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Installation Manual Installation Manual

1. A Maintenance Procedures B Combustion Chamber Coil Cleaning Instructions for Mod Con 300 500 Only Inspection and Maintenance Start Up Charts Boiler Manual nnnn 0211 GAS FIRED BOILER PART 1 PRODUCT AND SAFETY INFORMATION Boiler Manual SPECIAL ATTENTION BOXES The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the product DEFINITIONS DANGER CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage This appliance must be installed by qualified and licensed personnel in accordance with local codes or in the absence of local codes by the national fuel gas code ANSI 7223 1 2002 This appliance is for indoor installations only Clearance to combusitble materials 0 top bottom sides and back Front must have room for service 24 recommended A combustible door or removable panel is acceptable front clea
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3. 12 OVER MAXIMUM _ SNOW LEVEL OR 24 WHICHEVER IS GREATER T gt RIGHT SIDE VIEW EXTERIOR WALL INTAKE AIR VENT Figure 6 11 LP 205 G Rev 5 6 08 NOTE When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler GENERAL NOTE All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 74 per foot back to the heater to allow drainage of condensate MAD UUIV GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen 10 0 MIN ROOF EXHAUST RAIN CAP STAINLESS STEEL ROOF VENTING WITH SUED STAINLESS STEEL AL294C AIR INTAKE 24 MN GALVANIZED B VENT CH 12 OVER MAXIMUM e SNOW LEVEL OR 24 WHICHEVER IS GREATER i SUPPORT BRACKETS SIDEWALL VENTING 0 WITH STAINLESS STEEL CT CF Em Ne en cC n Be C inn SIDE WALL EXHAUST TERMINATION 4 Z FLEX 2SVSRTFO4 6 L FLEX 2SVSRTX06 12 SUPPORT BRACKETS 7 or1 AIR INTAKE ABOVE MAX GALVANIZED POTENTIAL VENT SNOW LEVEL NOTE VENT MUST BE AT LEAST 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS GREATER CHECK WITH LOCAL CODE REQUIREMENTS Figu
4. The gas is off All electrical power is disconnected DANGER When servicing or replacing components that are in direct contact with the boiler water be certain that There is no pressure in the boiler Pull the release on the relief valve Do not depend on the pressure gauge reading The boiler water is not hot The electrical power is off A WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Contact a qualified service technician to inspect the boiler and to repair or replace any part of the boiler that has been under water prior to placing the boiler back in operation A CAUTION This appliance has wire function labels on all internal wiring Observe the position of each wire before re moving it Wiring errors may cause improper and dan gerous operation Verify proper operation after servicing A CAUTION If overheating occurs or the gas supply fails to shut off do not turn off electrical power to the circulating pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply to the boiler at the gas service valve DO cAs FIRED BOILER Boiler Manual PART 12 TROUBLESHOOTING CONTINUED Table 12 1 926 Control Board ERROR Codes Outside sensor shorted or Inspect wiring from outside sensor for damage or shorted connections repairing as necessary temperature les
5. 15 pue jo no JO J9 eM YIM elesuepuoo joeuuo siq Ajesso2au usiue dey e si eJeu ens 1ezi esjneu ejesuepuoo 12949 7 ejesuepuo pelelduoo 156 146 SOIPIAI IY nntno 11103429 JONWNILNIVIN ONY 11011214611 031108 71 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth When installed in the Commonwealth of Massachusetts or where applicable state codes may apply the unit shall be installed with a CO detector per the requirements listed below 5 08 Modifications to NFPA 54 Chapter 10 1 Revise NFPA 54 section 10 5 4 2 by adding a second exception as follows Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed and shall be equipped with a manually reset device that will automatically shut off the gas to the burner in the event of a sustained back araft 2 Revise 10 8 3 by adding the following additional requirements a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less
6. FLANGE 0 1 7350P 034 1 SWIRL PLATE includes item 12 32 OPTIONAL 34 35 z 39 7000 805 PLASTIC TUBING 3 16 ID X 5 16 OD X 12 Fig 13 3 REV 5 1 08 66 GAS FIRED BOILER Boiler Manual PART 13 MAINTENANCE continuen 1 70993 7500038 7506282 ECO HIGH UMIT SENSOR amp 7505 00 750050 75009002 ECORUESENSOR 1 1 2 INLET NIPPLE w O RING 300 only ES 7350P 003 7350P 004 7350P O04 INLET NIPPLE w O RING 8 7350 071 7350P 072 7350P 072 _ O RING INLET OUTLET NIPPLE 1 1 2 INLET OUTLET NIPPLE CLIP 300 only 1 1 2 OUTLET NIPPLE w O RING 300 only T Jai 755012 CONDENSATE COLECTOR 350P 065 350P 065 350P 065 150 RELIEF VALVE 3 4 NPT LP 205 H Fig 13 4 REV 5 12 08 67 GAS FIRED BOILER PART 13 MAINTENANCE continuen Fig 13 5 It ZO 7350P 047 7350P 047 7350 047 FRONT w SCREWS 2 7350P 048 7350P 048 7350 048 LOWER FRONT w SCREWS 7350P 046 JACKET UPPER FRONT w MOD CON LABEL SCREWS 8 32 X 3 8 PAN HD PHILLIPS SCREW DISPLAY PANEL 24 eo 7350 129 7950P 129 7350P 129 FUSE 3 15 AMPS 7350P 025 7350P 026 7350 043 120 WIRING HARNESS LOCATION 27 7350P 024 7350P 044 7350P 045 LOW VOLTAGE WIRING HARNESS LOCATION 28 7350P 105 7350P 105 7350P 105 COMBUSTION BLOWER WIRING HA
7. Install Purge and Balance Valve or shut off valve and drain on system return to purge air out of each zone Install a Back Flow preventor on the Cold Feed Make Up Water line Install a Pressure Reducing Valve on the Cold Feed Make Up Water line 15 PSI nominal on the system return Check Temperature and Pressure Gauge when operating It should read minimum pressure of 12 PSI Install a circulator as shown In piping details this section Make sure the circulator 15 10 Boiler Manual properly sized for the system and friction loss Install an Expansion Tank on the system supply Consult the tank manufacturer s instruction for specific information relating to expansion tank installation Size the expansion tank for the required system volume and Capacity Install an Air Elimination Device on the system supply Install a drain valve at the lowest point of the system Note The Mod Con Boiler can not be drained completely of water without purging the unit with an air pressure 15 PSI The relief valve is installed at the factory A pipe discharge line should be installed 6 above the drain in the event of a pressure relief The pipe size must be the same size as the relief valve outlet NEVER BLOCK THE OUTLET OF THE SAFETY RELIEF VALVE H CIRCULATOR SIZING The Mod Con Boiler Heat Exchanger does have pressure drop which must be considered in your system design Refer to the graph in Fig 5 1 for pressure drop th
8. SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING STRAIGHT EXHAUST COUPLING VENT PORT OVE MAX POTENTIAL SNOW LEVEL RIGHT SIDE VIEW AIR INTAKE VENT NOTE VENT MUST BE AT LEAST 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS GREATER CHECK WITH LOCAL CODE REQUIREMENTS Figure 6 9 LP 205 E Rev 5 15 08 Figure 6 10 SIDEWALL VENTING WITH KIT VENT KIT SEE CHART peer SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING EXHAUST VENT 7 1 ABOVE MAX POTENTIAL SNOW LEVEL RIGHT SIDE VIEW INTAKE AIR VENT NOTE VENT MUST BE AT LEAST 12 OVER MAXIMUM SNOW LEVEL OR 24 WHICHEVER IS GREATER CHECK WITH LOCAL CODE REQUIREMENTS LP 205 F Rev 5 15 08 GENERAL NOTE All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 74 per foot back to the heater to allow drainage of condensate NOTE When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler 32 UU GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen J DIAGRAM FOR VERTICAL VENTING ROOF VENT WITH TEE INTAKE AND COUPLING EXHAUST STRAIGHT om N 24 MIN
9. at 120 volts If a pump that requires more current or voltage other than 120 volts supplied an external motor starter or contactor will be required D ALARM CONNECTIONS 1 The MOD CON control includes a dry contact alarm output This is an SPDT circuit rated at 5 amps at 120 volts This contact can be used to activate an alarm light or bell or notify a building management system if the boiler goes into a lockout condition The circuit between the ALARM COM and NC terminals is closed during normal operation and the circuit between ALARM COM and NO is open during normal operation The connections depicted in figure 8 1 shows two 120 volt lights connected to the alarm terminals One light will be on when the boiler is in normal 40 UU GAS FIRED BOILER PART 8 FIELD WIRING continuen mode and the other light will be on when the boiler is in lockout mode E LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER 1 All low voltage cables should enter the electrical junction box through the provided knock out holes as shown below Knock out locations for low voltage connections to electrical junction box 2 Connect all low voltage field devices to the low voltage terminal strip located in the electrical junction box shown in Figure 8 1 41 Boiler Manual RAN 21211 GAS FIRED BOILER Boiler Manual PART 8 FIELD WIRING continuen MOD CON CONTROL CAT3 CAT 5 CONNECTION POINTS OPTIONAL 0 10 VOLT
10. boiler is set up as the cascade master and you press the key again the DHW pump will shut off the display will begin alternating between SEP and Sh and the system pump will come on Using the and keys in this manner you can toggle between running each pump in the system as required to help bleed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump op eration becoming very quiet Pressing and together at any time will return the boiler control to normal opera tion i After the system has operated for while eliminate any residual air by using the manual air vents located throughout the system If purge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents k Refill to correct pressure E CHECK FOR GAS LEAKS A WARNING Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leak at once 50 51 inn 2021 GAS FIRED BOILER Boiler Manual PART 9 START UP PREPARATION continuen WARNING Propane boilers only Your propane supplier mixes an odorant with the propane to make its pr
11. om gt c rommoom p mooup GAS FIRED BOILER CONTENTS cour Part 8 Field Wiring Line Voltage Wiring for Standard Boiler Low Voltage Connections for Standard Boiler Optional 0 10 Volt Building Control Signal Optional High Gas Pressure Switch Optional Low Gas Pressure Switch Optional UL353 Low Water Cutoff Switch Wiring of Cascade System Communication Bus Start Up A Installation Must Comply With B Field Wiring C D Alarm Connections E F Thermostat G Outdoor Sensor H Indirect Sensor L Part 9 Check Control Water Chemistry B Freeze Protection when used C Fill and Test Water System D Purge Air from Water System E Check for Gas Leaks Check Thermostat Circuit s G Condensate Removal H Final Checks Before Starting Boiler Cascade System Part 10 Start Up Procedure A Operating Instructions B Adjusting the Set Point C Status Menu D Test Mode Part 11 Start Up Procedures for the A Programming for the Installer B Program Access C Program Navigation Part 12 A Mod Con Error Code B Boiler Error C Boiler Fault Part 13
12. than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gastitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner secure the service of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b the event that the requirements of this subdivision cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operat
13. CHAMBER COIL CLEANING INSTRUCTIONS FOR MOD CON 300 500 ONLY Boiler Manual b Disconnect the condensate piping from the outside connection not from the Mod Con Boiler side so the flow from condensate reservoir can be observed c Disconnect electrical connections from the gas valve spark electrode and flame rectification probe and combustion blow d Remove the 4 screws the aluminum NPT connector on the right side of the gas valve e Disconnect the wiring connected to the combustion blower motor f Remove the 6 10MM nuts from the burner plate assembly 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 Using a spray bottle filled with the recommeded product RYDLYME or CLR spray liberally on the coils making sure the solution penetrates and funnels down through the condensate sys tem If the condensate system is blocked let the chemical penetrate for at least 15 minutes or until it drains Use the nylon stainless steel or brass brush do not use steel and scrub coils to remove any buildup then vacuum the debris from the coils WARNING Follow precautions above opray the coils with clear water making sure to confine the spray to the area being cleaned Try to avoid getting the back ceramic wall of the unit wet Flush the combustion chamber with fresh water until clear wate
14. J4 INPUT CASCADE BUS ZONE CONTROL ONLY THERMOSTAT 0 10 LI LIL D OUTDOOR SENSOR D 55 LL LL DHW D SENSOR DHW SENSOR D S 2 lt Q gt Wav v DHW NEU DHW HO BOILER GRD BOILER NEU BOILER HOT GROUN NEUTRA 120 VOLTS BLACK HOT dWNd 43108 134 dWNd MHG 24 GREEN GROUND WHITE NEUTRAL BLACK HOT LINE VOLTAGE IN 120 VAC 1370 JONSINSANOO L L GROUND SS C Fig 8 1 LP 205 JJ Rev 5 12 08 to run Caution should be used to ensure neither of the terminals become connected to F THERMOSTAT 1 Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box shown in figure 8 1 Alternately any dry contact closure across these terminals will cause the MOD CON unit ground Mount the thermostat on an inside wall as central as possible to the area being heated but away from drafts or heat producing 42 inn 2021 GAS FIRED BOILER PART 8 FIELD WIRING continuen devices such as television sets that could influence the ability of the thermostat to measure room temperature If the thermostat is equipped with anticipator and it is connected directly to the MOD CON boiler the anticipator should be set at 1 amps If the thermostat is connected to other devices the anticipator should be set to match the power requirements of
