HTP 140M, Installation Manual

Page 1: ...NGE THESE FACTORY SETTINGS Refer to the Control Program Reference Chart within this manual for selections that apply to this model This manual must be used by a qualified installer service technician Read all instructions in this manual before installing Perform steps in the given order Failure to comply could result in substantial property damage severe personal injury or death NOTICE HTP reserve...

Page 2: ...VICINITY OF THIS OR ANY OTHER BOILER WHAT TO DO IF YOU 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 ...

Page 3: ...epartment 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 HTP Inc reserves the right to modify product technical specifications and components without prior notice FOR THE I...

Page 4: ... F when there is no anticipated heat load based upon the outdoor sensor and the Outdoor Reset Curve sensor response curve in the boiler software This feature may be over ridden as described below in specific installations The boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems for systems with total input of 300 000 BTU hr or g...

Page 5: ... 20 G HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND MULTIPLE BOILERS 20 H CIRCULATOR SIZING 21 I ZONING WITH ZONE VALVES 23 J ZONING WITH CIRCULATORS 23 K MULTIPLE BOILERS 23 L FILL AND PURGE HEATING SYSTEM 23 M PIPING DETAILS 24 PART 6 PIPING WITH OPTIONAL VISION 1 SYSTEM 31 A VISION 1 SYSTEM PIPING 31 B ZONING WITH ZONE VALVES USING VISION 1 31 C ZONING WITH CIRCULATORS USING VISION 1 31 D PI...

Page 6: ...M WATER SYSTEM 59 E CHECK FOR GAS LEAKS 60 F CHECK THERMOSTAT CIRCUIT S 60 G CHECK CONDENSATE REMOVAL 60 H FINAL CHECKS BEFORE STARTING BOILER 60 PART 12 START UP PROCEDURE 61 A OPERATING INSTRUCTIONS 61 B ADJUSTING THE SET POINT 61 C STATUS MENU 62 D TEST MODE 62 PART 13 START UP PROCEDURES WITH VISION 1 OPTION 63 A PROGRAMMING THE VISION I OPTION 63 B VISION 1 PROGRAM ACCESS 63 C VISION 1 PROGRA...

Page 7: ...Operating a previously submerged boiler could result in property damage severe personal injury or death NOTE Boiler damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty Be sure to disconnect electrical power before opening boiler cabinet or performing service Failure to do so could result in an electrical shock that could result in property damage...

Page 8: ...o not fill boiler or operate with water containing chlorine in excess of 100 ppm NOTE It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in Part 15 Section B of this manual Hardness 7 grains Chloride levels 100 ppm pH levels 6 8 TDS 2000 ppm Sodium 20 mGL G WINTERIZING NEVER use any toxic chemica...

Page 9: ...d gas and provides a wide range of firing rates Electrical Field Connections with Terminal Strips The electrical cover plate allows access to the line voltage and low voltage terminal strips Attach line voltage conduits to the three holes at the right of the line voltage terminal strip for power CH pump and DHW pump Route low voltage wires through the opening to the left of the low voltage termina...

Page 10: ...could result in wasted time money and possible property damage and personal injury A BEFORE LOCATING THE BOILER Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk Ensure that the boiler installation location adheres to the information included in this manual Failure to do so could result in property damage serious personal injury or death Failure o...

Page 11: ...re personal injury or death 4 Gas control system components must be protected from dripping water during operation and service 5 If the boiler is to replace an existing boiler check for and correct any existing system problems such as System leaks Location that could cause the system and boiler to freeze and leak Incorrectly sized expansion tank 6 Clean and flush system when reinstalling a boiler ...

Page 12: ...12 LP 185 Rev 9 9 14 Figure 1 Dimensions T 50M T 80M 80M ...

Page 13: ...13 LP 185 Rev 9 9 14 Figure 2 Dimensions 140M 199M 399M ...

Page 14: ...re manual as it could save time and money B LEVELING Figure 3 Boiler Leveling In order for the condensate to properly flow out of the collection system the boiler must be installed with 1 8 per foot pitch toward the back The location must also support the boiler when it is full of water The boiler comes equipped with leveling feet Should the floor beneath the boiler be uneven use a wrench to adjus...

