensor D H W Flow sensor Flue temp probe Return temp probe Outlet temp probe N N FUSE 5AT FUSE 5AT L N...

Page 47: ...MCU H B RETURN 5 Vdc A NEUTRAL filtered FAN CIRCUIT SMPS Nf HOT filterd Hf Safety Ground NEUTRAL FLAME CIRCUIT Hf Hf 3 WAY VALVE RELAYS CIRCUIT SENSORS CIRCUIT HMI B Nf Nf C D Nf A G G OUT1 TANK Hf DHW SYSTEM Hf OUT2 OUTDOOR C B Ebus B C G A 3 WAY VALVE CIRCUIT Nf FLAME ELECTRODE FAN A A BOILER PUMP IGNITER EXTERNAL PUMPS OVERHEAT INPUT GAS VALVE uP G D C G A G C C A G HMI G C A COMMUNICATION G ...

Page 48: ... SUPPLY OUT 1 120 VAC LINE HT 120V AC 2 120 VAC NEUTRAL CN4 PROTECTIVE EARTH 1 CN7 PROTECTIVE EARTH 1 CN9 PROTECTIVE EARTH 1 CN26 NTC HEAT RETURN 1 5V SELV 5V 2 CH RETURN NTC SENSOR SIGNAL NTC HEAT FLOW 1 3 5V 4 CH FLOW 1 NTC SENSOR SIGNAL 5 NOT USED 6 NTC FLUE 7 5V 8 FLUE NTC SENSOR SIGNAL AIR PRESSURE SWITCH Bridged on 150WBN 199WBN and 199WCN models 9 24V SELV 24V 10 APS DETECTION SIGNAL Bridge...

Page 49: ... EBUS2 SIGNAL SELV 24V 12 GROUND CN16 FAN MANAGEMENT 1 GROUND SELV 24V 2 PWM FAN DRIVER 3 HALL_EFFECT SENSOR 4 24V CN19 EXTERNAL CLIP IN 1 24V SELV 24V 5V 2 GROUND 3 CLIP IN SERIAL TX SIGNAL 4 CLIP IN SERIAL RX SIGNAL CN12 HMI 1 5V SELV 24V 5V 2 GROUND 3 HMI SERIAL TX SIGNAL 4 HMI SERIAL RX SIGNAL 5 24V CN22 PWM PUMP 1 PWM PUMP SIGNAL SELV 24V 2 NOT USED 3 GROUND CN23 FLAME 1 FLAME SENSOR SIGNAL H...

Page 50: ...el Gas Code Latest Edition 3 LP Liquid Propane Gas Pipe Sizing Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure B Gas Connection Requirements 1 The gas connection fitting is NPT NOTE The gas pipe size must not be less than NOTE DO NOT USE 1 2 quick flex gas lines Doing so w...

Page 51: ...nts shown in Table 22 Natural Gas Minimum Pressure 3 5 WC Maximum Pressure 10 5 WC LP Gas Minimum Pressure 8 WC Maximum Pressure 13 WC Table 22 Gas Pressure Requirements NOTICE Do not fire operate the boiler until all connections have been completed and the heat exchanger is filled with water Doing so will damage the boiler and void the warranty Figure 56 Gas Valve Detail 8 Leak test the gas line ...

Page 52: ...n the button will flash for five 5 seconds Display Icon Description Digits Indicating Boiler Status Temperature oF with bar level Error Codes ERROR Press Reset Button Request RESET boiler lockout Menu Settings Technical assistance request Flame detected with indication of power used CH Heating Operation Set CH Heating Operation Active DHW Operation Set DHW Operation Active Hot Water Comfort Activa...

Page 53: ...reen by pressing the DHW buttons See Figure 60 The DHW temperature range is 97 140oF The previously set value will flash on the display Figure 60 Domestic Hot Water DHW Temperature Adjustment DANGER Hotter water increases the risk of scald injury Scalding may occur within five 5 seconds at a setting of 140o F Water temperature over 125o F can instantly cause severe burns or death from scalds Child...

Page 54: ... 0 Fixed Outlet Temperature Automatic Temperature Control AUTO OFF 1 Basic Temp Control without Optional Room Sensor or Outdoor Sensor 2 Indoor Temp Reset With Optional Room Sensor 3 Outdoor Temp Reset With Included Outdoor Sensor or weather from the internet if the boiler is connected to WiFi 4 Indoor and Outdoor Temp Reset With Optional Room Sensor and Included Outdoor Sensor or weather from the...