15. METALLIC EXHAUST VENTING MATERIAL STANDARDS FOR INSTALLATION IN UNITEDSTATES CANADA Table 6 6 APPROVED METALLIC INTAKE VENTING MATERIAL STANDARDS FOR INSTALLATION IN NITED STATES Table 6 7 APPROVED STAINLESS STEEL VENT ADAPTERS AND TERMINATIONS Z FLEX PART NUMBER 2SVSMK04 2SVSRTF04 2SVSRCF04 Z FLEX PART NUMBER Boiler Adapter 6 7350P 114 2SVEP06 5 Horizontal Vent Terminal 4 7350P 608 2SVSRTXOO6 Rain Cap 6 7350P 610 2SVSRCFO6 25 cAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen WARNING You must not use B Vent in an exhaust application B vent is for intake applications only Failure to do so will result in serious injury or death WARNING Both exhaust and intake air vents must exit from the same side of the building to assure correct appliance operation D EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION Please refer to chart below for U L approved stainless steel adapters and terminations 1 Determine exhaust vent location Total length of vent may not exceed the limits specified in the venting Sizing Section The vent piping for this boiler is approved for zero clearance to combustible construction See illustration within this section of clearances for location of exit terminals of direct vent venting systems Avoid terminating exhaust vent near shrubs air conditione
16. PANEL ELECTRICAL BOX COLD WATER GAS LINE LEGS ADJUST D 1 1 4 3 E CONDENSATE DISCHARGE RIGHT SIDE REAR LEFT SIDE MOD CON 500 850 ALL MODELS MOD CON 500 850 EXHAUST ACCESS PANEL ELECTRICAL BOX AIR INTAKE woe PLEASE NOTE ALL DIMENSIONS ARE APPROXIMATE AND HEIGHTS DO NOT INCLUDE ADJUSTABLE LEGS BTU HR BTU HR DOE M m FAN SPEEDS MODEL INPUT INPUT HEATING ON Ub ui Bee CONNECTION CONNECTION DIAMETER HIGH IGNITION MOD CON 300 60 000 300 000 282 000 1 1 2 1 1 4 5400 1500 3000 MOD CON 500 100 000 500 000 470 000 1 1 2 6930 1250 3000 MOD CON 850 170 000 850 000 799 000 Dow Tou 5500 1250 3000 Figure 2 1 LP 205 C Rev 5 6 08 GAS FIRED BOILER Boiler Manual PART 3 PREPARE BOILER LOCATION continuen B INSTALLATIONS MUST COMPLY WITH Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI 2223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes e Incorrectly sized expansion tank e Lack of freeze protection in boiler water causing system and boiler to freeze and leak Excessive glycol which will affec
17. Water Heater and the Minimum run time for Central Heating Range 0 to 60 Minutes Bus Addressing Boilers Cascade 8 Boiler Max Master Address 0 Followers Address 1 thru 7 Note Never address boiler with number 8 which ts not to be used Range 0 8 Allows the installer to connect up a 0 10 Volt directly from Building Management System To activate change value to 2 Warning Values 1 and 3 are not to be programmed into board Range 0 3 Allows the user to control the function of the 0 10 volt input 0 Boiler Temperature 1 Boiler Power Step Modulation Regulates the burner output 6 steps In one minute intervals This reduces short cycling 1 0 off Indirect boiler set point flow Temperature default 119 to 180 Low water cut off Do not change O none 1 water pressure switch 2 flow switch 3 low water cutoff MODCON default Boiler Manual Function Default Function Number 21 22 29 24 25 26 Value 0 100 24 Description Allows the installer to set the con trol to display error If out door sensor is open or shorted Koi error does not prevent boil er from running 0 displayed 1 90 displayed if outdor sen sor shorted or open Maximum boiler output percent age Default 100 This param eter can be adjusted to lower the maximum boiler output if neces sary Example MODCON5S500 boil er setting at 80 boiler
18. above Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand GAS VALVE GAS VALVE ON OFF Remove front cover Turn gas shutoff valve to off Handle will be across the piping do not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step Turn gas shutoff valve to on Handle will be in line with piping Install Front Cover Turn on all electric power to appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove Front Cover 4 Turn gas shutoff valve to off Handle will be across the piping Do not force 5 Install Front Cover LP 175 Rev 4 3 11 08 Mnn UU GAS FIRED BOILER Boiler Manual Part 1 Product and Safety 4 6 Part 2 Before You 6 7 What s In The Box How The Boiler Operate
19. completion of the installation LP 172 REV 2 16 06 73 MAINTENANCE NOTES eS S T ED 7 25 D I 2 W 2 M 0 d U S p ro d uct S L 2 0 5 R E V 5 1 6 0 8
20. display in the lower left corner of the screen The number displayed here must be greater than 128 and should be greater than 250 Use this as a troubleshooting guide as you follow the steps below Remove 10 pin Molex connector from customer connection board If LOU code clears then the problem is with external sensor wiring Examine external sensor wiring for shorts to ground repairing as necessary If LOU code is still present and the boiler is so equipped dis connect high gas pressure switch then low gas pressure switch then UL 353 low water cut off in this order one at a time to see if LOU code clears Replace faulty part Check low volt age wire harness in boiler for shorts to ground If LOU only occurs when burner tries to light check gas valve for excessive current draw If LOU is present with the low voltage harness disconnected from the 926 control board re place the 926 control board System sensor failure Check wiring to system sensor Repair as necessary Cascade Master only Check sensor resistance Compare to the table in Fig 12 4 Replace if not correct Check to see if boiler circulator is functioning Repair as necessary water flow Be sure water is flowing in the system Check for valves that should be open plugged filter screens etc Check flow switch and wiring Repair as necessary 24 volt low 99 12121 1 GAS FIRED BOILER Boiler Manual PART 12 TROUBLESHOOTING CONTINUED Tab
21. heater injury Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition 61 cAS FIRED BOILER PART 13 MAINTENANCE continuen WARNING The combustion chamber insulation in this product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources 15 carcinogenic to humans Group1 Avoid breathing dust and 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 the 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 and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent dust Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye irrigate immediately Breathing Fresh air B COMBUSTION
22. performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY READ BEFORE OPERATING BEBE WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance 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 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance 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 Use only your hand to turn the gas control knob Never use tools If the handle will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information
23. settings 1st time 6 Boiler Temperature Set Point 2nd time 6 Boiler Differential Set Point 3rd time Indirect Temperature Set Point 4th time Indirect Differential Set Point 5th time Temperature measurement in Fahrenheit to Celsius To increase or decrease the values press the to decrease and WE to increase Changes are directly stored and the display returns to normal mode after one minute C STATUS MENU Installers are also able to check the current sta tus of the Mod Con Boiler parameters by press ing the key for 3 seconds Once acti vated the display will show alternating value of the actual supply temperature To change to the next function value the user can press the alternating down to previous function value or press the key alternating up to the next function value Actual values are dis played for each function Listed below are the values which can be displayed These values cannot be changed To exit menu simply press key to resume normal operation Function Value d1 Actual Temperature from supply sensor d2 d3 Actual Temperature from return sensor Indirect Temperature will be displayed if a Superstor indirect fired water tank and 7250 325 sensor is connected If a mechanical control is used the display will show if the control is open and a J if it is closed If an DHW tank is not connected the display will read EPI Not u
24. the boiler D PURGE AIR FROM WATER SYSTEM Purge air from system a Connect a hose to the purge valve and route hose to an area where water can drain and be seen b Close the boiler or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water make up line e Open purge valve f One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rise to correct cold fill pressure It is recommended that you put the pumps into manual operation to assist in purging the circuits h Disconnect the wires that are connected to the THERMOSTAT terminals of the cus tomer connection board Apply power to the boiler The display will show the tem Boiler Manual perature of the water in the boiler Press the and keys simultaneously and hold for 1 second The Display will begin alternating between SEP and CH and the Central Heating pump will come on If you then press the key the Central heat ing pump will shut off the display will begin alternating between SEP and DH and the DHW pump will come on If the
25. will see in the display and the actual fan speed The measurement of the com bustion levels should always be taken at the high est and lowest fan speed After 20 minutes the Test mode stops automatically To exit Test Mode press and key together for 1 second COMBUSTION SETTINGS ON ALL MODELS Natural Gas Propane LP r r 0 20 ppm 70 ppm 135 ppm 0 20 ppm 80 ppm 150 ppm 0 99 107 914 107 Fig 10 1 54 2021 GAS FIRED BOILER Boiler Manual PART 11 START UP PROCEDURES FOR THE INSTALLER A PROGRAMMING FOR THE INSTALLER This section allows the installer to set system limits and the heat curve for the Mod Con Boiler These system limits should not be changed by the user It is important to document your set tings within this manual after you program the sytem parameters so this will be recorded for future reference Record settings in Fig 11 3 B PROGRAM ACCESS To start press down and hold the and simultaneously for three seconds You will notice that the display will change to Then with your key on the display press down until you see 2 This is the pass code To confirm that the pass code is correct you will need to press and hold the for 1 second to confirm If the pass code is entered incorrectly the controller program function will be cancelled and the control returns to normal operation If the code is entered correctly the control
26. AFETY INFORMATION conto FREEZE PROTECTION FLUIDS A CAUTION NEVER use automotive or standard glycol antifreeze ethylene glycol made for hydronic systems Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems CAUTION Consider piping and installation when determining boiler location change by internal or external signals which enhance the overall performance of the system Control The integrated control system monitors the system and regulates the fan speed to control the boilers output This allows the boiler to only deliver the amount of heated energy required and nothing more This control can be set up to monitor outdoor temperature through an outdoor sensor to regulate the set point of the boiler The system can be further enhanced by connecting up to an indirect water heater to provide domestic hot water The control can regulate the output of multiple boilers through Its cascade system function The cascade system is capable of connecting up to eight boilers together in such a way that they function as one boiler system This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize efficiency The cascade system works by establishing one boiler as the master and the other connected boilers as f
27. Boilers Space Heating Only BALL VALVE TYPICAL 4 PIPE DIAMETER AIR ELIMINATOR SPACING MAXIMUM SUPPLY SENSOR FROM SYSTEM OPTIONAL gt SWING CHECK VALVE TYPICAL DRAIN VALVE SYSTEM CIRCULATOR LL 7 3 EXPANSION TANK DRAIN VALVE 10 SYSTEM PURGE POINT BOILER CIRCULATOR TYPICAL MAKE UP WATER BACKFLOW PREVENTER PRESSURE RECUDING VALVE PRESSURE GAUGE BOILER CIRCULATOR TYPICAL BOILER 1 MASTER UNION TYPICAL BOILER 2 FOLLOWER 1 DRAIN VALVE TYPICAL BOILER 3 FOLLOWER 2 TEMP PRESSURE GAUGE PRESSURE RELIEF TYPICAL VALVE NOTES 1 This drawing is meant to show system piping concept only 2 An Anti Scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 3 Install a minimum of 12 diameters of straight pipe upstream of all circulators 6 System Flow Secondary Loop must be greater than the boiler s primary loop flow LP 205 0 Rev 5 14 08 19 GAS FIRED BOILER PART 5 BOILER PIPING continuen A CAUTION The Mod Con Boiler should not be operated as a potable Hot Water Heater It should not be used as a direct Hot Water Heating Device Basic steps are listed below with Illustration that will guide you through the installation of the Mod Con 1 Connect the system return marked Boiler Return Connect the system supply marked Boiler Supply