Page 15: ...ailure to follow this warning could result in substantial property damage severe personal injury or death The space must be provided with correctly sized combustion ventilation air openings for all other appliances located in the space with the boiler Do not install the boiler in an attic Failure to comply with these warnings could result in substantial property damage severe personal injury or de...

Page 16: ...anufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches laundry detergents and cleaning solvents Garages and workshops Adhesives used to fasten building products Table 2 Contaminant Table You must pipe outside air to the boi...

Page 17: ...location BELOW 0 o F before installation handle with care until the plastic components come to room temperature A REMOVE BOILER FROM PACKAGING The boiler is easy to handle Care must be taken to place it in a safe location prior to installation to prevent damage to the mechanical connections B WALL MOUNTING CONSIDERATIONS T50M and T80M boilers may be wall mounted Use only the wall mounting instruct...

Page 18: ...wrench to prevent the boiler return or supply line from turning Failure to prevent piping connections from turning could cause damage to boiler components 1 The water supply should be shut off while connecting the boiler A manual control valve must be placed on the inlet connection to the boiler Unions can be used on both the hot and cold water lines for future servicing and disconnection of the u...

Page 19: ...peration of the relief valve after filling and pressurizing the system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly immediately replace with a new properly rated relief valve Test relief valve at least once annually to ensure the waterway is clear If valve does not operate turn the boiler off and call a plumber immediately Take care whenever op...

Page 20: ...e system fill connection at the same point as the expansion tank connection to the system 4 Most chilled water systems are piped using a closed type expansion tank DO NOT install automatic air vents on closed type expansion tank systems Air must remain in the system and return to the tank to provide its air cushion An automatic air vent would cause air to leave the system resulting in water loggin...

Page 21: ...r the boiler 1 Connect the system return marked Boiler In 2 Connect the system supply marked Boiler Out 3 Install purge and balance valve or shut off valve and drain on system return to purge air out of each zone 4 Install a back flow preventer on the cold feed make up water line 5 Install a pressure reducing valve on the cold feed make up water line 15 psi nominal on the system return Check tempe...

Page 22: ...d Temperature Rise Chart LP 171 F NOTE The recommended circulators are based on 1 gpm per 10 000 btu hr with 20 t The chart below represents various system temperatures respective flows and friction loss through the boiler to aid in circulator selection ...

Page 23: ...in you will see a steady stream of water without bubbles Close balance and purge valve or drain to stop the water from flowing Disconnect the hose and connect it to next zone to be purged Repeat this procedure for additional zones one at time For installations that incorporate standing iron radiation and systems with manual vents at the highest points Follow the above section and starting with the...

Page 24: ...lycol manufacturer s concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You must carefully figure the additional system friction loss as well as the reduction in heat transfer coefficients M PIPING DETAILS Figure 7 ...

Page 25: ...9 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe dia...

Page 26: ...9 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe dia...

Page 27: ...99 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe di...

Page 28: ...99 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe di...

Page 29: ...99 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe di...

Page 30: ...99 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe di...

Page 31: ...ONING WITH ZONE VALVES USING VISION 1 1 Connect the boiler to the system as shown in piping details 3A through 3C 2 Connect the DHW circulator P2 directly to the boiler as shown in the piping details The boiler circulator P1 will shut down when there is a DHW demand C ZONING WITH CIRCULATORS USING VISION 1 1 Connect the boiler to the system as shown in piping details 4A through 4H 2 Connect the DH...

Page 32: ...nimum pipe size for connecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of str...

Page 33: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 34: ...ulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe diameters o...

Page 35: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 36: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 37: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 38: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 39: ...onnecting the unit is 1 25 and 2 for the 399 5 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream o...

Page 40: ... valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 9 All clos...

Page 41: ... valves Purge valves can be used with the circulator flanges as an alternative 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119o F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 9 All clos...

Page 42: ...r operation This boiler cannot share a common exhaust or intake with multiple appliances Failure to follow this instruction will result in substantial property damage severe personal injury or death NOTE To avoid contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors Improper seating of vent pipe gaskets can cause eventual gasket failure a...

