Kiturami EFTC-140W Installation, Start-Up, Maintenance, Parts, Warranty Download

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LP-520 REV. 7.26.16

Summary of Contents for EFTC-140W

Page 1: ...Drinking Water Act Section 1417 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE DO NOT STORE 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 phon...

Page 2: ...2 LP 520 REV 7 26 16 ...

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: ...MPLY 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 C...

Page 5: ...INED VENT LENGTHS 24 D TIGHTENING APPLIANCE COLLAR TO EXHAUST VENT AND INTAKE PIPE 25 E VENT TERMINATION 26 1 Direct Vent Two Pipe Roof and Sidewall Vent Terminations 26 2 Direct Vent Optional Horizontal and Vertical Vent Kits 27 3 Screen Installation 27 4 Power Vent Indoor Combustion Air Installation in Confined or Unconfined Space 28 PART 6 INSTALL THE CONDENSATE DRAIN 30 PART 7 GAS PIPING 31 A ...

Page 6: ...AL 58 M 0 10 VOLT INPUT 59 PART 11 START UP PREPARATION 60 A CHECK CONTROL WATER CHEMISTRY 60 B GLYCOL ANTIFREEZE SOLUTIONS 60 C CHECK FOR GAS LEAKS 61 D FILL AND TEST WATER SYSTEM 61 E PURGE AIR FROM CH AND INTERNAL STORAGE TANK 62 F PURGE AIR FROM DHW SYSTEM 62 G CHECK THERMOSTAT CIRCUIT S 63 H CONDENSATE REMOVAL 63 I FINAL CHECKS BEFORE STARTING APPLIANCE 63 J ADJUSTING GAS PRESSURE AT THE APPL...

Page 7: ...ssure Relief Valve With X 1 Bushing CH Line 30 psi 7855P 077 1 Each Vent Screens 3 7855P 085 2 Screens Outdoor Sensor with Screws and Anchors 7855P 084 1 Venting Kit for Combi Boiler 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...

Page 8: ...oper installation and or operation can cause a potentially hazardous situation which if not avoided could result in serious injury or death and will void the warranty HTP Inc cannot anticipate every circumstance that might involve a potential hazard Each installation has its own specialized characteristics requirements and possible hazards Therefore all possible incidents are not included in these...

Page 9: ...eat shutdown limit In the event the appliance water exceeds the set point of the control limit the cutoff will trip and the appliance will shut down Certain local codes require additional temperature limits In addition certain types of systems may operate at temperatures below the minimum set point of the limit provided with the appliance Contact a qualified service technician for additional overh...

Page 10: ... Total Hardness 200 mg l 12 grains gallon Manganese 0 05 mg l Aluminum 0 05 to 0 2 mg l pH 6 5 8 5 Chloride 250 mg l Sulfate 205 mg l Copper 1 mg l Total Dissolved Solids TDS 500 mg l Iron 0 3 mg l Zinc 205 mg l Table 2 Water Quality Specifications F FREEZE PROTECTION Consider appliance piping and installation when determining appliance location NOTE Damages resulting from incorrect installation o...

Page 11: ...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 Gallon 1 5 Gallons Heat Exchanger Capacity 4 Gallons 3 5 Gallons Total Water Capacity 5 Gallons Main Controller Control Pa...

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: ...ch 11 CH Pressure Gauge 26 Exhaust Vent Pipe 12 DHW Outlet Adapter 27 Exhaust Vent Adapter 13 Gas Inlet Adapter 28 CH Return Filter 14 DHW Inlet Adapter With Filter and Flow Restrictor 29 Relief Valve Adapter 15 Condensate Adapter 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: ...ent 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 seve...

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: ... is rated ANSI Z21 13 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed for pressurized venting Exhaust vent and intake pipe may be vented vertically through the roof 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...

Page 18: ...r it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code ANSI Z223 1 Whe...

Page 19: ...excessive flow at the faucets See Flow Charts this manual for more information If it is necessary to further increase flow to the system replace the factory installed white flow restrictor with the blue included with the appliance by following the instructions below If the appliance is already fully installed turn the gas power and water off to the appliance and drain all water from the appliance ...

Page 20: ...20 LP 520 REV 7 26 16 Figure 8 Water Pressure vs Flow Through the Restrictors 140W Models ...

Page 21: ...26 16 Figure 9 Water Pressure vs Flow Through the Restrictors 199W Models 0 1 2 3 4 5 6 7 8 9 10 11 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Flow GPM Pressure PSI 199W No Restrictor White Restrictor factory ...