28. CH If an optional high gas pressure switch is used it should be installed on the outlet side of the gas valve This is normally closed and will open if the pressure goes above 1 w c on the outlet side Locate the two pigtails hanging from the electrical box inside of the boiler cabinet Remove and discard the jumper plug from one of the unused pigtails Connect the high gas pressure switch to the pigtail that you removed the jumper plug from cAS FIRED BOILER PART 8 FIELD WIRING continuen K OPTIONAL LOW GAS PRESSURE SWITCH 1 If an optional low gas pressure switch is used It should be installed on the inlet side of the gas valve This is normally closed and will open if the pressure goes above 172 w c 2 Locate the two pigtails hanging from the electrical box inside of the boiler cabinet Remove and discard the jumper plug from one of the unused pigtails 3 Connect the low gas pressure switch to the pigtail that you removed the jumper plug from L OPTIONAL UL353 LOW WATER CUTOFF SWITCH 1 If an optional UL353 low water cutoff switch is used the control box of the LWCO should be mounted to the left side of the boiler cabinet near the low water cutoff probe which is located on the outlet nipple of the boiler 2 Remove the wire connected to the low water cutoff probe on the boiler and connect it to the orange wire from the newly mounted LWCO Control Box 3 Connect the singl
29. Con 300 1 1 2 for the Mod Con 500 and 2 for the Mod Con 850 It is mandatory that this fitting is used for connection to a field fabri cated drip leg as shown in the illustration above per the National Fuel Gas Code You must ensure that the entire gas line to the connection at the Mod Con is no smaller than the unit sup plied connection Once all the inspections have been performed the piping must be leak tested 22 Boiler Manual the leak test requirement is a higher test pres sure than the maximum inlet pressure you must isolate the Mod Con from the gas line In order to do this you must shut the gas off using fac tory and field installed gas cocks This will pre vent high pressure Failure to do so may dam age the gas valve In the event the gas valve 15 exposed to a pressure greater than 7 PSI 14 w c 3 5 kPa the gas valve must be replaced Never use an open flame match lighter etc to check gas connections B GAS PIPING 1 Runthe gas supply line in accordance with all applicable codes 2 Locate and install manual shutoff valves in cordance with state and local requirements 3 In Canada the Manual Shutoff must be identified by the installing contractor 4 It is important to support gas piping as the unit 15 not designed to structurally support large amount of weight 5 Purge all gas lines thoroughly to avoid start up Issues with air in the lines 6 Sealing compound must be
30. EFRACTORY GASKET BURNER 6 7250P 687 CHANNEL Li zmeess ea Fig 13 1 Boiler Manual IM4X29MMSCREW SCREW Pa seo puexsew smHRsON LP 205 A REV 5 6 08 64 GAS FIRED BOILER PART 13 MAINTENANCE continuen Fig 1 65 MOD CON 500 Description Item Replacement No Part 7350 006 500 000 BTU MOD CON MODULE 7350P 016 BURNER DOOR 7350P 018 7350P 03 1 BURNER DOOR REFRACTORY BURNER 3 73509018 _4 73s0r 031_ e s 7200p 07s GASKET CHANNEL RLOWER 7 3 4 x 3 4 NPT STREET ELBOW 12 3 4 NPT X 3 NIPPLE PHOSPHATE COATED 1 1 2 SS SOCKET CAP SCREW ADAPTER BLOCK 7 3 2 Boiler Manual 23 LOW GAS PRESSURE SWITCH w O RING OPTIONAL 3 4 NPT x 2 NIPPLE PHOSPHATE COATED 3 4 NPT X 6 NIPPLE PHOSPHATE COATED 3 4 X 1 1 2 NPT REDUCING COUPLING BLK IRON PLASTIC TUBING 3 16 ID X 5 16 OD X 12 LP 205 V REV 5 16 08 00 GAS FIRED BOILER Boiler Manual PART 13 MAINTENANCE continuen MOD CON 850 OOO 723 7350P 099 1 GAS BALL VALVE 724 7350 097_ NPT X 4 NIPPLE PHOSPHATE COATED V NPT 90 DEGREE ELBOW 74 73502029 AR GAS CHANNEL CONICAL 26 7350 098 NPT X 2 NIPPLE PHOSPHATE COATED 7 7350P 030 SCREW AIR CHANNEL TO BURNER DOOR HIRSCHMAN CONNECTOR 29 N A ORING
31. FTING RINGS PROVIDED ALWAYS LIFT WITH AT LEAST 2 PEOPLE LIFTING RINGS PART 5 BOILER PIPING A RELIEF VALVE Connect discharge piping to a safe disposal location follow the guidelines in the WARNING below A WARNING To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge Discharge line must be as short as possible and be the same size as the valve discharge connection throughout its entire length Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain where any discharge will be clearly visible The discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater Do not pipe the discharge to any place where freezing could occur No shutoff valve shall be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line Test the operation of the valve after filling and pressurizing system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve Failure to comply with the above guidelines could result in failure of the relief valve to ope
32. KE UP 7 Nu MODCON BOILER BACKFLOW PREVENTER ANTLSCALD PRESSURE REDUCING ANS VALVE HOT WATER PRESSURE GAUGE rm COLD WATER v _ _ INLET ao 5M low HOT WATER CIRCULATOR SWING CHECK VALVE PRESSURE RELIEF UNION RE TYPICAL DRAIN VALVE NOTES 1 This drawing is meant to show system piping concept only 2 An Anti Scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 3 Install a minimum of 12 diameters of straight pipe upstream of all circulators Piping shown is Primary Secondary 5 System Flow Secondary Loop must be greater than the boiler s primary loop flow T LP 205 L Rev 5 14 08 16 HNN GAS FIRED BOILER Boiler Manual PART 5 BOILER PIPING continuen Cascade Multiple Mod Con Boilers with Indirect Priority on One Boiler BALL VALVE 4 PIPE DIAMETER TYPICAL SPACING MAXIMUM AIR ELIMINATOR FROM SUPPLY SENSOR SYSTEM DRAIN VALVE ae MAKE UP WATER BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE SYSTEM CIRCULATOR EXPANSION TANK DRAIN VALVE TO SYSTEM PURGE POINT INDIRECT HOT WATER TANK BOILER CIRCULATOR TYPICAL ANTI SCALD MIXING VALVE HOT WATER OUTLET COLD WATER MASTER INLET DOMESTIC HOT WATER CIRCULATOR UNION BOILER 2 TYPICAL FOLLOWER 1 SWING CHECK VALVE TYPICAL DRAIN VALVE BOILER 3 FOLLOWER 2 TEMP PRE
33. LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHARTIN COMBUSTION SETTING 5 AG 10 1 GAS PRESSURE SWITC H BLOCK GASOUILET PRESSURE TAP OFFSET ADJ USIMENT CAUTION DO NOTREMOVE THIS SC REW GASVALVE ORATIEMPTTO MAKE ANY USIMENTTO THIS 5 REW WITHOUT A COMBUSTION ANALYZER GAS INLET PRESSURE TAP GAS PRESSURE SWITCH BLOCK GASINL GAS SHUT OFF VALVE Fig 7 3 LP 205 BB Rev 6 3 08 38 GAS FIRED BOILER Boiler Manual PART 7 GAS PIPING continuen MOD CON 850 GAS VALVE THRO TILE ADJ USTER NOTE IF FOR ANY REASON THE THROTILE NEEDS TO BE USTED ITIS VERY IMPORTANT THATA COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE USTER TO THE TO INCREASE GAS SUPPLY OR TO THE TO DECREASE GAS SUPPLY THIS ADJ USTMENT C OULD AFFECT CO LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHART IN THE COMBUSTION SETTINGS SECTION 10 1 i __ DETAILA SCALE 2 1 5 l GASVALVE GAS PRESSURE SWITCH BLOCK INTERMEDIATE GAS SHUT OFF PRESSURE VALVE GAS PRESSURE SWITCH BLOCK GASOU GASIN GAS OUTLET i GAS INLET PRESSURE PRESSURE TAP TAP OFFSET ADJ USIMENT CAUTION DO NOTREMOVE THIS SC REW OR ATIEMPT TO DETAIL B MAKE ANY ADJ USTMENT TO THIS SC REW WITHOUT USING SCALE 2 1 5 A COMBUSTION ANALYZER Fig 7 3 LP 205 0 Rev 5 27 08 29 UUU GA
34. MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approval side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the
35. OILER PART 8 FIELD WIRING continuen Boiler Manual MOD CON Cascade Follower OPTIONAL DHW SENSOR LIGHT OFF WHEN LOCKOUT PUMP GREEN GROUND WHITE NEUTRAL BLACK HOT LINE VOLTAGE IN 120 VAC Fig 8 4 MOD CON CASCADE FOLLOWER PUMP AND SENSOR WIRING 1 Connect the boiler pump to the terminals labeled BOILER HOT BOILER NEUT BOILER GND 2 If you are using an indirect fired water tank connected directly to the follower boiler connect the pump for it to the DHW HOT DHW NEUT and DHW GND terminals If you desire an alarm bell or light can be con nected to the alarm contacts of the follower boil er Optionally the normally closed alarm contact may be used to turn a device off if the boiler goes into lockout mode The alarm contacts are rated 5 amps at 120 VAC 47 5 CONNECTION POINTS CASCADE BUS ZONE CONTROL ONLY THERMOSTAT THERMOSTAT OUTDR SEN OUTDR SEN DHW SENSOR DHW SENSOR BOILER BOLLER NEUT _ GROUND ES EI 13 J4 191409 Z4 dWNd 43108 13 4 1300 39N3IN3ANOO LP 205 JJ1 Rev 5 12 08 To connect an alarm device connect the power for the device to the ALARM COM terminal Connect the alarm device hot wire to the ALARM NO terminal Connect the neutral or return of the alarm device to the neutral or return of th
36. OT covered by warranty 2 Size the piping and components in the space heating system using recognized design methods F HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND MULTIPLE BOILERS The Mod Con Boiler is designed to function in a closed loop Hydronic System We have also in cluded a Temperature and Pressure gauge that al 2 The expansion tank must be located as shown in Boiler Piping Part 5 or following 14 GAS FIRED BOILER PART 5 BOILER PIPING continuen lows the user to monitor the system pressure and outlet temperature from the Mod Con Boiler It is important to note that the Mod Con Boiler has a minimal amount of pressure drop and must be cal culated when sizing the circulators Each Mod Con Boiler installation must an Air Elimination de vice that will remove air from the system Install the Mod Con Boiler so the gas ignition system com ponents are protected from water dripping spray ing etc allowing clearance for basic service of boiler circulator valves and other components Observe minimum 1 clearance around all un in sulated hot water pipes when openings around pipes are not protected by non combustible ma terials a Mod Con Boiler installed above radia tion level some states and local codes require a low water cut off device which is standard on the Mod Con boiler Check with local codes for addi tional requirements If the Mod Con Boiler supplies to Boile
37. RALIZER HORIZONTAL LINES MUST BE INSTALLED WITH A PITCH OF 1 4 PER FOOT PIPE SUPPORT CLEAN OUT PORT WARNING YOU MUST MAKE SURE THAT THIS CAP IS SECURE AFTER SERVICING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Fig 6 2 LP 205 W Rev 5 7 08 The condensate line must remain unobstructed When installing a condensate pump select one allowing free flow of condensate If condensate approved for use with condensing boilers and is allowed to freeze in the line or if the line is furnaces The pump should have an overflow obstructed in any other manor condensate can switch to prevent property damage from exit from the boiler tee resulting in potential condensate spillage water damage to property Condensate from the Mod Con Boiler will be slightly acidic typically with a pH from 3 2 to 4 5 Install a neutralizing filter if required by local codes 28 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen Location of exit terminals of mechanical draft and direct vent venting systems Reference National Fuel Gas Code ANSI Z223 1 NFPA 54 2002 po DIRECT VENT IF A IS LESS THAN 4 TERMINATION 10 FT THEN IS 42 MINIMUM P Ex 12 MIN T FORCED AIR INLET 12 MIN Fig 6 3 Multiple Vents 10 to 6ft 10 to 6ft 36 10 to 6ft 10 to 6ft Minimum Fig 6 4 Multiple Vent Spacing No
38. RNESS LOCATION NIN NIN N e Boiler Manual LP 205 B REV 5 20 08 68 Boiler Manual JULIU cAS FIRED BOILER pJo291 12 401S JedngS ay jo pue AJJ9A JelesU 12 Z 591 p109 1 Bureau pJ029y 9 eer ieee 14 6 epixououi uoqJeo uessaoau ysnfpe pue yey evo 209 9J14 YBIH epixoip uoqJeo AJessadau JI jsnfpe pue 42949 uonsnquio 29 9 6 E suonoeuuoo jUaA ol Je SOWWJaY dn uonejedQ wayshs p ET IJ 6 n uonoes dn iejs 995 5 5 ay uo Bulpeas 12949 juan uoneziuo pJ029H 2 MEME Ul Uey ON Ho 1461 uo doJp S UM 2 M 01 6 1 55 10 566 9945 NENNT JOO jeuonoipsunf 3jnsuoo Alleool 6ulsn 159 peuoddns Apiedoud enjj pue Buidid seau 9508 0 WalsAs y ur poj e1sur s 02 6 eue Adoud jo epelueoJed jeuM ulajs s ojesuopuoo 194e M PPV 6461 01 15 ezunsseJq 3461 Aay suonoeuuoo seb pue 29 2 5 5 ay 4 pejejduioo ejeq SeniAnoy HO 3461 180418 dh 19115 83108 69 Boiler Manual SISV8 V NO qd3dInD3d SI
39. S FIRED BOILER PART 8 FIELD WIRING WARNING ELECTRICAL SHOCK HAZARD For your safety turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death NOTICE Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only TEW 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition A INSTALLATION MUST COMPLY WITH 1 National Electrical Code and any other national state provincial or local codes or regulations 2 n Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes B FIELD WIRING All connections made to the MOD CON boiler in the field are done inside the electrical junction box located on the side of the unit The electri cal junction box is located on the left side of MOD CON 500 and MOD CON 850 units and on the right side of MOD CON 300 units Multiple knockout locations are available to route field wires into and out of the electrical junction box The control used in the MOD CON series of boil ers is capable of directly controlling 2 pumps when in standard mode and 3 pumps when con figured as a cascade master boiler When con figured as a standard unit each pump output can provide a maximum of 3 amps at 120 volts If pumps u
40. SSURE GAUGE PRESSURE RELIEF VALVE NOTES 1 This drawing is meant to show system piping concept only 2 An Anti Scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F Install a minimum of 12 diameters of straight pipe upstream of all circulators Piping shown is Primary Secondary Reference Figure 5 2 to determine manifold pipe sizing System Flow Secondary Loop must be greater than the boiler s primary loop flow D LP 205 J Rev 5 14 08 17 00 GAS FIRED BOILER Boiler Manual PART 5 BOILER PIPING continuen single Mod Con Boiler Space Heating BALL VALVE 4 PIPE DIAMETER TYPICAL SPACING MAXIMUM AIR ELIMINATOR _ FROM SYSTEM SUPPLY SENSOR OPTIONAL DRAIN VALVE OILER B SYSTEM CIRCULATOR CIRCULATOR SWING CHECK VALVE TYPICAL EXPANSION TANK TO SYSTEM DRAIN VALVE PURGE POINT MAKE UP WATER BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE UNION TYPICAL DRAIN VALVE PRESSURE RELIEF VALVE NOTES 1 This drawing is meant to show system piping concept only 2 Install a minimum of 12 diameters of straight pipe upstream of all circulators 3 Piping shown is Primary Secondary 6 System Flow Secondary Loop must be greater than the boiler s primary loop flow LP 205 R Rev 5 14 08 18 00 GAS FIRED BOILER Boiler Manual PART 5 BOILER PIPING continuen Cascade Mod Con
