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HTP Elite XL ELX-800 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-800 Specifications

General IconGeneral
ModelELX-800
TypeCondensing Boiler
Fuel TypeNatural Gas or Propane
Input BTU800, 000 BTU/h
Efficiency95%

Summary

Installation Guide

Safety First: Before Operation

Smelling Gas: Immediate Actions

Critical steps to take if the presence of gas is detected.

Understanding Hazard Symbols

DANGER Alerts

Indicates imminently hazardous situations resulting in severe injury or death.

WARNING Alerts

Indicates potentially hazardous situations resulting in injury or death.

CAUTION Alerts

Indicates potentially hazardous situations resulting in minor injury.

Foreword and Installer Information

General Safety Information

Improper Combustion Hazards

Precautions and risks associated with improper combustion.

Boiler Servicing Safety

Safety procedures to follow when performing maintenance on the boiler.

Boiler Preparation Steps

Installation Clearances and Venting

Exhaust and Intake Vent System

Requirements and guidelines for the boiler's exhaust and intake venting.

Combustion Air and CO Detectors

Carbon Monoxide Detector Installation

Mandatory installation requirements for CO detectors per codes.

Preventing Air Contamination and Venting

Preventing Combustion Air Contamination

Methods to prevent contamination of combustion air intake.

Water Chemistry Requirements

Critical water chemistry parameters for boiler system operation.

Piping Installation Instructions

Relief Valve Discharge Piping

Guidelines for safe installation and operation of relief valve discharge piping.

Circulator and Hydronic System Piping

Circulator Sizing Guide

Plumbing System Checks

Water Chemistry Verification

Procedure for checking and maintaining proper water chemistry.

System Zoning and Multiple Boilers

System Piping Applications

Venting System Requirements

General Venting Principles

General principles and requirements for boiler venting systems.

Vent Pipe Materials and Canadian Requirements

Approved Vent Pipe Materials

List of approved materials for exhaust and intake vent piping.

Vent Termination Location

Vent Pipe Sizing and Installation

Exhaust and Intake Pipe Sizing

Calculations and limits for sizing exhaust vent and intake piping.

Exhaust and Intake Pipe Installation

Detailed steps for installing the exhaust vent and intake piping.

Direct Vent System Applications

Direct Vent Exhaust and Intake Installation

Specifics on direct vent installation for exhaust and intake components.

Combustion Air Requirements

Power Venting and Indoor Air Requirements

Requirements for power venting and using indoor air for combustion.

Condensate Removal and Neutralization

Boiler Wiring (400-1500 Models)

Standard Boiler Wiring

UL 353 Internal Low Water Cut-Off

Information on the internal low water cutoff safety device.

Boiler Wiring Connections

Boiler Wiring (2000 Models)

Field Wiring Procedures

Instructions for making field wiring connections to the 2000 model boiler.

Line Voltage Wiring

Wiring instructions for standard boiler line voltage connections.

Standard Boiler Wiring and Sensors

Cascade System Communication Bus Wiring

Wiring instructions for connecting boilers in a cascade system.

Boiler System Wiring Connections

Gas Connection Procedures

Gas Piping Installation

Guidelines for running and connecting the gas supply piping.

Checking Inlet Gas Pressure

Start-Up Preparation Steps

Water Chemistry Check

Procedures for checking and maintaining water chemistry.

Gas Leak Detection

Procedure for checking for gas leaks before boiler operation.

Boiler Start-Up Procedure

Condensate Removal System

Instructions for proper condensate drainage and material selection.

Touch Screen Display Navigation

Boiler System Startup

Single Boiler Start-Up

Step-by-step guide for starting up a single boiler system.

Cascaded System Start-Up

Procedures for starting up a cascaded boiler system.

Cascade System Programming and Operation

Cascade System Programming

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

Programming User Settings

User Screen 2: DHW Settings

Programming Installer Settings

Outdoor Reset Curve Configuration

Setting the outdoor reset curve for efficient heating.

Installer Menu Parameters

Installer Menu Overview

Overview of the installer menu and its adjustable parameters.

Maintenance Schedule and Service Mode

Service Mode: Combustion and LWCO Test

Accessing service mode for combustion testing and LWCO verification.

Boiler Monitoring Functions

Cascade System Status

Monitoring the status and settings of a cascaded boiler system.

Troubleshooting Common Issues

Blocking Message Resolution

Understanding and resolving blocking messages displayed by the control.

Fault (Lockout) Condition Resolution

Understanding and resolving lockout conditions indicated by the control.

Troubleshooting Sensor Faults

Flue Temperature Sensor Faults

Troubleshooting flue temperature sensor errors.

Supply Sensor Lockout

Troubleshooting supply sensor failure or differential issues.

High Supply Temperature Lockout

Addressing issues with high supply temperatures or maximum lockout.

Troubleshooting Operational Faults

Return Temperature Lockout

Troubleshooting excessive return temperatures or maximum lockout.

No Ignition Faults

Troubleshooting ignition failures and no ignition conditions.

Flame Fault Resolution

Troubleshooting flame fault conditions during boiler operation.

Flame Signal Standby/Purge Faults

Troubleshooting flame signal issues during standby or purge cycles.

Troubleshooting Speed and Water Level Faults

Internal LWCO Fault

Troubleshooting internal low water cutoff faults.

External LWCO Fault

Troubleshooting external low water cutoff faults.

Troubleshooting Component Faults

Boiler Blocking Codes

Routine Boiler Maintenance

Boiler Shutdown Procedures

Installation Checklist

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