Page 55: ...oor Temp Reset The boiler target temperature automatically adjusts between the Min and Max Temperature Settings 4 2 6 and 4 2 5 based on the input temperature provided by the included Outdoor Sensor or Internet Weather via WiFi connection in accordance with the following formula Boiler Target Temp Min Temp 4 2 6 Slope of Outdoor Reset Curve 4 2 2 X Room Setpoint 4 0 0 Outdoor Temp Parallel Shift o...

Page 56: ...the needs of the heating system The function boosts the boiler target temperature by increasing the Slope 10 every 10 minutes a call for heat is continuously active to a maximum of 2X the nominal Slope setting 4 2 2 While the heat call is satisfied the Slope decreases by 1 every minute to a minimum of the nominal Slope setting 4 2 2 Auto Boost is only applicable when 4 2 1 3 or 4 NOTE The boiler s...

Page 57: ...NTERING THE ACCESS CODE To access the Menus proceed as follows in this example Parameter 2 3 1 1 Simultaneously press the and buttons for 5 seconds The display shows 222 2 Press the button to select 234 the service code 3 Press the OK button The display shows the first quick setting PCB 4 Press the button until the display shows MENU 5 Press the OK button The display shows menu 0 6 Press the butto...

Page 58: ...egulation parameters 8 Service Parameters 0 Boiler Statistics 1 1 Boiler Statistics 2 2 Boiler 3 Boiler Temperature 4 Storage 5 Service 6 Error History 7 Free parameters 8 Reset Factory Settings 9 Other 1 10 Other 2 11 HTP Zone Controller Parameters 0 General 1 Diagnostics 25 Cascade Manager Parameters 0 General 1 System Settings 2 Domestic Hot Water 3 System Diagnostics 4 Cascade Diagnostics 5 Er...

Page 59: ...t Temperature WCN Models 97 140 F 36 to 60 C 125 Also settable via the home screen see item 2 Figure 57 not applicable when 2 2 8 2 DHW Setpoint Temperature WBN Models 104 149 F 40 to 65 C 125 2 0 1 DHW Preheating 0 Disabled 1 Enabled 1 Enables disables comfort on off setting via COMFORT button and parameter 2 5 0 2 1 FREE PARAMETERS DO NOT USE 2 1 1 DO NOT USE 2 1 2 DO NOT USE 2 1 3 DO NOT USE 2 ...

Page 60: ... models set to 0 Deactivated COMFORT function is not active ELU WCN models set to 1 or 2 On activates conditionally once per Comfort Anti cycling Time Activating the COMFORT function keeps the DHW heat exchanger temperature warm when a DHW demand is not active This reduces the amount of time it takes for the boiler to meet a hot water demand COMFORT will display when this function is active NOTE P...

Page 61: ...placement controller Replacement controllers have generic settings that may not be specific to the boiler model Reset OK yes ESC no To Reset all parameter settings press the OK button 2 10 0 CH On Differential Temperature 0 36oF 0 20oC 11 Determineshowmuchtheboiler outlet temperature can drop below target before turning the boiler back on 2 10 1 DHW Modulation Setpoint 68 179oF 20 82oC 179 Boiler ...

Page 62: ...S 4 2 0 Temperature Range 0 68 122 F low temperature 1 86 179 F high temperature 1 4 2 1 Type of Temperature Control 0 Fixed Outlet Temperature 1 Basic Temp Control 2 Indoor Temp Reset 3 Outdoor Temp Reset 4 Indoor and Outdoor Temp Reset 3 See Table 26 and F Type of Temperature Control for details 4 2 2 Slope of Outdoor Reset Curve 0 2 0 8 when 4 2 0 0 0 6 low temperature 0 4 3 5 when 4 2 0 1 1 3 ...

Page 63: ...t Only applicable when using an optional HTP Room Sensor and when 4 2 1 2 or 4 4 2 5 MAXIMUM Temperature Setting 86 179 F 179 if Parameter 4 2 0 1 68 122 F 120 if Parameter 4 2 0 0 4 2 5 sets the allowable boiler operating temperature range for Zone 1 heating limiting Automatic Temperature Control and manual adjustments from the User Menu 4 2 6 MINIMUM Temperature Setting 86 179 F 120 if Parameter...