41. address boilers in the order that they PART 10 START UP PROCEDURE FOR YOUR OWN SAFETY READ BEFORE OPERATING 1 This appliance does not have 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 appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do nottry to light any appliance Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions are wired No two boilers can have the same ad dress e tis not required to use all consecutive address numbers Example In a 2 boil er system with an indirect connected to the follower the follower address would be 2 address 1 not used 1 Make sure there is no demand for heat being supplied to the master boiler 2 Apply power to the follower boiler you are working on 3 Enter the installer Menu following instructions in part 11 of this manual 4 Set parameter 15 to 1 for the first follower 2 for the second follower etc depending on which boiler you are programming 5 Verify that parameter 23 is set to 0 This makes the boiler be a follower 6 Exit the installer menu NOTE The temperature set point of the follow er must mat
42. al flow rate of 20 GPM To cor rectly size the manifold feeding these 5 Mod Con 300 Boilers you would need a pipe size of Multiple Boiler Manifold Piping Pipe Diameter Size Inches ATE Combined Boiler Water Flow GPM Figure 5 2 MULTIPLE BOILER MANIFOLD PIPING Flow rate 30 50 60 90 100 120 150 170 180 200 210 240 250 255 509 sao sso 400 425 510 595 680 Pipe Dia 2 2 4 2 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 5 5 6 6 6 FILL AND PURGE HEATING SYSTEM e Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain Close the other side of the balance and purge valve or the shut off valve after the drain Open first zone balance and purge or drain valve to let water flow out the hose If zone valves are used open the valves one at a time manually Note You should check valve manufacturer s instruction prior to opening valves manually so as not to damage the valve e Manually operate fill valve regulator When water runs out of the hose while it s connected to the balance and purge valve or drain 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 e R
43. anical draft systems operating under positive pressure Follow these venting instructions carefully Failure to do so may result in severe personal injury death or substantial property damage B GENERAL Install the boiler venting system WARNING Use only the materials listed in table 6 1 for the venting systems Failure to do so could result In severe personal injury death or substantial property damage REQUIREMENTS FOR INSTALLATION IN CANADA 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada in Canada supplying vent material listed to ULC S636 Additionally you may use AL244C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe from the appliance flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings WARNING Do not use Cellular Foam Core Pipe in any portion of the exhaust piping from this boiler Use of Foam Core Pipe may result in severe personal Injury death or substantial property damage Cellular foam core piping may be used on air inlet piping only accordance with these instructions and with the National Fuel Gas Code ANSI Z223 1 NFPA 54 CAN CGA B149 and or applicable provisions of local building codes 2 This boiler is a direct vent ap
44. approved for gas connection Care must be taken when applying compound to prevent blockage or obstruction of gas flow which my effect the operation of the unit WARNING Never use an open flame Match or Lighter to check for Gas leaks Use A soapy solution to test gas connection for leaks Failure to use soapy solution test or check gas connection for leaks can cause substantial property damage severe personal injury or death NOTICE CSA or UL listed Flexible gas connections can be used when installing The Mod Con Boiler Flexible gas connections have different capacities and must be sized correctly for the connected boiler firing rates Consult with the flex line supplier to assure the line size is adequately sized for the job Follow local codes for proper installation and service requirements UU GAS FIRED BOILER PART 7 GAS PIPING continue C GAS TABLE Refer to Table 7 1 to size the supply piping to minimize pressure drop between meter or regulator and unit Table 7 1 Boiler Manual Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0 5 w c or Less and a Pressure Drop of 0 3 Inch w c NATURAL GAS SUPPLY PIPING CAPACITY CHART 0 6 specific gravity gas 0 5 WC pressure drop Schedule 40 iron pipe size in nominal inch size Boiler Model Cubic Ft Hr 30 60 _ Boiler Model Cubic Ft Hr 500 250 of pipe gt 212 3 Boiler Boil
45. are rated ANSI Z21 13 Category IV pres surized vent likely to form condensate in the vent You must also install air intake piping from out doors to the boiler flue adaptor The resultant installation is categorized as direct vent sealed combustion Note To prevent combustion air contamination see Table 3 2 in this section when considering exhaust vent and intake air vent termination Intake and exhaust must terminate near each other and may be vented vertically through the roof or out a side wall The intake and exhuast venting methods are detailed the Venting Section Do not attempt to install the Mod Con Boiler using any other means Be sure to locate the boiler such that the air intake and exhaust vent piping can be routed through the building and properly terminated The air intake and exhaust vent piping lengths routing and termi nation method must all comply with the methods and limits given in the venting section 11 G PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the Mod Con Boiler as described in the Venting section Do not termi nate exhaust in locations that can allow contam ination of intake air WARNING You must pipe outside air to the boiler air intake Ensure that the intake air will not contain any of the contaminants below Contaminated air will damage the boiler resulting in possible severe personal injury death or substantial property damage For example do not p
46. ch the master boiler set point in order for the system to operate properly e If you cannot reach your gas supplier call the fire department e Turn off gas shutoff valve located inside of the Boiler so that the handle 15 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 Donotuse this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under waiter 5 The Mod Con Boiler shall be installed so the gas ignition system components are protected from water dripping spraying 02 2021 GAS FIRED BOILER Boiler Manual PART 10 START UP PROCEDURE continuen rain etc during appliance operation and service circulator replacement condensate trap control replacement etc A OPERATING INSTRUCTIONS Remove boiler cover 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 appliance 2 Adjust the temperature setpoint of the Mod Con Boiler if desired The factory default setting is 180 If changes are necessary follow Adjusting The Mod Con Setpoint in this section 3 On the intial start up of this boiler you will note a lock
47. continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette 6 After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 2223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 Note For Canadian Installations it is required that Non Metallic Vent Installations conform to ULC 5636 Where plastic venting is not allowed HTP recommends AL294C Stainless Steel Venting be used for Exhaust venting installa tions and B vent for intake air Please refer to 6 7 below for U L Approved Stainless Steel Vent Adapters MAN Cf GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION amp CONDENSATE REMOVAL continuen DIAGRAMS FOR SIDEWALL VENTING SIDEWALL VENTING W TEE INTAKE AND COUPLING EXHAUST AIR INTAKE VENT TEE 8 MAX NT STRAIGHT COUPLING TOP VIEW
48. e Termination Vent Kit V4000 High and Low Gas Pressure Switch Kit with Manual Reset Part 7350P 600 U L 353 Compliant Low Water Cut Off Interface Kit with Manual Reset Part 7350P 601 Alarm System Part 7350P 602 to monitor any failure Stacking Kit Part 7350P 603 PC Connection Kit Part 7350P 320 Boiler Caster Kit Part 7350P 404 Mod Con Condensate Neutralizer Part 7350P 611 These additional options may be purchased through your HTP Distributor many factors that have to be addressed that are covered in detail in this installation manual Please read the entire manual as it could save GAS FIRED BOILER Boiler Manual PART 3 PREPARE BOILER LOCATION cour time and money Piping Venting Condensation addressed prior to the installation of the boiler Removal are just a few issues that need to be A CAUTION When preparing the boiler location make sure the area where you are placing the boiler is level In order for the condensate properly to flow out of the collection system the boiler must be level to assure proper flow direction The Mod Con Boiler comes equipped with leveling feet Should you find the floor beneath the boiler is uneven with a wrench adjust the leveling feet INCORRECT CORRECT INCORRECT CORRECT Mn GAS FIRED BOILER Boiler Manual DIMENSIONS LEFT SIDE FRONT RIGHT SIDE MOD CON 300 ALL MODELS MOD CON 300 POWER SWITCH ACCESS PANEL e DISPLAY
49. e power for the alarm device To connect a device that should be powered off during a boiler lockout condition follow the same instructions as above except use the ALARM NC terminal rather than the ALARM NO terminal Note that in a cascade system the alarm output of the Boiler addressed as 1 will also be active if the master boiler has a lockout condition The alarm output of Boilers addressed as 2 7 will only sound if a lockout condition occurs on that specific boiler GAS FIRED BOILER Boiler Manual PART 8 FIELD WIRING continuen MOD CON CONNECTION DIAGRAM 72 7 06 1 607 lt lt SWITCH RIBBON CABLE 6 1 6 4 2 2 46 4 J2 X5 8 SUPPLY X418 RETURN AK 4712 MAN RESET AUTO RESET SEE DETAIL A HIGH WATER HIGH WATER J6 5 FOR MOD CON 500 TEMP o oo X43 X5 5 lt lt 1 lt WIRING APPLICATION pec cc gt 926 HIGH GAS CONTROL 0 0 X4 18 ALARM RELAY COIL 2 xe 4 4 8 7 ORANGE eee SPARK CABLE TO SPARK ELECTRODE LOW WATER HIGH FLUE i LEVEL PRESSURE KEH x4 10 TT TERMINALS 102 QC xes J3 3 J3 4 RS485 BUS 300 500 GAS VALVE J3 5 J4 3 _ CONDENSATE 4 6 FULL X4 15 _ BLOWER a A A C 4 14 OUTDOOR J1 DHW TANK ASK a idi SE J1 X4 3 10 VOLT 1 l
50. e red wire from the control box to the low water cutoff probe on the boiler 4 Route the rest of the wires through the provided hole in the cabinet and down by the main electrical enclosure 5 Locate the two pigtails hanging from the main electrical enclosure Select the pigtail which has a white red and brown wire in it If the pigtail is connected to a gas pressure switch skip to step 7 If this pigtail is not Boiler Manual connected to a gas pressure switch remove the jumper plug from the end of the pigtail and place the jumper plug into the mating connector coming from the LWCO control box Connect the pigtail to the remaining plug coming from the LWCO control box Installation is complete If the pigtail located in step 5 is connected to a gas pressure switch disconnect it from the gas pressure switch and connect the pigtail to the mating connector coming from the LWCO control box Connect the gas pressure switch to the remaining connector from the LWCO control box M WIRING OF CASCADE SYSTEM COMMUNICATION BUS Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers These cables are readily available at any office supply computer electronic department or discount home supply store in varying lengths If you possess the skills you can also construct custom length cables It is recommended to use the shortest length cable that will reach between t
51. e space as the Mod Con Boiler The boiler cover must be se curely fastened to the boiler to prevent the boil er from drawing air from inside the boiler room This is particularly important if the boiler is lo cated in the same room as other appliances Failure to comply with the above warnings could result in severe personal injury death or sub stantial property damage GAS FIRED BOILER Boiler Manual PART 3 PREPARE BOILER LOCATION continuen E RESIDENTIAL GARAGE INSTALLATION Precautions Take the following special precautions when installing the boiler in a residential garage If the boiler is located in a residential garage per ANSI 2223 1 paragraph 5 1 9 e Mount the boiler with a minimum of 18 inches above the floor of the garage to the bottom of the boiler to ensure the burner and ignition devices will be no less than 18 inches above the floor e Locate or protect the boiler so it cannot be damaged by a moving vehicle F EXHAUST VENT AND INTAKE AIR VENT WARNING Vents must be properly supported The Mod Con s Intake and Exhaust Connections not designed to carry heavy weight Vent support brackets must be within 1 foot of the boiler and the balance at 4 foot intervals The Mod Con venting must be readily accessible for visual inspection for the first three feet from the boiler The Mod Con Boiler requires a special vent sys tem designed for pressurized venting Mod Con Boilers