Page 43: ... certified to ULC S636 IPEX is an approved vent manufacturer in Canada 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 the boiler flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with o...

Page 44: ...erials will be subject to corrosion or deterioration However use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement If pipe is used deburr and chamfer pipe to allow proper mating ...

Page 45: ...we find Total Equivalent Length 20 23 3 46 feet The total equivalent length is 46 feet which is well below the maximum of 85 feet c The exhaust vent and intake pipe are intended to penetrate the same wall or roof of the building d Effort should be made to keep a minimum difference in equivalent length between the exhaust vent and intake pipe 3 The minimum total equivalent length is 32 equivalent f...

Page 46: ...or PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is located where it will not be exposed to prevailing winds 5 In all roof venting applications exhaust discharge must point away from the pitch of the roof 6 To prevent water leakage install adequate roof flashing where the pipe enters the roof 7 Do not locate vent over public walkways driveways or parking l...

Page 47: ...support any piping 14 A screened straight coupling is provided with the boiler for use as an outside exhaust termination 15 A screened inlet air tee is provided with the boiler to be used as an outside intake termination The following information on Table 8 lists optional exhaust intake terminations available from HTP DESCRIPTION STOCK CODE 2 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0501CVT 3 PVC ...

Page 48: ...48 LP 185 Rev 9 9 14 I DIAGRAMS FOR SIDEWALL VENTING Figure 25 Venting ...

Page 49: ...49 LP 185 Rev 9 9 14 Figure 26 Sidewall Venting ...

Page 50: ...50 LP 185 Rev 9 9 14 J DIAGRAMS FOR VERTICAL VENTING Figure 27 Vertical Venting ...

Page 51: ...s valve In the event the gas valve is exposed to a pressure greater than PSI 14 water column the gas valve must be replaced Never use an open flame match lighter etc to check gas connections Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 5 psi or less and a ...

Page 52: ...as piping connection could damage the boiler beyond repair Such damage IS NOT covered by warranty C CHECK INLET GAS PRESSURE The gas valve is equipped with an inlet gas pressure tap that can be used to measure the gas pressure to the boiler To check gas pressure perform the steps listed below 1 IMPORTANT Before you connect to the inlet pressure shut off the gas and electrical power to boiler 2 Loo...

Page 53: ... lines This gas valve must not be replaced with a conventional gas valve under any circumstances DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure and requires no field adjustment Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve and cause substantial property dam...

Page 54: ...Canadian Electrical Code Part 1 and any local codes B FIELD WIRING The boiler box has a 24 volt terminal strip on the boiler cabinet and a 120 volt terminal strip enclosed in the electrical box Each terminal connection is clearly marked to assure correct installation C LINE VOLTAGE WIRING 1 Connect 120 VAC power wiring to the line voltage terminal strip located inside the electric junction box as ...

Page 55: ...55 LP 185 Rev 9 9 14 Figure 29 ...

Page 56: ...56 LP 185 Rev 9 9 14 Figure 30 NOTE A resistor is provided between Bus Lines A and B DO NOT REMOVE THIS RESISTOR DOING SO WILL EFFECT HEATER OPERATION AND VOID WARRANTY ...

Page 57: ...ommended that you do not exceed 5 minutes on the DHW pump post purge cycle to avoid cooling down your DHW tank Indirect Sensor The Indirect Sensor connects to the boiler main control Route wires from the terminal strip to the sensor or the mechanical control Honeywell part L4080b1395 not included in Vision I Package into the control well located in the front of the water heater This will allow the...

Page 58: ...assure extended service life it is recommended to test water quality prior to installation Listed below are some guidelines Do not use petroleum based cleaning or sealing compounds in boiler system Damage to elastomer seals and gaskets in system could occur resulting in substantial property damage Sodium less than 20 mGL Water pH between 6 0 and 8 0 1 Maintain boiler water pH between 6 0 and 8 0 C...

Page 59: ...ill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a Typical cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases Operating pressure mu...

Page 60: ... CHECK CONDENSATE REMOVAL 1 This a high efficiency condensing boiler therefore the unit has a condensation drain Condensate is nothing more than water vapor derived from combustion products similar to an automobile when it is initially started The condensation is slightly acidic typically with pH of 3 to 5 and must be piped with the correct materials Never pipe the condensate using steel copper br...

