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HTP Elite XL ELX-650 User Manual

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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-650 Specifications

General IconGeneral
BrandHTP
ModelElite XL ELX-650
CategoryBoiler
LanguageEnglish

Summary

Installation Sections

Start-Up

Guide for initiating boiler operation and ensuring proper function after installation.

Operating Instructions

Special Attention Boxes

For the Installer

Section providing guidance and requirements specifically for installers.

Installation Compliance Requirements

Lists essential codes and regulations for boiler installations.

Notices and Important Information

System Type Warning

Critical safety warning about using the boiler in closed-loop systems only.

Part 1 - General Safety Information

Installer Guidelines

Direct instruction for installers on reading and following manual procedures.

User Scope Definition

Defines the intended user of the manual as qualified installers/technicians.

Submersion Hazard Warning

Critical warning against operating boilers submerged in water.

Part 3 - Prepare the Boiler

Boiler Location Requirements

Critical requirements for selecting the boiler installation location.

Installation Clearances and Location

Service Clearances and Warnings

Mandatory clearances for service access and related warnings.

Exhaust Vent and Intake Pipe

Venting Hazard and Method Warnings

Critical warnings regarding venting hazards and approved methods.

Combustion Air and Carbon Monoxide Detectors

Indoor Combustion Air Requirements

Requirements for using indoor air for combustion and ventilation.

Carbon Monoxide Detector Installation

Mandatory safety requirement for CO detector installation.

Water Chemistry Requirements

Water Chemistry Damage Warning

Critical warning about damage caused by improper water chemistry.

K. Technical Specifications

Part 4 - Piping

Piping Warnings and Material Restrictions

Covers piping failure warnings and material restrictions.

Relief Valve Installation and Maintenance

Critical safety component installation and inspection requirements.

Plumbing Components and System Piping

Hydronic Piping Configurations

Piping configurations for systems with circulators, zone valves, and multiple boilers.

G. Circulator Sizing

O. Applications*

Thermostatic Mixing Valve Warning

Critical safety warning regarding thermostatic mixing valves.

Part 5 - Venting

General Venting Requirements and Warnings

General requirements and hazard warnings for venting systems.

Venting Material and Installation Precautions

Covers pipe gaskets, support, pitch, and solvent hazards.

Carbon Monoxide Hazard and Venting

CO hazard warning and general venting safety.

Venting Materials and Canadian Requirements

Approved Venting Materials

Lists approved materials for exhaust and intake vent piping.

Venting System Component Mixing Warning

Warning about mixing components from different venting systems.

Exhaust Vent and Intake Pipe Location

Vent Termination Clearances

Specifies required clearances for vent terminations.

Termination Blockages and CO Detector Warnings

Warnings about vent blockages and CO detector placement.

Exhaust Vent and Intake Pipe Sizing and Installation

Vent Pipe Sizing Limits

Defines maximum equivalent lengths for vent pipes.

Vent Pipe Installation Procedures

Detailed steps for installing vent piping correctly.

Venting Configuration Examples

Vent Pipe Support and Pitch Warning

Prominent warning about adequate support and pitch of vent piping.

Indoor Combustion Air Requirements

Condensate Removal and Carbon Monoxide Warning

Carbon Monoxide Hazard Warning

Safety warning about the hazards of carbon monoxide.

Part 7 - Wiring - 400 - 1500 Models

Part 8 - Wiring - 2000 Models

Electrical Safety and Compliance Warnings

Covers electrical shock hazards and compliance with codes.

Wiring Connections for Standard Boilers (2000 Models)

Cascade System Communication Wiring

Wiring instructions for cascade system communication bus.

Part 9 - Gas Connections

Gas Connection Safety Warnings

Critical warnings regarding gas connection hazards.

Gas Pressure Checks and Warnings

Inlet Gas Pressure Check Procedure

Procedure for checking inlet gas pressure.

Gas Pressure and Safety Warnings

Gas pressure requirements and critical safety warnings.

Boiler Gas Valve Operation and Adjustment

Gas Conversion and Adjustment Hazards

Warnings about gas conversion and adjustment hazards.

Part 10 - Start-Up Preparation

Pre-Start System Checks

Checks for water chemistry, gas leaks, freeze protection, and filling.

Water Chemistry Requirements and Maintenance

Water chemistry parameters and cleaning recommendations.

Gas Leak Detection Procedure

Safety procedure for checking for gas leaks.

System Filling and Leak Testing

Procedures for filling the system and performing leak tests.

Pre-Start Checks and Start-Up Procedure

Condensate Removal Procedures

Detailed steps for condensate removal and piping.

Final Checks Before Starting Boiler

Pre-start checklist including water level and wiring.

Start-Up Procedure Overview and Safety

Core operational procedure and essential safety precautions.

Touch Screen Display Navigation

System Purging and Boiler Start-Up

Single Boiler Start-Up and Operation

Step-by-step guide for starting a single boiler unit.

Cascaded System Start-Up and Operation

Guide for starting up and operating cascaded boiler systems.

Cascade System Lockout Conditions

Explains lockout conditions within a cascaded system.

Cascade System Programming and Operation

Cascade System Configuration

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

General Operating Instructions

Guidance on pre-operation checks and initiating system operation.

I. Programming User Settings

J. Programming Installer Settings

Outdoor Reset Curve Configuration

Configuration of the outdoor reset curve for heating.

Installer Settings Menu

Installer Settings Configuration

Installer Settings - Advanced Configuration

Maintenance Schedule Reset and Service Mode

Service Mode Operations

Procedures for combustion testing and LWCO testing.

Boiler Status Monitoring

Accessing Status Screens

How to navigate to and view boiler status screens.

Boiler History Screens

Fault and Block Code Screens

System Analytics and Cascade Monitoring

Troubleshooting Common Issues

Critical Safety Warnings

Covers overheating, submersion, and wiring error warnings.

Troubleshooting Specific Fault Codes

Troubleshooting Specific Fault Codes (Cont.)

Troubleshooting Specific Fault Codes (Cont. 2)

Troubleshooting Specific Fault Codes (Cont. 3)

Boiler Blocking Codes

Part 14 - Maintenance

Combustion Chamber Cleaning Instructions

Specific instructions for cleaning the combustion chamber.

Combustion Chamber Cleaning Procedure

Part 15 - Shutdown

Shutdown Procedure and Warnings

How to shut down the boiler and related warnings.

Failure to Operate Troubleshooting

Troubleshooting ignition failures and lockout conditions.

Replacement Parts Identification

Replacement Parts Identification (1500-2000 Models)

Replacement Parts Identification (2000 Model Heat Exchanger)

Part 17 - Installation Checklist

Part 18 - Maintenance Report

Maintenance Inspection Checklist Details

ELX Boiler Limited Warranty

Warranty Exclusions Overview

Provides an overview of common warranty exclusions.

Warranty Exclusions and Limitations

Warranty Service Request Procedures

Steps for making a warranty claim and contacting HTP.

Warranty Terms Limitations

Legal limitations and disclaimers of the HTP warranty.

Customer Installation Record Form

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