52. eat exchanger can be damaged by buildup or corrosion due to sediment build up For zoned systems flush each zone sepa rately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system Flush system until water runs clean and you are sure piping is free of sediment Test replace freeze protection fluid 1 49 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory Freeze protection fluid must be replaced period Boiler Manual ically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions B FREEZE PROTECTION WHEN USED WARNING NEVER use automotive or standard glycol antifreeze even ethylene glycol made for hydronic systems Use only freeze prevention fluids certified by fluid manufacturer as suitable for use with stainless steel boilers verified in fluid manufacturer s literature Throroughly clean and flush any system that has has used glycol before installing the new Boiler Provide boiler owner with a material safety data sheet MSDS on the fluid used Determine freeze protection fluid quantity using total system water content following fluid manufacturer s instructions Remember to include expansion tank water content Local codes may require back flow preventer or actual disc
53. ecially noticeable in E DUNGS GAS VALVE Boiler Manual NEW LP installations and also in empty tank sit uations This can also occur when a utility com pany shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with a conventional gas valve under any circumstances MOD CON 300 GAS VALVE GAS INLET PRESSURE TAP GAS SHUT OFF VALVE Fig 7 2 p y zt DETAILA SCALE 2 3 THRO TILE ADJ USTER NOTE IF FORANY REASON THE THROTILE NEEDS USTED ITIS VERY IMPORTANT THATA COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE ADJ USTER TO THE TO INCREASE THE GAS OR TO DECREASE THE GAS SUPPLY THIS USTMENTC OULD AFFECTCO CO LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHARTIN COMBUSTION SETTINGS 10 1 OFFSET ADJ USM ENT CAUTION DO NOTREMOVE THIS SC REW ATIEMPTTO MAKE ADJ USIMENTTO THIS SC REW WITHOUTA COMBUSTION ANALYZER LP 205 AA Rev 6 3 08 JULIU GAS FIRED BOILER Boiler Manual PART 7 GAS PIPING continuen MOD CON 500 GAS VALVE THRO TILE ADJ USTER NOTE IF FOR ANY REASON THE THROTILE NEEDS TO BE USTED ITIS VERY IMPORTANT THATA COMBUSTION ANALYZER BE USED ENSURE SAFE AND PROPER OPERATION TURN THE USTER TO THE TO INCREASE THE GAS OR TO DECREASE THE GAS SUPPLY THIS USIMENT COULD AFFECT CO CO
54. ed carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified LP 172 REV 2 16 06 72 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS the following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required to be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes C
55. epeat this procedure for additional zones one at time 22 2021 GAS FIRED BOILER PART 5 BOILER PIPING continuen A CAUTION For installation that incorporates standing iron radiation and systems with manual vents at the high points Follow previous section and starting with the nearest manual air vent open vent until water flows out then close vent Repeat procedure working your way toward furthest air vent It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present Annual cleaning of the strainer may be necessary Boiler Manual CAUTION It is highly recommended that you carefully follow the glycol manufacturer s recommended concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You must carefully figure the additional friction loss in the system as well as the reduction in heat transfer co efficients J ZONING WITH ZONE VALVES Upon completion make sure that the fill valve is in the automatic position and each zone balance and purge or shut off is in an open position and zone valves are positioned for automatic opera tion WARNING Connect the boiler to the system as shown in Piping Details when zoning with zone valves The primary secondary piping shown ensures the boiler loop will have sufficient flow It also avoids applying the high head of the boiler circulato
56. er Model 00 500 2 Cubic Ft Hr 850 2 D 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 unit To check Gas Pressure perform the steps listed below 1 Before you connect to the inlet pressure you must shut off the gas and electrical power to unit 2 Loosen the pressure tap with a small screwdriver Refer to Figures 7 2 and 7 3 for location 3 Each unit is equipped with a needle valve that will accept a 5 16 ID hose to connect to a digital manometer or liquid gauge to measure incoming pressure from 0 35 w c 4 Turn on the Gas and Power up the unit 5 Put the unit into manual service mode Details on service mode in back of this manual In service mode monitor pressure to assure it does not drop below 1 inch from its idle reading If Gas Pressure is out of range or pressure drop is excessive contact the gas utility gas supplier qualified installer or _ EN wr EF ___ _ 1 Boiler 7 Boilers 8 Boilers 85 1700 2550 saoo 4250 5100 ModCon 850 100 of pipe gt 212 4 4 ModCon 850 250 of pipe 2127 3 4 4 4 Boilers 5 Boilers 6 Boilers 8 Boilers 4 Boilers 5 Boilers 6 Boilers 7 Boilers 8 Bolles 4000 E ov 7 Boilers 8 Boilers 6800 4250 5100 6800 5950 _ service agency to de
57. er patent medicines Substantial property damage damage to boiler and or serious personal injury UUU GAS FIRED BOILER may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by make up water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent make up water PART 2 BEFORE YOU START A WHAT S IN THE BOX Also included with the Mod Con are Pressure and Temperature Gauge Outdoor Sensor Installation Manual Warranty CSD 1 Form H 3 Data Sheet B HOW BOILER OPERATES Mod Con Condensing Technology is an intelli gent system that delivers highly efficient hydronic heating while maximizing efficiency by measuring the data parameters of your heat ing system Outlined below are the features of the system and how they operate 1 Stainless Steel Heat Exchanger The highly efficient Mod Con Stainless Steel Heat exchanger Is designed to use the cold return water from the system and extract the last bit of heat before it is exhausted Modulating Combustion System combustion system will modulate the output of the burner during operation to match the system demand and achieve the control set point while in operation The set point can Boiler Manual PART 1 PRODUCT AND S
58. erature at the maximum outside temperature Function 11 NOTICE It is important to note that the user can adjust the heat curve down by adjusting the central heating temperature to a lower setting CENTRAL HEATING CURVE Factory Default FUNCTION 9 176 167 158 T q DEFAULT RESET CURVE Lu 149 ac 5 H 131 122 LL 113 104 D 95 FUNCTION 11 gt 86 5 77 68 i s 41 59 41 24 9 9 27 45 63 81 99 5 68 OUTSIDE TEMPERATURE F Fig 11 2 CENTRAL HEATING CURVE Plot your Curve OUTSIDE TEMPERATURE F CONTROL PROGRAM REFERENCE CHART Function 6 O minutes 8 o de Nochange allowed 1800F No change allowed E up F 7 F Fig 11 3 Default Setting 30 minutes Programmed Setting 14 1 30 minutes 5 0 0 O 19 180 F NEN INN 0 2 0 24hrs Lx _ pe c _ el 2 2 030005 3 2 2 10 24 24 hrs No change allowed 26 UUU GAS FIRED BOILER PART 12 TROUBLESHOOTING A MOD CON ERROR CODE If any of the sensors detect an abnormal condi tion or an internal component fails during the operation of the ModCon Boiler the display may show an error code This code may either be the result of a temporary condition in which case the display will revert
59. esence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas F CHECK THERMOSTAT CIRCUIT S Disconnect the two external wires connected to the boiler thermostat terminals low voltage terminal strip Connect a voltmeter across these two incoming wires with power applied to 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 There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to boiler low voltage terminal strip Allow the boiler to cycle G CONDENSATE REMOVAL The Mod Con 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 an automobile when it 16 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 brass or other materials that will be subject to corro
60. fgfAAL 9 HeatTransfer A MODEL OF CONSERVATION a TE T hi nt B AL LI e Li Installation Installation Startup Maintenance Parts N M CONTROLS member MH27745 ew LISTED 6 US A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage NOTICE Heat Transfer Products Inc reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature nnnn 77277 GAS FIRED BOILER Boiler Manual WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do light any appliance Do not touch any electrical switch do not use any phone tn your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Installation and service must be
61. han 1 microampere clean the flame rectifier probe If the flame rectifier probe continues to read low replace it Check the stability of the flame rectification signal If the signal is unstable you may need to replace the burn er gasket Turn the gas off to the unit at the service valve False Flame Signal The Ifthe flame signal is still present replace the flame rectification probe boiler will lock out if it Ifthe flame signal is not present after turning off the gas supply check the gas valve electrical connection senses a flame signal Remove the valve and check for obstruction in the valve seat or replace the gas valve when there should be Turn the gas on at the service valve after corrective action is taken none present Check for condensate back up Condensate back up can damage the refractory wall and if the wall falls against the rectifier probe it may conduct the signal to ground giving a false reading Loss of Flame Signal The boiler will relight 4 times before the control goes into this lockout condition Will reset in 1 hour DIRO NS N gt Combustion Fan Speed too low or high Boiler Check the combustion air fan wiring will lock out if it senses Check the 24 VAC signal by measuring from any connected safety to ground A low voltage situation may fan speed is less than cause a false error code 70 or greater than Replace the combustion air fan 130 of its expected ra
62. hat there is adequate flow through the boiler by accessing the status menu and assuring that there is 230 _ less than a 50 F rise from the return thermister to the supply thermister Check circulation pump operation Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermister to the supply thermister Check direction of flow on boiler circulator See Piping Details in this manual Return Inlet Temperature Exceeded 230 Watch the igniter through the observation window provided If there is no spark check the spark electrode for the proper 4 gap Use 2 quarters together as a gauge hold ignitor against to check gap distance See Fig 12 3 Remove any corrosion from the spark electrode and flame rectifier probe If there is a spark but no flame check the gas supply to the boiler If there is a flame check the flame sensor Check any flue blockage or condensate blocks No flame detected The boiler will make three at tempts at ignition before the control goes into this lockout condition Monitor the gas pressure to the unit while in operation Assure that the flame is stable when lit Check to see if the green light on the display module is out while the boiler is running If the green light doesn t come on or goes off during operation check the flame signal on the status menu If the signal reads less t
63. he boilers and create a neat installation Do not run unprotected cables across the floor or where they will become wet or damaged Avoid running communication cables parallel and close to or against high voltage 120 volt or greater wiring HTP recommends that the maximum length of communication bus cables not exceed 200 feet Route the communication cables through one of the knockouts in the cabinet 44 GAS FIRED BOILER PART 8 FIELD WIRING continuen Connect the boilers in a daisy chain configuration as shown below It is best to wire the boilers using the shortest wire runs rather than trying to wire them in the order that they are addressed The communication Boiler Manual are interchangeable so you can use either one or both in any order to connect the cable to If you have connected the boilers to each other properly two of the boilers will have one open connection port on them bus jacks on the customer connection panel UNUSED COMMUNICATION B JACK AVAILABLE CONNECT TO VISION 2 UNUSED COMMUNICATION BUS JACK AVAILABLE CONNECT TO VISION 2 Fig 8 2 LP 205 Ju 45 0217 GAS FIRED BOILER PART 8 FIELD WIRING continuen Boiler Manual MOD CON Cascade Master OPTIONAL 0 10 VOLT INPUT NOTE SYSTEM fos sos THERMOSTAT o OUTDOOR SENSOR You must place the SENSOR Cascade Master label included in shipping envelope on top of the Standard Mod C
64. ion Code c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining PART 4 PREPARE BOILER A WARNING Uncrating Boiler Any Claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee CAUTION Cold weather handling If boiler has been stored in a very cold location below 0 F before installation handle with care until the plastic components come to room temperature Remove all sides of the Mod Con shipping crate in order to allow the boiler to be lifted into Its installation location You must pick the boiler up by the lift rings to avoid damage to the boiler 12 GAS FIRED BOILER Boiler Manual PART 4 PREPARE BOILER continuen enclosure You can use either a solid 34 in diameter black iron pipe or lift ing straps to lift the boiler off of its shipping crate You must have at least two individuals to handle the boiler properly to avoid damage as care should be taken as the Mod Con is very heavy The Mod Con is also equipped with leveling feet that can be used to level the boiler properly if the surface location is not level If sur face flooring is rough care should be taken when sliding boiler into posi tion you could catch the leveling feet and damage the boiler if it is slid to its location INSERT BLACK IRON PIPE WITH TEES OR LIFTING STRAPS INTO LI
