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HTP Elite XL ELX-400 User Manual

HTP Elite XL ELX-400
87 pages
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Elite XL®
Commercial Boilers
Installation
Start-Up
Maintenance
Parts
Warranty
ELX-400 / 500 / 650 / 800 / 1000 / 1500 / 2000 Models*
*”B” Denotes Boiler Models,
”N” Denotes Natural Gas, “LP” Denotes Propane,
and “F” Denotes Floor Mount Models
Example Model: ELX-1000FBN
DANGER
!
This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before installing.
Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.
NOTICE
HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd. New Bedford, MA 02745 www.htproducts.com
lp-666 Rev. 003 Rel. 001 Date 2.25.20
WARNING
!
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property
damage, severe personal injury, or death.
Heat Exchanger Bears the ASME “H”
Stamp
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Table of Contents

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HTP Elite XL ELX-400 Specifications

General IconGeneral
BrandHTP
ModelElite XL ELX-400
CategoryBoiler
LanguageEnglish

Summary

Installation Guide

Start-Up Procedures

Step-by-step guide for initiating boiler operation.

Maintenance Guidelines

Instructions for routine upkeep and servicing of the boiler.

Operating Instructions

Gas Leak Emergency Procedures

Emergency steps to follow if a gas leak is detected.

Pre-Operation Safety Checklist

Critical safety precautions before operating the boiler.

Appliance Gas Shut-Off Procedure

Safe procedure for shutting off the gas supply to the appliance.

For the Installer

Installation Compliance Requirements

Lists codes, laws, and regulations for boiler installations.

General Safety Information

Improper Combustion Hazards

Discusses hazards of improper combustion and necessary precautions.

Gas Supply Safety Guidelines

Safety rules for handling and connecting the gas supply.

Maintenance Procedures

Routine Maintenance Guidelines

General guidelines for periodic maintenance tasks.

Boiler Preparation Guidelines

Boiler Location Selection Criteria

Guidelines for selecting an appropriate installation location for the boiler.

Boiler Installation Clearances and Venting

Exhaust and Intake Vent System Installation

Guidelines for the proper installation of exhaust and intake vent systems.

Combustion Air and CO Detector Requirements

Carbon Monoxide Detector Installation Mandates

Requirements for installing CO detectors, especially in Massachusetts.

Combustion Air Contamination and Water Chemistry

Preventing Combustion Air Contamination

Lists products and areas to avoid for clean combustion air intake.

Boiler Water Chemistry Standards

Crucial parameters for boiler water quality to prevent damage and ensure efficiency.

Technical Specifications

Electrical, Ignition, and Control Specs

Details power supply, fuse ratings, operating conditions, ignition, and control panel information.

Piping and System Connections

Relief Valve Installation and Safety Warnings

Instructions and warnings for installing and maintaining the relief valve.

Backflow Preventer and Expansion Tank Requirements

Requirements for backflow preventers and sizing expansion tanks.

Boiler Piping and Circulator Requirements

Hydronic Piping, Zoning, and Freeze Protection

Details on hydronic piping, zone valves, multiple boilers, and freeze protection fluids.

Circulator Sizing and Manifold Piping Recommendations

Circulator Sizing and Pressure Drop Data

Data and charts for sizing circulators based on boiler pressure drop.

Multiple Boiler Manifold Piping Sizing

Recommendations for pipe sizes in manifold systems for multiple boilers.

Boiler Venting Requirements and Safety

General Venting Installation Rules

Essential rules for venting the boiler, including material and installation requirements.

Vent Pipe Sizing and Installation Procedures

Vent Pipe Sizing Calculation Methods

Guidance on calculating equivalent lengths for vent pipe sizing using friction loss tables.

Vent Pipe Installation Steps and Precautions

Detailed steps for installing vent pipes, including cleaning, priming, cementing, and slope.

Combustion Air Requirements for Power Venting

Indoor Combustion Air Supply Calculations

Rules for using indoor air for combustion, including volume and opening size requirements.