Page 64: ...5 2 6 MINIMUM temperature setting 86 179 F 120 if parameter 5 2 0 1 68 122 F 80 if parameter 5 2 0 0 5 2 6 sets the allowable boiler operating temperature range for Zone 2 heating limiting Automatic Temperature Control and manual adjustments from the User Menu 5 3 ZONE 2 DIAGNOSTICS 5 3 0 Room Temperature Read only Only applicable when using an HTP room sensor 5 3 1 Room Temperature Setpoint Read ...

Page 65: ...ic Temperature Control and manual adjustments from the User Menu 6 3 DIAGNOSTICS 6 3 0 S W function activation 0 OFF 1 ON 0 Only applicable when using an HTP room sensor 6 3 1 S W temperature threshold 50 86 F 68 6 3 4 S W delay time 0 300 minutes 60 6 7 ZONE 3 REGULATION PARAMETERS 6 7 5 Auto Boost 0 OFF 1 ON 0 See description of Parameter 475 8 SERVICE PARAMETERS 8 0 BOILER STATISTICS 1 Read Onl...

Page 66: ...enance 8 5 1 Enable Maintenance Warning 0 OFF 1 ON 0 8 5 2 Maintenance Warning Reset Reset OK Yes Esc No Resets Maintenance Advice and clears the Warning 8 5 4 SW Version Display Interface 8 5 5 SW Version Main Controller 8 6 ERROR HISTORY 8 6 0 10 last errors ERROR 0 ERROR 9 This parameter displays the last 10 boiler errors indicating the error code day month and year of occurence When the parame...

Page 67: ...r gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leaks at once PROPANE BOILERS ONLY The propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and per...

Page 68: ...amage severe personal injury or death 1 Make sure the CH and DHW lines are open and full of water Turn on all electric power to boiler 2 Open hot water faucets in the DHW system Start with the faucets nearest the boiler 3 Keep faucets open until water runs freely and all air is purged Then move on to faucets further away from the boiler in the system 4 When water flows freely from all hot water fa...

Page 69: ...be respected Operation 1 Gas inlet pressure check Loosen screw 1 Torx 10 Line Pressure Test Port and connect a manometer to the port using applicable tubing Ensure the boiler is powered on Then enable Test Mode by pressing the RESET button for 10 seconds The display will show and the icon The gas line pressure must remain within the range provided in Table 22 for the gas type during all operating ...

Page 70: ...e directly to Operation 4 Adjusting the Gas Valve at Maximum Gas Flow Adjust the gas valve by turning setting screw 4 clockwise to increase the CO2 level counterclockwise to reduce the CO2 level 1 turn adjusts the CO2 level by approximately 0 3 Wait 1 minute after each change in setting for the CO2 value to stabilize 1 3 2 4 4 4 Figure 70 Max CO2 Adjustment If the value measured corresponds to the...

Page 71: ...Natural Gas to Propane Operation HTP boilers are factory set to operate on Natural Gas BEFORE OPERATING ON PROPANE the boiler must be converted to Propane using the included conversion kit specific to the boiler model ELU NATURAL TO PROPANE CONVERSION INSTRUCTIONS For Qualified Technician Installation Instructions This conversion kit shall be installed by a qualified service agency in accordance w...

Page 72: ...ion level Is vent piping properly supported Has vent piping been checked for leaks Has the exhaust vent line been pitched back to the boiler at a rate of 1 4 per foot Have the exhaust vent and intake pipes been properly installed to the boiler Is the condensate drain supported so as to not place strain on the boiler s condensate outlet fitting Install Condensate Piping Tubing and Components Yes No...

Page 73: ...act a qualified service technician if an error continues to occur In the event of Error 108 Shut off due to insufficient water pressure inside the heating circuit Pressure can be increased by filling the heating circuit See filling and purging procedures this manual If Error 108 occurs frequently and the system needs repeated refilling turn the boiler off Turn Figure 73 Blocking Error Example Figu...

Page 74: ...appens again 1 Check the water pressure on the pressure gauge 2 Purge the air from the central heating circuit 3 Check for the correct functioning and positioning of the supply and return temperature probes 4 Check for the correct functioning and positioning of the circulation pump 1 08 Fill system No water in the primary circuit P Pmin This Error Code will go away when the condition is remedied I...