65. ipe intake air vent near a swimming pool Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants Table 3 2 Corrosive contaminants and sources Cements and glues Antistatic fabric softeners used in clothes dryers New building construction Adhesives used to fasten building products and other similar products Areas likely to have contaminants Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms GAS FIRED BOILER Boiler Manual PART 3 PREPARE BOILER LOCATION continuen H WHEN REMOVING A BOILER FROM AN EXISTING COMMON VENT SYSTEM DANGER Do not install the Mod Con Boiler into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follo
66. isual inspection for the first three feet of the boiler 6 Do not use the boiler to support any piping A screened straight coupling is provided with the boiler for use as an outside exhaust termination 8 A screened inlet air tee is provided with the boiler to be used as an outside intake termination H HEATER REMOVAL FROM A COMMON VENT SYSTEM At the time of removal of an existing heater the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to com mon venting system are not operating 1 Seal any unused openings in the common venting system 31 2 Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage leakage corrosion or other defi ciencies that could cause an unsafe condition 3 lf practical close all building doors windows and all doors between the space in which the appliance remains connected to the common venting system located and other spaces in the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum speed Do not operate a summer exhaust fan Close all fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust the thermostat so the appliance will operate
67. le 12 2 229 Board FAULT Codes Code Description Check circulation pump operation Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermister to the supply thermister Check thermister reading on supply thermister Replace switch if faulty If this is a new installation disconnect the two light grey wires from the zone control and twist the wires to gether Depress the S4 reset button If the fault clears the problem is outside the boiler If this is an existing installation with glycol in it check the condition of the water pressure switch It may be nec essary to jump out the water pressure switch temporarily only as a trouble shooting aid The 24 VAC signal may have grounded through the glycol if the water pressure switch is leaking If the boiler is equipped with High and or Low gas pressure switches examine the switch es to see if the yel low LED is illuminated on the switch If so correct the gas supply problem associated with the switch and reset ECO circuit 2 the switch by pressing on the cover of the switch over the red button to reset the switch Pressing the button Vent temperature requires a firm push Push the Reset button on the front panel of the boiler to reset the boiler control High Gas Pressure if Ifthe boiler has UL353 LWCO check to see if the LED on the LWCO control box is illuminated If
68. ndensate Neutralization The condensate from the boiler is slightly acidic with a ph of 3 2 4 5 Heat Transfer Products recommends neutralizing the condensate with a Condensate Neutralizer Kit p n 7350P 611 that be added to your system to avoid long term damage to the drainage system and to meet local code requirements The neutralizer kit is connected to the drain system and contains marble chips that will neutralize the ph level of the water vapor The neutralizer should be checked at least once a year and the marble chips should be replenished if necessary When replacing the marble chips they should no smaller than 3 4 to avoid blockage in condensate piping Refer to fig 6 1 and 6 2 for piping of the Condensate neutralizer GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen CONDENSATE NEUTRALIZER WITHOUT PUMP 3 4 SWEAT PVC TEE OPEN TO ATMOSPHERE PIPE HANGER ASSEMBLIES FOR SUPPORT CONDENSATE NEUTRALIZER 3 4 PVC SWEAT PIPING FITTINGS FLOOR DRAIN MUST BE INSTALLED WITH A PITCH OF 1 4 PER FOOT 58 PIPE SUPPORT CLEAN OUT PORT WARNING YOU MUST MAKE SURE THAT THIS CAP IS SECURE AFTER SERVICING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH 3 4 SWEAT PVC PIPING FITTINGS 3 4 SWEAT PVC TEE OPEN TO ATMOSPHERE Fig 6 1 PIPE HANGER ASSEMBLIES FOR SUPPORT LITTLE GIANT PUMP CONDENSATE NEUT
69. nnect the indirect tank sensor 7250P 325 Boiler Manual to the terminals marked DHW SENSOR shown in figure 8 1 in the electrical junction box Caution should be used to ensure neither of these terminals become connected to ground OPTIONAL 0 10 VOLT BUILDING CONTROL SIGNAL A signal from a building management system may be connected to the MOD CON boiler to enable remote control This signal should be a 0 10 volt positive going DC signal When this input is enabled using the installer menu a building control system can be used to control either the set point temperature or the heat output of the MOD CON Boiler The control interprets the 0 10 volt signal as follows When the signal is between 0 and 1 volt the MOD CON Boiler will be in stand by mode not firing When the signal rises above 1 volt the MOD CON Boiler will ignite As the signal continues to rise towards its maximum of 10 volts the MOD CON boiler will increase either in set point temperature or firing rate depending on the setting of parameter 17 in the installer menu See Part 11 for details on the setting of parameters 16 and 17 for this option Connect a building management system or other auxiliary control signal to the terminals marked 0 10 VOLT 0 10 VOLT in the electrical junction box shown in figure 8 1 Caution should be used to ensure that the 0 10 VOLT connection does not become connected to ground J OPTIONAL HIGH GAS PRESSURE SWIT
70. o change the Indirect Circulator Post Purge Time once the sensor is satisfied Note it is recommend that Circulator Post Purge Time be set no greater than 5 minutes Range 0 to 10 minutes Outdoor temperature that you wish the central heating should be disabled warm weather shut off Range 41 F to 122 F Allows the installer to change the Minimum Outside Design Temperature Range 499 to 329F See Chart 11 1 to set out door reset curve Allows the installer to change the Design Supply Water Temperature from the Mod Con based on the Minimum Onutside Design Temperature Range 77 F to 200 F Allows the installer to change the Maximum Outside Design Temperature for Central Heating Range 95 F to 32 F Allows the installer to change the Design Supply Water Temperature from the Mod Con based on the Maximum Outside Design Temperature Range 32 F to 200 F Number 12 13 14 15 16 17 18 20 GAS FIRED BOILER PART 11 START UP PROCEDURES FOR THE INSTALLER continuen Function Default Value 68 F 0 Min 30 Min 180 Function Description Allows the installer to set the low est temperature on the Mod Con for Central Heating Range 32 F to 200 F Allows the installer to change the Central Heating Circulator Post Purge Time once the thermostat 15 satisfied Range 0 to 10 minutes Allows the installer to set the Maximum run time for the Indirect Fired
71. ollowers The master boiler will have a cascade system sensor and a cascade pump connected to it in addition to its own boiler pump The follower boilers will GAS FIRED BOILER PART 2 BEFORE YOU START cnr 10 11 12 have their own individual pump connected to each follower boiler System Display and Operation Led light Indicators The display allows the user to change the system parameters and monitor the system outputs Led light indicators monitor operation through illumination of Indirect Pump Boiler Pump System Pump Flame On System Fault Gas Valve The gas valve senses suction from the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing Swirl Plate or Integrated Venturi Controls the air and gas flow into the burner Burner Constructed of high grade stainless steel the burner uses premixed air gas and provides a wide range of firing rates Spark Ignition The burner is ignited by applying a high voltage through the system spark electrode This causes the spark from the electrode to ignite the mixed gas off of the burner Supply Water Temperature Sensor This sensor monitors the boiler outlet water temperature System Supply The control adjusts the boiler firing rate so the supply temperature will match the boiler set point Return Water Temperature Sensor This sensor monitors the boiler return water temperature System Ret
72. on Control m GREEN GROUND WHITE NEUTRAL BLACK HOT LINE VOLTAGE IN 120 VAC Fig 8 3 1 MOD CON CASCADE MASTER PUMP AND SENSOR WIRING Place the Cascade Master Overlay Sticker included onto the field connection board on the boiler designated as the Cascade Master Only Connect the system pump hot wire to the terminal marked SYS PUMP Connect the system pump neutral to the BOILER NEUT terminal and the pump ground wire to the BOILER GND terminal Connect a jumper wire from the 120 VOLT terminal to the SYS PUMP PWR terminal SYSTEM PUMP PWR SYSTEM PUMP EX BOILER GN EX BOILER NEU EX BOILER HOT RELAY BOILER GND d BOILER J 5 CONNECTION POINTS J3 J4 ASCADE BUS ZONE CONTROL ONLY 10V LOVLNOOD AMQ 24 dWNd 43108 13 131100 39N3IN3ANOO GROUND LP 205 JJ1 Rev 5 12 08 5 Connect the boiler pump to the terminals marked BOILER HOT BOILER NEUT and BOILER GND 6 Connect the system pipe sensor to the terminals marked SYS SENSOR 7 Connect the outdoor sensor if used to the terminals marked OUTDR SEN 8 Connect the signal to start the system to the terminals marked THERMOSTAT NOTE This signal can come from a room thermostat or a dry contact closure No power of any voltage should be fed into either of these terminals 46 nnnn GAS FIRED B
73. onnect from city water supply When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level C FILL AND TEST WATER SYSTEM Fill system only after ensuring the water meets the requirements of this manual Close manual and automatic air vents and boiler drain valve 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 must never exceed 160 psig At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further cAS FIRED BOILER PART 9 START UP PREPARATION continuen WARNING Eliminate all system leaks Continual fresh make up water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating heat exchanger and causing heat exchanger failure The system may have residual substances that could affect water chemistry After the system has been filled and leak tested verify water pH and chlorine concentrations are acceptable A CAUTION It is important that you purge the system of air to avoid damage to
74. out code of This is a low gas pressure switch lock out from the factory installed low inlet gas pressure switch located on the left for the Mod Con 500 and on the right for the Mod Con 850 You will also see a yellow LED illuminated under the cover of the inlet gas pressure switch Once the gas is turned on reset the gas pressure switch by FIRMLY pressing on top of the plastic cover over the red reset button You will note that yellow LED has now gone out Press and hold the key on the control panel for about 4 seconds to begin normal operation Set the thermostat to the desired setting 5 the appliance fails to start refer to the Troubleshooting section in the back of this manual B ADJUSTING THE SETPOINT NOTE Before you can change the temperature from the factory setting of 180 degrees you must make sure none of the thermostats are calling for heat The controller will not memo rize a program setting while in a heating cycle To adjust the temperature to the Mod Con Boiler Press the Key for seconds until you see a flashing C alternating to 180 this number is the factory set point of 180 To change the temperature set point Press the to decrease temperature Boiler temperature can go as low as 50 22 Press the to increase temperature Boiler temperature can go as high as 200 To access additional setting options Press to scroll through and view the following
75. pliance and is listed as a Category IV appliance with Underwriters Laboratories Inc C APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE AIR VENT 1 Use only Non Foam Core venting material or AL294C The following materials are approved for use as vent pipe for this boiler See Table 6 1 for all approved venting 24 mm 577 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen Table 6 1 APPROVED PLASTIC EXHAUST VENTING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN NITED 5 CPVC SCHEDULE 40 ANSI ASTM F441 ULC S636 Note IPEX is an approved Note Cellular Foam Core Pipe must only Manufacturer in Canada be used on INTAKE piping supplying vent material listed to ULC S636 Table 6 2 APPROVED PLASTIC INTAKE VENTING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN NITED STATES CANADA ULC S636 Note IPEX is an approved Note Cellular Foam Core Pipe must only Manufacturer in Canada be used on INTAKE piping supplying vent material listed to ULC S636 Table 6 3 APPROVED PLASTIC CONDENSATE PIPING MATERIAL STANDARDS FOR INSTALLATION IN NITED STATES CANADA ______ Note IPEX is an approved Manufacturer in Canada supplying vent material listed to ULC S636 Table 6 4 APPROVED PIPE CEMENT AND PRIMER FOR PLASTIC PIPE STANDARDS FOR INSTALLATION IN CANADA IPEX System 636 Cements and Primers Table 6 5 APPROVED