Page 61: ... A OPERATING INSTRUCTIONS Remove boiler cover If you smell gas STOP Follow listed safety instructions If you do not smell gas follow the next steps 1 Turn on all electric power to boiler 2 If desired adjust the temperature set point of the boiler The factory default setting is 180 o F If changes are necessary follow Adjusting the Set point in this section 3 Set the thermostat to the desired settin...

Page 62: ...fan speed displayed is 410 RPM x 10 4100 actual fan speed d7 Actual Ionization current read from Flame Rectification probe d8 Actual Status of the Central Heating Circulator Off 0 On 1 Vision option d9 Actual Status of the Indirect Fired Circulator Off 0 On 1 Vision option d10 Actual Status bus communication co connected no not connected d11 Central Heating Set Point d12 Power On Hours in units d1...

Page 63: ...fective immediately but not directly stored until the S4 key is pressed down for 3 seconds then the new values are stored Listed below are the varieties of functions the installer can program into the Vision I System NOTE The boiler cannot be programmed when there is a call for heat See Table 14 to set outdoor reset curve START UP PROCEDURES WITH VISION 1 OPTION DEFAULT FUNCTION FUNCTION VALUE DES...

Page 64: ...connected the supply temperature will depend on the factory default central heating curve To set your heat curve you will have to set the following parameters 1 Minimum outside design temperature Function 8 2 Design supply water temperature at the minimum design outside temperature Function 9 3 Maximum outside design temperature Function 10 4 Design supply water temperature at the maximum outside ...

Page 65: ...gested corrective actions are included in Table 15 3 In the case of E00 E13 and E14 this error if uncorrected will go into a fault condition as described is Paragraph C Boiler Fault C BOILER FAULT 1 When a fault condition occurs the controller will illuminate the red fault indication light and display a fault code in the format Example F00 on the display module 2 Note the fault code and refer to T...

Page 66: ...ch temporarily only as a troubleshooting aid The 24 VAC signal may have grounded through the glycol if the water pressure switch is leaking F01 Vent temperature limit exceeded 1 Push the red reset button on the vent temperature limit switch 2 Check the flue temperature during operation using a combustion analyzer 3 Replace the vent limit switch if faulty 4 Verify the combustion drain is clear and ...

Page 67: ...ier probe 6 If the flame rectifier probe continues to read low replace it 7 Check the stability of the flame rectification signal If the signal is unstable you may need to replace the burner gasket F11F False flame signal The boiler will lock out if it senses a flame signal when there should be none present 1 Turn the gas off to the unit at the service valve 2 If the flame signal is still present ...

Page 68: ... contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers ...

Page 69: ...the gas valve e Disconnect the wiring connected to the combustion blower motor f Remove the 6 10MM nuts from the burner plate assembly to access the coils g Pull the entire burner plate assembly with blower still attached towards you while removing or pushing aside any wiring to allow the removal of the assembly 2 Using a spray bottle filled with calcium and lime deposit remover spray liberally on...

Page 70: ...70 LP 185 Rev 9 9 14 Figure 31 ...

Page 71: ...71 LP 185 Rev 9 9 14 Figure 32 ...

Page 72: ...72 LP 185 Rev 9 9 14 Figure 33 ...

Page 73: ...73 LP 185 Rev 9 9 14 Figure 34 ...

Page 74: ...74 LP 185 Rev 9 9 14 Figure 35 ...

Page 75: ...75 LP 185 Rev 9 9 14 Figure 36 ...

Page 76: ...ler If necessary convert the boiler to the proper gas 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 the conversion registration Notes Table 19 MAINTENANCE REPORT In ...

Page 77: ...acuum combustion chamber Spark Electrode Clean Set gap at Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate hose Clean out dirt Fill with water to level of outlet and re install NOTE Verify the flow of condensate making sure th...

Page 78: ...78 LP 185 Rev 9 9 14 ...

Page 79: ...79 LP 185 Rev 9 9 14 ...

Page 80: ...80 LP 185 Rev 9 9 14 MAINTENANCE NOTES ...

Page 81: ...tallation Address Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make...