lp-666 Rev. 003 Rel. 001 Date 2.25.20
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F. 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 female socket weld fitting connection
(¾” in 400 to 1000 models and 1” in 1500 and 2000 models) 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.
G. 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.
WARNING
!
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.
Part 11 - Start-Up Procedure
WARNING
!
FOR YOUR OWN SAFETY READ BEFORE OPERATING
1. This boiler does not have a pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light
the burner by hand.
2. BEFORE OPERATING: Smell all around the boiler area for gas. Be
sure to smell next to the floor because some gas is heavier than air
and will settle on the floor.
3. WHAT TO DO IF YOU SMELL GAS
• Do not try to light any boiler.
• Do not touch any electric 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 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
fire or explosion.
4. Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the
boiler and to replace any part of the control system and any gas
control that has been damaged.
5. The boiler shall be installed so the gas ignition system
components are protected from water (dripping, spraying, rain,
etc.) during boiler operation and service (circulator replacement,
condensate trap, control replacement, etc.)
Failure to follow these instructions could result in property
damage, serious personal injury, or death.
If you discover any evidence of a gas leak, shut down the boiler
at once. Find the leak source with a bubble test and repair
immediately. Do not start the boiler again until the leak is repaired.
Failure to comply could result in substantial property damage,
severe personal injury, or death.
A. Control Overview
The control is one of the primary safety devices of the boiler. It
monitors the safety sensors of the boiler to assure safe and efficient
operation.
The control has many features associated with system design.
This section addresses programming features, including History,
Status, User Settings and Installer Settings, to help in customizing
your control. It is important to fully understand control capabilities
before customization, as its factory defaults may already fit your
system design and not require any adjustment at all.
E. 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.