76. ply only the boiler loop Install a separate circulator for each zone Connect DHW domestic hot water piping to indirect storage water heater as shown Piping Details L MULTIPLE BOILERS Connect multiple boilers as shown in Piping Details All piping shown 15 reverse return to assure balanced flow throughout the connected boilers Each connected boiler must have Its own circulator pump to assure adequate flow Connect DHW domestic hot water piping to indirect storage water heater as shown in Piping Details The system flow secondary loop must be greater than the boiler s primary loop flow nnnn 2211 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL A INSTALLING EXHAUST VENT AND INTAKE AIR VENT DANGER The Mod Con Boiler must be vented as detailed this section Ensure the exhaust and intake piping comply with these instructions regarding the venting system Inspect finished combustion air intake and exhaust piping thoroughly to ensure all joints are secure and airtight and comply with all applicable code requirements as well as with the instructions provided in this manual Failure to provide a properly installed vent system will cause severe personal injury or death WARNING This vent system will operate with a positive pressure in the pipe Do not connect vent connectors serving appliances vented by natural draft into any portion of mech
77. r Manual hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle Chilled Water Medium must be piped in parallel with the boiler Freeze Protection for new or existing systems must use glycol that is specifically formulated for this purpose It will include inhibitors that will prevent the glycol from attacking the metallic system com ponents Make certain that the system fluid 15 checked for the correct glycol concentration and in hibitor level The system should be tested at least once a year and as recommend by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping Example 50 by volume gycol solution ex pands 4 8 in volume for the temperature increase from 32 F to 180 F while water expands 3 with the same temperature rise GAS FIRED BOILER Boiler Manual PART 5 BOILER PIPING G BOILER PIPING DETAILS Single Mod Con Boiler Space Heating with Indirect Priority BALL VALVE TYPICAL 4 PIPE DIAMETER SPACING MAXIMUM AIR ELIMINATOR FROM SUPPLY SENSOR SYSTEM OPTIONAL SYSTEM DRAIN BOILER CIRCULATOR TYPICAL CIRCULATOR VALVE EXPANSION TANK TO SYSTEM uui lt gt pu p DRAIN VALVE PURGE ms is TEMPERATURE i PRESSURE GAUGE MA
78. r runs from the conden sate At this point the Mod Con should be ready to be re assembled a Inspect gaskets Before beginning this procedure you must have on b Re install the burner assembly hand the following items anylon stainless steel or brass brush not steel Rydlyme recommended for best results available on line www rydlyme com or CLR available at most hardware stores Gloves eye protection 1 Shut down the Mod Con Boiler by using the fol lowing steps a Close the gas valve shut down the unit and wait for the unit to be cool to the touch 62 Mn ffl GAS FIRED BOILER PART 13 MAINTENANCE continuen Replace and tighten the 6 nuts to the burner plate using staggered tighten ing sequence See detail 63 Boiler Manual Re connect all wiring connections Inspect gas valve to assure O ring is in place Replace the 4 screws on the alu minum connector on the gas valve Turn the gas back on IMPORTANT CHECK FOR GAS LEAKS Turn the Mod Con Boiler power back on and create a demand on the boiler When boiler is lit observe condensate flow from the boiler Be sure the boiler is oper ating properly Re connect the condensate piping to the outside condensate connection MOD GAS FIRED BOILER PART 13 MAINTENANCE continuen MOD CON 300 Description 300 000 BTU MOD CON MODULE EIE F BURNER DOOR 7350 018 BURNER DOOR R
79. r to the zone valves Connect DHW domestic hot water piping to indirect storage water heater as shown Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems Glycol mixtures should not exceed 50 K ZONING WITH CIRCULATORS Connect the boiler to the system when using circulator zoning as shown in Piping Details 23 Glycol in hydronic applications which is specially formulated for this purpose includes inhibitors that prevent the glycol from attacking metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level The glycol solution should be tested at least once a year and as recommended by the glycol manufacturer Anti freeze solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F to 180 F while water expands 3 with the same temperature rise Allowances must be made for this expansion the system design 30 mixture of glycol will result in a BTU output loss of 15 with a 5 increase in head against the system circulator 50 mixture of glycol will result in BTU output loss of 30 with a 50 increase in head against the system circulator when zoning with circulators NOTE The boiler circulator cannot be used for a zone must sup
80. rance This appliance has been approved for closet installation Do not install this appliance directly on carpeting For installation on combustible flooring directly Category IV vent systems only GAS FIRED BOILER Boiler Manual PART 1 PRODUCT AND SAFETY INFORMATION cour A WARNING Installer Read all instructions in this manual and Mod Con Venting section before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to User s Information Manual for your reference User Have this boiler serviced inspected by a qualified service technician annually Failure to comply with the above could result in severe personal injury death or substantial CAUTION Due to the low water content of the boiler mis sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure Heat Transfer Products DOES NOT warrant failures caused by mis sized boiler applications DO NOT oversize the boiler to the system Modular boiler installations greatly reduce the likelihood of boiler oversizing BEFORE INSTALLING WHEN SERVICING BOILER property damage To avoid electric shock disconnect electrical supply before performing maintenance WARNING dii Failure to adhere to the guidelines on this page can result in severe personal injury death or s
81. rate resulting in possibility of severe personal injury death or substantial property damage 13 GAS FIRED BOILER PART 5 BOILER PIPING continuen B GENERAL PIPING INFORMATION NOTICE The Mod Con Boiler control module uses temperature sensors to provide both high limit protection and modulating temperature control The control module also provides low water Boiler Manual recognized design methods See tank manufacturer s instructions for details Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator Always install the system fill connection at the same point as the expansion tank connection to the system protection by sensing the water level in the heat exchanger Some codes jurisdictions may 4 require additional external controls Most chilled water systems are piped using a closed type expansion tank Diaphragm or bladder expansion tank C BACKFLOW PREVENTER 1 Always install an automatic air vent on top of Use a backflow preventer specifically designed the air separator to remove residual air from for hydronic boiler installations This valve the system should be installed on the cold water fill supply E CIRCULATORS line per local codes See Boiler Piping Details CAUTION CAUTION DO NOT install automatic air vents on closed type expansion tank systems Air must remain in the system and return to the tank to pro
82. re 6 12 LP 205 Y Rev 5 28 08 NOTE When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler GENERAL NOTE All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 4 per foot back to the heater to allow drainage of condensate 34 UUI GAS FIRED BOILER PART 7 GAS PIPING A WARNING Failure to follow all precautions in this section could result in fire explosion or death A GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14 w c 3 5 kPa and a minimum of 3 5 w c 87 kPa The entire piping system gas meter and regulator must be sized properly to prevent pressure drop greater than 0 5 12 kPa as stated in the National Fuel Gas Code This information is listed on the rating label A WARNING It is very important that you are connected to the type of gas as noted on the rating plate LP for liquefied petroleum propane gas or Nat natural or city gas You must not do a gas conversion on this boiler All gas connections must be approved by the local gas supplier or utility in addition to the governing authority prior to turning the gas supply on The gas connection on the Mod Con is 1 1 4 for the Mod
83. rimed and cemented Use only cement and primer approved for use with the pipe material Refer to the Venting Table 6 4 A WARNING All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space 30 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen 4 Horizontal lengths of exhaust vent must slope back towards the boiler not less than 1 4 per foot to allow condensate to drain from the vent pipe If the exhaust pipe must be piped around an obstacle that results in the creation of a low point condensate will collect in this low point and form a blockage This condensate must be drained away using a field installed condensate drain assembly All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 4 per foot back to the boiler to allow drainage of condensate The condensate drain piping should be a minimum of 34 PVC Rigid Piping pitched at a minimum of per foot away from the boiler See Fig 6 1 6 2 5 All piping must be fully supported Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form When placing support brackets on vent piping the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe The boiler venting must be readily accessible for v
84. rough the Mod Con Boiler Heat Exchanger 20 nnnn WU GAS FIRED BOILER Boiler Manual PART 5 BOILER PIPING continuen MOD CON HEAT EXCHANGER PRESSURE DROP LL gt 10 12 14 16 18 20 22 24 26 28 30 32 34 36 FRICTION IN FEET OF HEAD MODCON 300 MODCON 500 MODCON 850 Figure 5 1 The chart below represents the various system design temperature rise through the Mod Con along with their respective flows and friction loss which will aid in circulator selection 20 At 2591 30 At 35 At A5 At Feet GPM Feet GPM Fee GPM Feet Feet Feet GPM _ 9 30 12 9 z 7 7 6 6 9 Mod 600 1 amp so w 4 29 S 75 4 Mod Con 850 38 85 2 6 18 4 amp 1v 4 8 14 23 36 LP 205 E Rev 12 5 07 21 nnnn UI GAS FIRED BOILER PART 5 BOILER PIPING continuen The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit To size simply add up the number of boilers and the required flow rates for the sys tem design temperature Boiler Manual Example 5 Mod Con 300 Boilers with a design of 30 degree temperature rise with each boiler having an individu
85. rs or other objects that will obstruct the exhaust stream The flue products coming from the exhaust vent will creat a large plume wne the boiler is in operation Avoid venting areas that will affect neighboring buildings or be considered objectionable The boiler vent system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 Note this does not apply to the combustion air intake of a direct vent appliance Provide a minimum of 1 foot distance from any door operable window or gravity intake into any building Provide a minimum of 1 foot clearance from the bottom of the exhaust above the expected snow accumulation level Snow removal may be necessary to maintain clearance e Provide 4 feet horizontal clearance from electrical meters gas meters gas regulators relief equipment exhaust fans and inlets In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained Do not locate the exhaust over public walkways where condensate could drip and or freeze and create a nuisance or hazard e When adjacent to a public walkway locate exit terminal at least 7 feet above grade Do not locate the exhaust directly under roof overhangs to prevent icicles from forming e Provide 6 feet clearance from the inside corner of vertical walls chimneys etc as well as horizontal corners created by roof o
86. s Optional Equipment Part 3 Prepare Boiler 7 12 Boiler Location Should Be Level Installations Must Comply With Before Locating Boiler Clearances for Service Access Residential Garage Installation Exhaust Vent and Intake Air Vent Prevent Combustion Air Contamination When Removing a Boiler from an Existing Common Vent System Part 4 Prepare 12 13 Part 5 Boiler 13 23 Relief Valve General Piping Information Backflow Preventer System Water Piping Methods Circulators Hydronic Piping with Circulators Zone Valves and Multiple Boilers Boiler Piping Details Circulator Sizing Fill and Purge Heating System Zoning with Zone Valves Zoning with Circulators Multiple Boilers Part 6 Venting Combustion Air 8 Condensate Removal 24 34 Installing Exhaust Vent and Intake Air Vent General Approved Materials for Exhaust Vent and Intake Air Vent Exhaust Vent and Intake Air Vent Pipe Location Exhaust Vent and Intake Air Vent Sizing Longer Vent Runs Exhaust Vent and Intake Air Pipe Installation Heater Removal from a Common Vent System Diagrams for Sidewall Venting Diagram for Vertical Venting Part 7 Gas 35 39 Gas Connection Gas Piping Gas Table Check Inlet Gas Pressure Dungs Gas Valve
