HTP EP-220 VWH Installation, Start-Up, Maintenance, Parts, Warranty Download Page 68

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LP-551 Rev. 3.9.16

Customer Installation Record Form

The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty
claim. After reading the important notes at the bottom of the page, please also sign this document.

Customer’s Name

Date of Installation

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 installer has fully reviewed the installation, safety, proper operation, and maintenance of the system.

If the system has any problems please call the installer. If you are unable to make contact, please call your sales representative.

Distributor / Dealer: Please insert contact details.

Summary of Contents for EP-220 VWH

Page 1: ...re personal injury or death HTPreservestherighttomakeproductchangesorupdateswithoutnoticeandwillnotbeheldliablefortypographical errors in literature NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 272 Duchaine Blvd New Bedford MA 02745 www htproducts com LP 551 Rev 3 9 16 The surfaces of these products contacted by potable consumable water contain less than 0 25 lead by weight as...

Page 2: ...ICINITY OFTHIS OR ANY OTHER APPLIANCE WHATTO DO IFYOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be provided by a qualified installer s...

Page 3: ...vidual 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 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 loca...

Page 4: ...5 B Gas 5 C When Servicing theWater Heating System 5 D BoilerWater 5 E Freeze Protection 5 F WaterTemperature Adjustment 6 Part 2 BeforeYou Start 6 A What s in the Box 6 B How the Boiler Operates 6 C Optional Equipment 7 Part 3 Prepare the Boiler 7 A Locating the Boiler 7 B Flooring 8 C Leveling 8 D Clearances for Service Access 9 E Residential Garage Installation 9 F ExhaustVent and Intake Pipe 9...

Page 5: ... warranty and could result in property damage personal injury or death This boiler has been designed to heat potable water ONLY Using this boiler to heat non potable fluid WILL VOID product warranty and could result in property damage personal injury or death Do not use this boiler for anything other than its intended purpose as described in this manual Doing so could result in property damage and...

Page 6: ...stem and how they operate Stainless Steel Heat Exchanger The highly efficient stainless steel heat exchanger is designed to use the cold water return from the storage tank and extract the last bit of heat before it is exhausted Modulating Combustion System The combustion system modulates the output of the burner during operation to match system demand and achieve the control set point while in ope...

Page 7: ... before installation handle with care until the components come to room temperature Failure to do so could result in damage to the boiler Carefullyconsiderinstallationwhendeterminingboilerlocation Please read the entire manual before attempting installation Failure to properly take factors such as boiler venting piping condensate removal and wiring into account before installation could result in ...

Page 8: ...ith relative humidity can lead to degradation of boiler components In these environments boilers must not be installed using direct vent systems which draw outdoor air for combustion Such boilers must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized Failure of the boiler or components due to incorrect ope...

Page 9: ...by a moving vehicle F Exhaust Vent and Intake Pipe The boiler is rated ANSI Z21 13 Category IV pressurized vent Failure to vent the boiler properly will result in serious personal injury or death Do not attempt to vent this boiler by any means other than those described in this manual Doing so will void the warranty and may result in severe personal injury or death Vents must be properly supported...

Page 10: ...venting system 2 Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage leakage corrosion or other deficiencies that could cause an unsafe condition This boiler requires fresh uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air NOTE To prevent combustion air conta...

Page 11: ...onnect the boiler to directly heat swimming pool or spa water Do not fill boiler or operate with water containing chlorine in excess of 100 ppm NOTE It is recommended to clean the heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in this manual Hardness Less than 7 grains Chloride levels Less than 100 ppm pH levels 6 8 TD...

Page 12: ...LP 551 Rev 3 9 16 12 Figure 4 Boiler Dimensions NOTE All Dimensions Are Approximate VWH in Model Number DenotesVolume Water Heater Model ...

Page 13: ...LP 551 Rev 3 9 16 13 Figure 5 Boiler Dimensions NOTE All Dimensions Are Approximate VWH in Model Number DenotesVolume Water Heater Model ...

Page 14: ...ge Plumbing of this product should only be done by a qualified licensed plumber in accordance with all local plumbing codes The boiler is designed to be connected to a storage tank to supply domestic hot water HTP offers 60 80 119 175 gallon size storage tanks in either stainless steel or glass lined construction These storage tanks will be directly connected to the boiler supply and return connec...

Page 15: ...rovide an air cushion An automatic air vent would cause air to leave the system resulting in improper operation of the expansion tank E Circulators EveryVWH system requires special attention to circulator size to overcome pressure drop through the boiler and its related piping All circulators installed on the VWH system must be designed for potable water installations Boiler pressure drop is detai...