Page 22: ...ion and vented to the outdoors type or as a direct vent sealed combustion type In power vent installations indoor air is used for combustion and exhaust gases are vented directly to the outdoors through a sealed exhaust vent piped through the wall or roof In direct vent installations combustion air must be supplied directly from the outdoors to the burner and the flue exhaust gases should be vente...

Page 23: ...assembly I Clearance to service regulator vent outlet 3 feet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 1 foot 3 feet K Clearance to a mechanical air supply inlet 3 feet above if within 10 feet horizontally 6 feet L Clearance above paved sidewalk or driveway located 7 feet M Clearance under veranda porch deck or balcony 1 foot Tabl...

Page 24: ...ollow the instructions included with the Cement Primer closely Clean and dry all applicable surfaces before applying Failure to follow these directions will result in substantial property damage severe personal injury or death Table 11 Approved Venting Materials Vent adaptors are not designed as load bearing devices and must not be used to support exhaust vent piping All vent pipes must be properl...

Page 25: ...t vent and intake pipe In order to use 2 pipe it is required to reduce pipe size in a vertical length of pipe with a reducing coupling not included Follow the steps below to install 2 or 3 pipe into the appliance collar See Figure 11 for additional details 1 Clean and dry the appliance connection DO NOT use primer or cement on the appliance connection 2 Push the included 6 length of CPVC pipe into...

Page 26: ...operly 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 inspection for the first three feet from the appliance ...

Page 27: ... 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 28: ...tal 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 th...

Page 29: ...29 LP 520 REV 7 26 16 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 30: ...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 31: ...he 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 ft 3 Contact the local gas supplier for actual BTU ft 3 rating 2 Natural Gas Pi...

Page 32: ...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 33: ... 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 34: ...ctions 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 De...

Page 35: ...35 LP 520 REV 7 26 16 Figure 24 Piping Legend ...

Page 36: ...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 37: ... 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 38: ...op 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 ...

Page 39: ...econdary 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 ...

Page 40: ... 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 41: ...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 42: ... property 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 applianc...

Page 43: ...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 1 st 1 minute 2 nd 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 ...

Page 44: ...44 LP 520 REV 7 26 16 Figure 32 Electrical Wiring Diagram ...

Page 45: ...45 LP 520 REV 7 26 16 Figure 33 Ladder Diagram ...

Page 46: ... 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 47: ...aust 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 48: ...48 LP 520 REV 7 26 16 Figure 34 Terminal Block Wiring Detail PART 10 OPERATING SYSTEM INSTRUCTIONS A CONTROL PANEL Figure 35 Appliance Control Panel Detail ...

Page 49: ...um 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 50: ...ds The scald warning letter H high temperature will display High temperature DHW Set Point range is 121 140 o F 49 5 60 o 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 140 o F 60 o C Water temp...

Page 51: ...r the boiler will automatically change the target temperature based on the outdoor reset curve When using 0 10V the boiler 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 operatin...

Page 52: ...tlet 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 Igniti...

Page 53: ...et the appliance will operate to heat CH water when water temperature falls below a differential setting Example If setpoint is 180 o F and differential is 27 o F the appliance will turn on when CH water temperature falls below 153 o F Range 9 27 o 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 50 110 o F 16 ...

Page 54: ...ressure 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 Igniti...

Page 55: ...heck sensor resistance 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 requirement...

Page 56: ...m persists replace the main control Er 76 Poor Communication This Error Code will go away when the condition is remedied If Error happens again 1 Check connections from main control to display panel 2 If the problem persists replace the display and or the main control Er 80 Low Water Level Sensor Low Water Level Detected Four 4 Consecutive times This Error Code will go away when the condition is r...

Page 57: ...57 LP 520 REV 7 26 16 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 58: ...rior 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 ro...

Page 59: ...ms 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 boiler controller to the boiler is correct Reversed polarity could lead to erratic and or no response from the boiler controller NOTE Outdoor Temperature Mode Icon on the display will flash if an Outdoor Sens...

Page 60: ...tact an authorized technician or licensed professional Contaminant Maximum Allowable Level Contaminant Maximum Allowable Level Total Hardness 200 mg l 12 grains gallon Manganese 0 05 mg l Aluminum 0 05 to 0 2 mg l pH 6 5 8 5 Chloride 250 mg l Sulfate 205 mg l Copper 1 mg l Total Dissolved Solids TDS 500 mg l Iron 0 3 mg l Zinc 205 mg l Table 26 Water Quality Specifications Clean system to remove s...