Page 75: ...ain replace the main PCB 3 04 Too many 5 resets in 15 minutes Switch the boiler OFF and ON at the main electrical power supply Blocking Auto Reset 1 1 Turn Off the Power to the Boiler 3 05 PCB internal error Switch the boiler OFF and ON at the main electrical power supply If the problem happens again replace the main PCB Blocking Manual Reset 3 06 PCB internal error Switch the boiler OFF and ON at...

Page 76: ...sure pressure is between 3 5 and 10 5 WC Natural Gas or between 8 and 13 WC for boilers converted to Propane LP operation 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 igniter transformer for proper connection 5 Clean the spark ignit...

Page 77: ... condition is remedied 1 Check exhaust temperature sensor Ensure connections are dry and secure 2 If flue is very cold 14 F 10 C remove sensor and warm it then reinstall 3 If flue is very hot see error 6 02 4 Check exhaust vent for blockages Blocking Auto Reset 6 12 Insufficient fan speed 500 for 3 seconds or RPM min 300 for 3 minutes Press the Reset button to clear the error code If Error happens...

Page 78: ... Terminations Verify that the boiler exhaust vent and intake pipe terminations are clean and free of obstructions Remove any debris from the exhaust B Maintenance That May be Performed by the User vent or intake pipe openings If removing the debris does not allow the boiler to operate correctly contact your qualified service technician to inspect the boiler and the vent system Check Exhaust Vent a...

Page 79: ...o the heating system in order to avoid the need for repeated draining Ensure the antifreeze used is compatible with the stainless steel boiler heat exchanger WARNING NEVER use any toxic chemical including automotive standard glycol antifreeze or ethylene glycol made for hydronic non potable systems These chemicals can attack gaskets and seals in water systems are poisonous if consumed and can caus...

Page 80: ...r types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent dust Was...

Page 81: ... pull the burner toward you NOTE Whenever replacing the burner ALWAYS replace the burner gasket Figure 82 Disassembled Burner Assembly Take care when removing the condensate hose as condensate may escape Failure to do so could result in property damage due to leaks personal injury or death WARNING Siphon Cap Retaining Clip Siphon Cap Cone Ball Figure 83 Clean the Condensate Trap Clean the Condensa...

Page 82: ...g for sagging and or leakage Repair any sags or leaks before restoring power to the boiler 8 If the boiler has a condensate pump ensure the pump operates properly before considering maintenance complete Cleaning the DHW Filter Combi Models ONLY 1 Remove the clip on the flow meter 1 5 Clean the filter with a toothbrush and clean running water 6 Reinstall the DHW inlet filter 7 Refill the DHW circui...

Page 83: ...e mixer and fan 5 Reinstall the fan and combustion assembly components as described in Cleaning the Heat Exchanger Combustion Chamber Ensure the gasket 6 is assembled between the fan and air inlet channel DANGER Failure to replace damaged or deteriorating gaskets or O Rings will result in exhaust gas leaks substantial property damage severe personal injury or death Replacing the Main Heat Exchange...

Page 84: ...e the user perform these regular tasks Check the system water pressure regularly If necessary restore pressure and vent the system Set the setpoints and control systems to ensure correct and economical control of the system Have the system serviced in accordance with regulations at regular intervals NEVER attempt to service the boiler or adjust the combustion system 7 Ensure there are no gas leaks...

Page 85: ...as written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to p...

Page 86: ... Set gap at 1 8 CONDENSATE Condensate Trap Clean debris from the condensate trap Fill with clean water Neutralizer Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate hose Clean out dirt and re install NOTE Verify the flow of condensate making sure that the hose is properly connected during final inspection GAS Pressure Measure incoming gas pressure 3 5 to 10 5 ...

Page 87: ...ect the problem If a technician is not available press a button on the display to wake it Then press the RESET button to remove the lockout state so additional trials for ignition can be performed If the RESET key is not pressed error code 501 or 503 the boiler will reset automatically after an hour C Important It is extremely important that whenever work is performed on the plumbing system that e...

Page 88: ...LP 719 Rev 000 Rel 000 Date 6 25 20 88 Maintenance Notes ...

Page 89: ...tallation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer Please only sign after the qualified installer service technician has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the quali...

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