Page 16: ...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 About 1 1 2 seconds 155oF About 1 second Table 5 ApproximateTime Temperature Relationships in Scalds H High Velocity Circulator Pump 7 Connect red wire from flow switch to boiler wire harness 8 When installation is complete power up the b...

Page 17: ... Ft Flow Rate GPM Friction Ft Flow Rate GPM 220 19 22 13 18 3 12 14 6 299 301 29 29 18 24 5 13 20 399 39 39 19 32 5 26 Table 9 Temperature Rise Friction Ft and Flow Rate The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit To size simply add up the number of boilers and the required flow rates for the sy...

Page 18: ... depending on local codes Water temperature above 140oF requires the circulator pump to run continuously and must have a water hardness of between 5 and 7 grains Hardness above 7 grains will damage the heat exchanger and shorten the service life of the boiler MinimumVWH Pipe Sizes 220 1 NPT 299 301 1 1 4 NPT 399 1 1 2 NPT Table 12 Minimum Pipe Sizes I Plumbing The boiler is designed to function in...

Page 19: ...m relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks must be installed with reverse return piping as shown 10 Expansion tank must be rated for use with potable water 11 Use either indirect tank sensor or system pipe sensor mounted on common return to the boiler 12 Aquastat or system pipe sensor connects to DHW sensor input on boiler The piping...

Page 20: ... diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks must be installed with reverse return piping as shown 10 Expansion tank must be rated for use with potable water 11 Use either indirect tank sensor or system pipe sensor mounted on common return to the bo...

Page 21: ...ough an unheated space such as an alcove or attic the space must be heatedorthepipemustbeinsulated Theinsulationmusthave an R value sufficient to prevent freezing of the condensate Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter Failure to do so could r...

Page 22: ... Approved Materials for ExhaustVent and Intake Pipe C Additional Requirements for Installation in Canada 1 Installations must be made with a vent pipe system certified toULC S636 IPEXisanapprovedventmanufacturerinCanada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe from ...

Page 23: ...inimum distance between exhaust vents and intake pipes on multiple boilers is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above grade 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 for zero clearance to combustible construction The flue...

Page 24: ...result in property damage serious injury or death 1 Use only solid PVC CPVC or stainless steel pipe or a Polypropylene vent system approved for use withCategory IV appliances FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS Foam core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be prop...

Page 25: ...outside There are three basic direct vent options detailed in this manual 1 Side Wall Venting 2 RoofVenting and 3 UnbalancedVenting Be sure to locate the boiler such that the exhaust vent and intake pipe can be routed through the building and properly terminated Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure see Optional Equipment in ...

Page 26: ...ithin 1 foot of the boiler and the balance of 4 foot intervals on the vent pipe Venting must be readily accessible for visual inspection from the first three feet from the boiler NOTES A For every 1 of overhang the exhaust vent must be located 1 vertical below overhang overhang means top of building structure and not two adjacent walls corner of building B Typical installations require 12 minimum ...

Page 27: ...nd add significantly to installation costs 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 failure Such failure IS NOT covered under warranty ConcentricVentingThrough an Existing Syst...

Page 28: ...nt 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 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 spa...

Page 29: ... system and to meet local code requirements HTP recommends neutralizing condensate with a Condensate Neutralizer Kit Part 7450P 212 for 80 110 150 220 299 301 models Part 7350P 611 for the 399 model The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the condensate The neutralizer kit should be checked annually and the limestone chips reple...

Page 30: ...nnections are being made Failure to follow these instructions could result in component or product failure serious injury or death Such product failure IS NOT covered by warranty Jumping out control circuits or componentsWILLVOID product warranty and can result in property damage personal injury or death Label all wires prior to disconnecting them when servicing the boiler Wiring errors can cause ...

Page 31: ...r below set point and could result in decreased performance substantial property damage or heightened risk of injury or death due to scalds G Tank Sensor or Mechanical Control Connect the tank sensor or mechanical controls to the TANK SENSOR terminals 10 11 of the low voltage terminal strip as shown in Figure 22 The control will automatically determine which type of sensor is connected and operate...

Page 32: ...s the floor where they may become wet or damaged Avoid running communication cables parallel and close to or against high voltage 120 volt or greater wiring HTP recommends that the maximum length of communication bus cables not exceed 200 feet 4 Route the communication cables through one of the knockouts in the cabinet 5 Connect the boilers in a daisy chain configuration as shown below It is best ...

Page 33: ...LP 551 Rev 3 9 16 33 Figure 24 Cascade Master and FollowerWiring ...

Page 34: ...LP 551 Rev 3 9 16 34 Figure 25 Internal Connection Diagram ...