Page 61: ...ic switch do not use any phone in your building Immediately 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 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...

Page 62: ...e 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 terminal block Apply power to the appliance After the control goes through the start up sequence the display will turn off i Pre...

Page 63: ...local authorities may be purchased from HTP 7450P 212 2 The appliance is provided with a X reducing coupling that must be installed on the appliance before the condensate is piped to 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 ...

Page 64: ... It is required to use a combustion analyzer to verify final adjustment according to the combustion chart Table 27 Failure to do so could result in serious personal injury 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 ...

Page 65: ...normally Ensure it is operating properly 6 Reinstall the 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 66: ...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 67: ...2 4 28409 4 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 1...

Page 68: ...ust the outlet water temperature refer to the procedure in 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 th...

Page 69: ...care of the appliance as outlined in this manual must be performed by the user 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...

Page 70: ...ct the primary pressure 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...

Page 71: ... performed by a qualified 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 applian...

Page 72: ...ves V3 and V4 on the hot water outlet and cold water inlet lines 6 Turn on the 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 valv...

Page 73: ...trap assembly will cause flue gases to leak and result in serious personal injury or death When servicing is complete 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 ...

Page 74: ...agging and or leakage Repair any sags or leaks before restoring power 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 i...

Page 75: ...P 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 I...

Page 76: ...8 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 77: ...64 1 Burner Body Assembly 7855P 354 69 Internal DHW Storage Tank 7855P 240 64 2 Burner Overheat Switch 7855P 066 70 CH Supply Temperature Sensor 7855P 030 64 3 Burner Body 7855P 067 71 Water Level Detection Sensor Low water Cutoff 7855P 029 64 4 Burner Gasket 7855P 266 72 Flame sensor bracket 7855P 356 64 5 Ceramic Fiber Burner 7855P 069 73 Flame sensor 7855P 031 64 6 Burner plate O Ring 7855P 249...

Page 78: ...an Outlet Gasket 7855P 425 87 gas valve Assembly 7855P 381 82 Burner Inlet Chanel Gasket 7855P 426 87 1 Gas valve outlet adapter 7855P 232 83 APS Hose Fitting 7855P 375 87 2 Gas Valve O ring 7855P 076 84 Fan Assembly 7855P 457 87 3 Gas valve 7855P 034 84 1 Fan 7855P 025 87 4 Gas valve inlet adapter 7855P 033 84 2 Air intake Chanel Orifice 7855P 458 87 5 Gas Valve Bracket 7855P 234 84 3 Air Gas Mix...

Page 79: ...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 273 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 80: ... 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 81: ...6 67 Storage Tank Clamp 7855P 291 76 3 Burner Gasket 7855P 419 68 Storage Tank Bracket 7855P 292 76 4 Ceramic Fiber Burner 7855P 420 69 CH Supply Pipe 7855P 293 76 5 Ignition Rod 7855P 607 69 1 3 4 CH Supply Pipe Gasket 7855P 073 76 6 Igniter Gasket 7855P 252 69 2 1 CH Supply Pipe Gasket 7855P 074 76 7 Burner Overheat Switch 7855P 066 70 Storage Tank 7855P 294 76 8 Heat Exchanger Top 7855P 619 71 ...

Page 82: ...2 Burner Inlet 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 91 Gas Orifice LP 6 3 mm 7855P 435 83 5 Air Ga...

Page 83: ...stration the warranty period for the appliance shall then be deemed to have commenced thirty 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 e...

Page 84: ... alleged defective or malfunctioning parts must be returned to HTP via the local distribution channels where original purchase was made NOTE Any parts or appliances returned to HTP for warranty analysis will become the property of HTP and will not be returned even if credit is denied If all warranty conditions are satisfied HTP will provide replacement parts to the retailer For questions about the...

Page 85: ... in the appropriate 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 ...

Page 86: ...ter heating safeties Temperatures Verify safe settings 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 circ...

Page 87: ...87 LP 520 REV 7 26 16 TECH SIGN OFF Table 43 Continue annual maintenance beyond the 4 th year as required ...

Page 88: ...88 LP 520 REV 7 26 16 ...

Page 89: ...89 LP 520 REV 7 26 16 ...

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