lp-445-r4 Rev. 006 Rel. 027 Date 7.21.20
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G. 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 automobile when it is initially started.
Condensation is slightly acidic (typically with a pH of 3 to 5) and must
be piped with the correct materials. Never pipe the condensate using
steel, copper, brass or other materials that will be subject to corrosion.
Plastic PVC or CPVC pipe are the only approved materials.
A condensate neutralizer, if required by local authorities, can be made
up of lime crystals, marble or phosphate chips that will neutralize the
condensate. This may be done by the installer or you may purchase a
condensate neutralizer from HTP (7350P-611).
2. The boiler is equipped with a ¾ female socket weld fitting
connection that must be piped to a local drain. It is very important
that the condensate line is sloped downward away from the boiler 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 condensate overflow, which, if not corrected, could cause
property damage.
3. If a long horizontal run is used, it may be necessary to create a vent
in the horizontal run to prevent a vacuum lock in the condensate line.
4. Do not expose the condensate to freezing temperatures.
5. It is very important you support the condensation line to assure
proper drainage.
It is important to purge the system of air to avoid damage to the
boiler.
E. Purge Air from Water System
Purge air from the system:
a. Connect a hose to the purge valve and route hose to an area
where water can drain and be seen.
b. Close the boiler or system isolation valve between the purge
valve and fill connection to the system.
c. Close zone isolation valves.
d. Open quick-fill valve on cold water make-up line.
e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow water to
run through the zone, pushing out the air. Run water until no
noticeable air flow is present. Close the zone isolation valves and
proceed with the next zone. Follow this procedure until all zones
are purged.
g. Close the quick-fill water valve and purge valve and remove
the hose. Open all isolation valves. Watch the system pressure rise
to correct cold-fill pressure. It is recommended that you put the
pumps into manual operation to assist in purging the circuits.
h. Disconnect the wires that are connected to the THERMOSTAT
terminals of the customer connection board. Apply power to the
boiler. The display will show the temperature of the water in the
boiler. Press the
v
and
ENTER
keys simultaneously and hold for 1
second. The display will read:
The central heating pump will come on. If you then press the
^
key, the central heating pump will shut off. The display will read:
The DHW pump will come on. If the boiler is set up as a cascade
master and you then press the
^
key again, the DHW pump will
shut off. The display will read:
The system pump will come on. Use the
^
and
v
keys to toggle
between running each pump in the system as required to help
bleed out all entrapped air. Some good indicators that air is
removed include the absence of gurgling noises in the pipes and
pump operation becoming very quiet. Pressing
^
and
v
together
at any time will return the boiler to normal operation.
i. After the system has operated for five minutes, eliminate any
residual air by using the manual air vents located throughout the
system.
j. If purge valves are not installed in the system, open manual air
vents in the system one at a time, beginning with the lowest floor.
Close vent when water squirts out. Repeat with remaining vents.
k. Refill to correct pressure.
F. Check Thermostat Circuit(s)
1. Disconnect the two external wires connected to the boiler
thermostat terminals (low voltage terminal strip).
2. Connect a voltmeter across these two incoming wires with power
supplied to the thermostat circuits. Close each thermostat, zone
valve and relay in the external circuit one at a time and check the
voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage reading does occur under any condition, check and
correct the external wiring. (This is a common problem when using
3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and corrected
if necessary, reconnect the external thermostat circuit wires to the
boiler low voltage terminal strip. Allow the boiler to cycle.
H. Final Checks Before Starting Boiler
1. Read Startup Procedures within this manual for proper steps to start
boiler. (See Startup Report to record steps for future reference.)
2. Verify the boiler and system are full of water and all system
components are correctly set for operation.
Ensure the boiler is full of water before firing the burner. Failure to do
so will damage the boiler. Such damage IS NOT covered by warranty,
and could result in property damage, severe personal injury, or
death.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and securely attached.
5. Inspect exhaust vent and intake piping for signs of deterioration
from corrosion, physical damage or sagging. Verify exhaust vent and
intake piping are intact and correctly installed per Venting Section and
local codes.
I. Setting Up a Single Boiler
When power is applied to the boiler, the control first completes a
power-up systems check. During this time the combustion fan may run.
The display will initially show the current boiler supply temperature. If
a fault is detected during the power-up test, the control will display the
appropriate fault code. Otherwise, the display will continue to show
the boiler supply temperature and stand-by, waiting for a demand for
heat.
When a demand for heat is received, the control begins the following
demand sequence. The boiler first turns on the pump. The control
will measure the supply temperature. If it is below the set point
temperature minus the ignition differential the control will ignite the
burner.
After the burner is lit, the control modulates the firing rate to control
the supply water temperature and meet the heat demand. When the
thermostat or indirect water heater temperature is met, the control
will extinguish the burner and run the combustion fan to purge gasses