Page 35: ...lly support a large amount of weight 5 Purge all gas lines thoroughly to avoid start up issues with air in the lines 6 Sealing compound must be approved for gas connections Support gas supply piping with hangers not by the boiler or its accessories The boiler gas valve and blower will not support the weight of the piping Make sure the gas piping is protected from physical damage and freezing where...

Page 36: ...lexible gas connections can be used when installing the boiler Flexible gas connections have different capacities and must be sized correctly for the connected boiler firing rates Consult with the flex line supplier to assure the line size is adequate for the job Follow local codes for proper installation and service requirements Ensurethepressuretapscrewisproperlytightenedtoprevent gas leaks Fail...

Page 37: ...re explosion severe personal injury or death Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO Failure to follow this instruction could result in fire explosion property damage severe personal injury or death C Boiler Gas Valve Strain on the gas valve and fittings may result in vibration...

Page 38: ...rant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas C Condensate Removal 1 The boiler is a high efficiency condensing boiler Therefore the unit has a condensate drain Condensate fluid is nothing more than water vapor derived from combustion products similar to that produced by an autom...

Page 39: ...s a demand for heat it determines which boiler is first in the firing sequence and sends that boiler a command to begin a demand sequence That boiler will then begin a demand sequence as described above Once the boiler ignites the master boiler control will increase the firing rate command to that boiler until the system sensor temperature is at the tank set point temperature plus the supply offse...

Page 40: ... call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department Turn off the gas shutoff valve located outside the boiler 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...

Page 41: ...o adjust the ignition differential set point from 1oF to 36oF Factory Default 7oF Degrees below set point must be equal to or below tank differentials TANK SETPOINT 120 oF Adjusts the tank set point from 59oF to 180oF Factory Default 120oF TANK DIFF SETPOINT 7 oF Adjusts the tank differential set point from 1oF to 18oF Factory Default 7oF Degrees below set point where demand starts TEMP DISPLAY C ...

Page 42: ...e week CLOCK DATE MODE 08 28 2009 Fr 10 01A Allows the user to switch to European date format 2009 08 28 from US format 08 28 2009 CLOCK YEAR 08 28 2009 Fr 10 01A Adjusts the year setting CLOCK MONTH 08 28 2009 Fr 10 01A Adjusts the month setting CLOCK DATE 08 28 2009 Fr 10 01A The clock is set Screen Description Function 4 Burner Off Differential BURNER OFF DIFF 20 oF 4 This is the amount of degr...

Page 43: ...ction FREEZE PROTECTION ON 28 Allows the user to set freeze protection on the boiler Factory Default ON Range ON OFF Function 29 DHW Modulation Mode DHW MODULATE MODE NORMAL MOD 29 Not applicable on this product Function 30 Extra Boiler Mode EXTRA BOILER MODE OFF 30 Allows for a non HTP boiler to be controlled when the cascade output has risen above the percent of the cascade firing rate set in th...

Page 44: ...nctions press ENTER The left most digit will begin to blink Use the or v arrows to change the digit Use the arrow keys to switch between digits When you ve made your selection press ENTER again Screen Description Function 33 Year SERVICE SCHEDULE YEAR 00 00 2000 33 Allows the user to set the year of the next service reminder Hours SERVICE SCHEDULE 10000 s 000000 33 Allows the user to set the left ...

Page 45: ...tween multiple boilers If in a single boiler configuration the display will show NO CONN In a multiple boiler configuration if this is the Master Boiler and other boilers are connected to the communication bus and powered this screen will show the address of each boiler connected to the bus Press v once POWER ON 0H CH ON 0H The top line indicates the amount of hours the boiler has been powered ove...

Page 46: ...e will display the date and time that the fault occurred Table 26 Boiler Fault Screens Screen Description BLOCKING HISTORY 1 08 28 2009 Fr 5 19A This screen displays the most recent boiler control blocking error The top line will alternate between the words BLOCKING HISTORY and the blocking code encountered Press v once BLOCKING HISTORY 2 08 28 2009 Fr 5 19A This screen displays the second oldest ...

Page 47: ...tatus The VWH in the center of the top line shows that cascade demand is coming from the tank sensor or thermostat You may also see 0 10 if the demand is from a 0 10 volt input The following numbers show which boiler addresses are currently communicating to the master If a boiler address is not used or communicating the number will not display In the example to the left boiler address 4 is not com...

Page 48: ...y condition in which case the display will revert to its normal readout when the condition is corrected or it may be a condition that the controller has evaluated as not safe to restart the boiler In this case the boiler control will be locked out the red FAULT light will be lit and the message LOCKOUT will be displayed on the readout in the lower line Theboilerwillnotstartuntilaqualifiedtechnicia...