Condensate Piping and Electrical Wiring Safety

Electrical Wiring Safety Precautions

Critical warnings and precautions before performing any electrical wiring.

Electrical Code Compliance for Wiring

Requirements for complying with electrical codes for installation.

Boiler Wiring for Standard Models

Line Voltage Wiring Connections

Instructions for connecting line voltage power and pump relays.

Boiler Wiring for 2000 Models

2000 Model Installation Code Compliance

Requirements for complying with electrical codes for boiler installation.

Gas Connections and Piping Safety

Gas Piping Installation Guidelines

Guidelines for running and supporting gas supply lines according to codes.

Gas Connection Safety and Leak Testing

Warnings and procedures for leak testing gas connections.

Gas Pressure Measurement and Requirements

Checking Inlet Gas Pressure Steps

Step-by-step instructions for measuring gas pressure to the unit.

Gas Pressure Specifications and Warnings

Details on required gas pressures and warnings about adjustments.

Boiler Gas Valve Adjustments and Safety

Gas Valve Components and Adjustment Cautions

Explanation of gas valve components and the caution against unauthorized adjustments.

Start-Up Preparation and System Checks

Water Chemistry and System Cleaning Procedures

Procedures for checking water chemistry, cleaning the system, and testing freeze protection.

Boiler Start-Up Procedures and Safety

Pre-Startup Safety and Operational Steps

Critical safety warnings and initial steps before operating the boiler.

System Purging and Boiler Start-Up Operations

Air Purging Procedure for Heating Systems

Step-by-step instructions for removing air from the heating system.

Cascade System Programming and Operation

Cascade System Boiler Programming

Steps for programming the master and follower boilers in a cascade system.

Installer Settings - Outdoor Reset Curve

Setting the Outdoor Reset Curve Parameters

Adjusting parameters for the outdoor reset curve to optimize heating.

Maintenance Schedule and Service Mode

Entering and Using Service Mode

How to enter service mode for testing combustion and LWCO.

Troubleshooting - General Interface and Codes

Blocking and Lockout Condition Explanations

Explanation of blocking and lockout messages and their causes.

User Interface Display Lockout Code Reference

Reference for lockout codes, messages, descriptions, and possible remedies.

Troubleshooting - Lockout Codes F01-F05

F01-F05 Lockout Code Troubleshooting

Explanations and remedies for specific lockout codes related to sensors and temperature limits.

Troubleshooting - Lockout and Blocking Codes F06-F11

F06, F09, F10, F11 Code Troubleshooting

Troubleshooting for codes related to return temperature, ignition, flame faults, and standby flame signals.

Troubleshooting - Fan and Water Level Codes F13-F22

F13-F22 Lockout Code Troubleshooting

Troubleshooting for codes related to fan speed, condensate, and water level issues.

Troubleshooting - Fault and Error Codes F24-F43

F24, F26, F31, F41, F42, F43 Code Troubleshooting

Troubleshooting for codes related to burner door, gas pressure, program errors, and internal faults.

Troubleshooting - Blocking Codes FL, E07

FL, E07 Blocking Code Troubleshooting

Troubleshooting for blocking codes related to outdoor sensor, flow switch, and flue temperature.

Boiler Maintenance Procedures

Combustion Chamber Coil Cleaning Instructions

Detailed instructions for cleaning the combustion chamber and related components.

Boiler Shutdown and Operation Failure Handling

Troubleshooting Boiler Ignition Failures

What to do when the boiler fails to ignite or operate correctly.

Replacement Parts - 400-1000 Models

Replacement Parts - 1500-2000 Models

ELX Boiler Limited Warranty Terms

Warranty Coverage Periods and Rates

Details on basic and extended warranty coverage terms and periods.

Warranty Exclusions and Limitations

Conditions and circumstances not covered by the warranty.

Warranty Claims and Limitations

Warranty Claim Submission Process

Steps for submitting and processing warranty claims.

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