Page 49: ...his manual to see if it corresponds to the temperature of the sensor If the resistance does not agree with the sensor replace the sensor If the sensor is OK disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter Repair or replace as necessary If this error is present the boilers in the cascaded group will run and ignite simultaneously when there is ...

Page 50: ...ng there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Check the direction of flow off the boiler circulator See Piping Details in this manual 4 Troubleshoot the dual supply thermistor by following steps in F02 RETURN TEMP HIGH F06 PUMP ON TIME This display indicates that the boiler return temperature is excessive When accompanied by the red FAULT light and LOCKOUT...

Page 51: ...P ON TIME The fan is not running at the speed determined by the control Fan speed has been more than 30 faster or slower than the commanded speed for more than 10 seconds This is a serious safety issue as indicated by the illuminated red light and the word LOCKOUT flashing on the display This boiler will not restart until a technician determines and repairs the cause and pushes RESET on the displa...

Page 52: ... reset 1 If an indicator light is illuminated investigate the source of the error for that particular switch 2 With boiler in service mode measure the gas pressure in the supply line with a gas pressure meter Monitor the gas pressure during both low and high fire conditions for correct pressure range 3 If there are no optional switches or none of the indicator lights is illuminated on the optional...

Page 53: ...cates there is a demand for heat on the boiler the pump is powered on and the supply sensor temperature is too high for the boiler to ignite This occurs because the water temperature measured by the supply sensor is higher than the tank temperature ignition diff setting Thismessagewillstaypresentuntilthewatertemperature measured by the supply sensor is less than the tank temperature ignition diff ...

Page 54: ...g 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 Wash potentially contaminated clothes separately...

Page 55: ...ause flue gases to leak and result in serious personal injury or death 1 Ensure the boiler 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 detach the condensate trap from the drain tube Remove the condensate trap from the ...

Page 56: ...size and pitch could result in condensate leakage and potential water damage to property The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condensate can exit from the tee resulting in potential water damage to property 10 If the boiler has a condensate pump ensure the pump operates properly ...

Page 57: ...LP 551 Rev 3 9 16 57 Figure 30 Combustion System Replacement Parts 220kBTU Model ...

Page 58: ...LP 551 Rev 3 9 16 58 Figure 31 Combustion System Replacement Parts 299 399kBTU Models ...

Page 59: ...LP 551 Rev 3 9 16 59 Figure 32 Replacement Parts All Models ...

Page 60: ...NE TOUCHPAD 8 7450P 322 928 CONTROL BOARD 9 7500P 115 6 32 X 1 4 PAD HEAD SCREW ELECTRONIC BOARDS 10 7250P 378 FUSE CONTROL BOARD 6 3 AMPS 11 7250P 150 PRESSURE SWITCH 12 7450P 142 6 32 FLANGED NUT PRESSURE SWITCH 13 7350P 370 FIELD CONNECTION BOARD 14 6300P 037 FUSE FIELD CONNECTION BOARD 2 0 AMPS 15 7450P 902 7450P 903 FLUE KIT includes items 1 2 3 16 7000P 805 PLASTIC TUBING PRESSURE SWITCHES N...

Page 61: ...ary convert the boiler to the proper fuel type Locate the stickers in the appropriate locations on the boiler 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 Mail in conversion registration Notes Table 33 Installation Checklist Allowing the boiler to operate wi...

Page 62: ...n in uA d7 in Status Menu in Start Up Procedures Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1stYear 2ndYear 3rdYear 4thYear Neutralizer Check condensate neutralizer Replace if necessary Condensate Pipe Disconnect condensate pipe Clean out dirt Fill with water to level of outlet and reinstall NOTE Verify the flow of condensate making sure that the hose...

Page 63: ...NOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wir...

Page 64: ...NTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting syste...

Page 65: ...H or any component part or connection thereto should leak the resulting flow of water will not cause damage to the area in which it is installed WARRANTY EXCLUSIONS HTP does not warrant 1 All labor charges incurred by any person in connection with the examination or replacement of parts claimed by the purchaser to be defective 2 Any failed components of the heat system not manufactured by HTP as p...

Page 66: ... OR NOT ARISING FROM HTP S NEGLIGENCE ACTUAL OR IMPUTED THE REMEDIES OF THE PURCHASER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION INCIDENTAL OR CONSEQUENTIAL DAMAGES SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO PROPERTY DAMAGE LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF HTP TO MEET ...

Page 67: ...LP 551 Rev 3 9 16 67 Maintenance Notes ...

Page 68: ...f Installation 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 installer has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the installer If you are unable t...

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