87. s than 40 Measure resistance of outdoor sensor and compare to resistance chart If not within range on Degrees Fahrenheit chart shorted or open replace sensor Inspect power wiring to boiler and repair as necessary If connected to line voltage notify power company If connected to alternate power source such as generator or inverter make sure line voltage frequency supplied by the device is 60 Hz Check condensate lines for obstructions Condensate error Check float switch in condensate reservoir Check wiring from condensate reservoir to 926 control and repair as necessary Assure that the vent is not blocked Check the switch wiring by applying a jumper in place of the switch If the code clears with Blocked vent pressure the jumper in place REPLACE the flue switch and connect the wires to the new switch switch BEFORE running unit WARNING Do not use jumper to remedy this error Faulty switch MUST be replaced Failure to do so could result in serious injury or death Line voltage frequency out of range Check boiler feed water system to be sure it is supplying make up water to boiler system Water level in boiler is Be sure all air is bled from the system low Check for leaks in boiler and system piping and repair as necessary Inspect low level switch and wiring for damage and repair as necessary Check line voltage Must be between 100 128 volts If available connect PC and using HTP service software check the 24v supply
88. sed Actual Temperature from the outdoor sensor if connected e db cAs FIRED BOILER Boiler Manual PART 10 START UP PROCEDURE continuen Function Value 06 Actual Fan speed multiplied by 10 Example If fan speed displayed is E50 RPM x 10 4100 actual fan speed Actual lonization current read from Flame Rectification probe Actual Status of the Central Heating Circulator Off 4 On Actual Status of the Indirect Fired Circulator Off 4 On Actual Status bus communication connected 61 not connected Central Heating Set Point Power On Hours in thousands display will not read until 100 hrs Example Display x 1000 Power on Hours 12 3 x 1000 12300 Hours Total Central Heat Hours in Thousands display will not read until 100 hrs Example Display x 1000 Power on Hours 12 3 x 1000 12300 Hours Total Domestic Hot Water Hours in Thousands display will not read until 100 hrs Example Display x 1000 Power on Hours 12 3 x 1000 12300 Hours Passed Ignition Attempts in Thousands display will not read until 100 ignition attempts Example Display x 1000 Power on Hours 12 3 x 1000 12300 ignition attempts This function only becomes active when the Boiler is set as the Master It allows the user to monitor the System Pump connected to the Master Boiler and the connected boilers Followers in a multiple boiler installation Each boiler firing outpu
89. sed require more than this amount of power an external contactor or motor starter is needed If the boiler is configured as a cascade master the system pump output is a dry contact output capable of switching 5 amps at 120 volts in addition to the boiler pump and DHW pump outputs sourcing 3 amps each Boiler Manual The electrical junction box has separate clearly marked terminal strips for line voltage and low voltage wiring Special jacks are provided for trouble free cascade system wiring using stan dard or CAT5 patch cables C LINE VOLTAGE WIRING FOR STANDARD BOILER 1 Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals 120V Neutral Ground shown in figure 8 1 2 A line voltage fused disconnect switch may be required to be externally mounted and connected according to local codes that may apply 3 Connect the central heating pump as shown in Figure 8 1 to the terminals marked BOILER HOT BOILER NEUT BOILER GND The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts If a the pump requires more current or voltage other than the 120 volts supplied an external motor starter or contactor will be required 4 lfusing DHW connect the domestic hot water pump as shown in Figure 8 1 to the terminals marked DHW HOT DHW NEUT DHW GND The connections shown are suitable for a maximum continuous pump draw of 3 amps
90. set for operation Fill condensate trap with water Verify electrical connections are correct and securely attached Inspect intake piping and exhaust piping for signs of deterioration from corrosion physical damage or sagging Verify intake piping and exhaust piping are intact and correctly installed per Venting section and local code CASCADE SYSTEM If the boiler is used in a stand alone configuration skip this section Programming The Master Boiler 1 Make sure there is no demand for heat being supplied to the boiler 2 Apply power to the boiler GAS FIRED BOILER Boiler Manual PART 9 START UP PREPARATION continuen 3 Enter the installer Menu following instructions Part 11 of this manual 4 Verify that parameter 15 is set to 0 This makes the master boiler address 0 NOTE The Master Boiler MUST be addressed as O 5 Change parameter 23 from 0 to 1 This makes it the master boiler 6 Exit the installer menu NOTE The temperature set point of the master must match the follower boiler set point in order for the system to operate properly 3 Follower Boilers NOTE READ THE NOTES BELOW BEFORE PROGRAMMING FOLLOW ER BOILERS The boiler addressed as 1 will share its alarm output with the master boiler f one of the follower boilers has an in direct fired water heater connected to it the address of this boiler must be 2 or greater tisrecommended but not necessary to
91. sion Plastic PVC or CPVC pipe are the only approved materials A condensate filter 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 Heat Transfer Products Inc P N S7350 025 The Mod Con Boiler is equipped with connection that must be piped to a local drain It is very important that the condensate line is sloped downward away from the Mod Con to a suitable inside drain If the condensate outlet on the Mod Con is lower than the drain you must use a condensate removal pump available from Heat Transfer Products 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 If a long horizontal run is used it may be necessary to create a vent in the horizontal to prevent a vacuum lock in the condensate line Do not expose the condensate to freezing temperatures It 15 very important you support the condensation line to assure proper drainage H FINAL CHECKS BEFORE STARTING BOILER Read Startup Procedures within this manual for proper steps to start boiler See Startup Report to record steps for future reference Verify the boiler and system are full of water and all system components are correctly
92. so correct equipped the low water condition and press the reset button on the LWCO control box to reset the LWCO Press the reset Low gas pressure if button on the front panel of the boiler to reset the boiler control equipped Check the flue for obstructions or any sign of damage especially signs of excessive heat Repair as necessary Low Level if equipped Push red reset button on flue temperature switch located on the flue inside the rear access door of the boiler with UL353 LWCO Run the boiler and check the flue temperature If the flue temperature is within specs and the switch trips re place the switch If the flue temperature is excessive check and adjust combustion controls on the boiler If problem persists inspect the target wall in the combustion chamber and replace it if cracked or damaged Interrupted or Shorted Check the electrical connection to the thermister the outlet manifold Verify 5 VDC by checking in Molex Supply Outlet connector Verify thermister values by referencing chart in this manual Thermister Replace thermister if necessary Tg High Limit Exceeded Check the electrical connection to the thermister on the inlet manifold Verify 5 VDC by checking in Molex connector Verify thermister values by referencing chart in this manual Replace thermister if necessary Interrupted or Shorted Return Inlet Thermister 2 Supply Outlet 1 Check circulation pump operation Temperature exceeds 2 Assure t
93. st vent 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 intake air vent pipe and the exhaust vent 3 The minimum combined equivalent length 15 15 equivalent feet F LONGER VENT RUNS 1 The maximum combined equivalent length can be extended by increasing the diameter of both exhaust vent and intake air vent pipe equally However the transitions should begin a minimum of 15 equivalent feet from the boiler on both the intake and exhaust equally a The maximum equivalent length for the increased diameter vent pipes is 275 feet which includes the combined 30 feet from the boiler 15 ft inlet 15 ft exhaust 30 ft combined with transition total of 245 ft upsize piping for longer vent runs Table 6 9 Vent Transition Fitting Size Reducing Coupling Final Vent Size b Transitions must always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe c If the transition occurs at a distance greater than 15 equivalent feet from the boiler the maximum equivalent length will be reduced G EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION 1 Use only solid PVC or CPVC schedule 40 or 80 pipe and AL294C Stainless Steel FOAM CORE PIPING IS ONLY ALLOWED FOR INTAKE PIPING 2 Remove all burrs and debris from joints and fittings 3 joints must be properly cleaned p
94. t X8 3 J4 4 RS485 BUS Js SEE DETAIL FOR MOD CON 850 GAS VALVE WIRING APPLICATION 926 RESET CONTROL HIGH FLUE TEMP BLOWER MOTOR DETAIL A DETAIL B Fig 8 3 LP 205 X Rev 3 30 08 48 GAS FIRED BOILER PART 9 START UP PREPARATION A CHECK CONTROL WATER CHEMISTRY WARNING 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 Water pH between 6 0 and 8 0 1 Maintain boiler water pH between 6 0 and 8 0 Check with litmus paper or have chemically analyzed by water treatment company If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains 1 Consult local water treatment companies for unusually hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 3 Using chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm Do not connect the boiler to directly heat swimming pool or spa water Do not fill boiler or operate with water containing chlorine in excess of 200 ppm Clean system to remove sediment 1 3 You must thoroughly flush the system without boiler connected to remove sediment The high efficiency h
95. t percent is displayed To toggle between values press the to go down and the key to go up The first function you will see is d7 410 411 412 d13 414 415 416 System Pump 0 1 Master Boiler PO alternating 0 100 Percentage firing rate Follower Boiler 1 P1 alternating 0 100 Percentage firing rate Follower Boiler 2 P2 alternating 0 100 Percentage firing rate Follower Boiler alternating 0 100 Percentage firing rate Follower Boiler 4 P4 alternating 0 100 Percentage firing rate Follower Boiler 5 alternating 0 100 Percentage firing rate Follower Boiler 6 P6 alternating 0 100 Percentage firing rate Follower Boiler 7 P7 alternating 0 100 Percentage firing rate NOTE If you toggle beyond parameters of con nected boilers the display will go into the next function value D TEST MODE This function is intended to simplify the gas valve adjustment if needed Listed below are the rec ommended limits on each Mod Con Boiler and the Combustion Settings Automatic modulation does not take place when the controller is in Test mode only temperature limitation based on the Mod Con Boiler Central Heating set point The user will be allowed to increase or decrease the fan speed by pressing in either the or keys To activate the Test mode simply press the and key together for 1 second Once activated you
96. t the boiler system operation Clean and flush system when re installing a boiler D CLEARANCES FOR SERVICE ACCESS See Figure 3 1 for recommended service clearances If you do not provide minimum clearances shown it might not be possible to service the boiler without removing it from the space NOTICE The Mod Con Boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI 221 13 latest edition SERVICE CLEARANCES C BEFORE LOCATING THE BOILER 1 Check for nearby connections to e System water piping e Venting connections e Gas supply piping e Electrical power Condensate drain 2 Check area around boiler Remove any e cm MM a a 24 7 combustible materials gasoline and other flammable liquids Figure 3 1 LP 205 M Rev 5 27 08 A WARNING WARNING Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 3 The Mod Con Gas Control System components must be protected from dripping water during operation or service If the Mod Con Boiler is to replace an existing boiler check for and correct any existing system problems such as e System leaks The space must be provided with combus tion ventilation air openings correctly sized for all other appliances located in the sam
97. te 3 Replace the control board for less than 60 seconds Check condensate lines for obstructions Condensate cup is full Check float switch in condensate reservoir Check wiring from condensate reservoir to 926 control and repair as necessary Parameters Programmed Press 54 reset for at least 1 second Program Parameter Error Control must be re programmed pgramming does not solve problem control must be replaced 60 BEE BE B BABB BH nnnn 7711 GAS FIRED BOILER Boiler Manual PART 12 TROUBLESHOOTING CONTINUED Resistance Tables Outdoor Sensor 7250P 319 System Sensor 7250P 324 Outside Temperature F Resistance ohms Boiler Sensor 7250P 667 goce Fig 12 3 NOTE If receiving an 09 fault code check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap There should be a slight resistance Fig 12 4 A MAINTENANCE PROCEDURES A WARNING Periodic maintenance should be performed BEFORE EACH HEATING SEASON A trained once a year by a qualified service technician to and qualified service technician should perform assure that all the equipment is operating safely the inspections as per the boiler inspection and and efficiently The owner should make neces maintenance schedule in the back of manual sary arrangements with a qualified heating con Failure to do so could result in death or serious tractor for periodic maintenance of the
98. te Exhaust must extend out 1 foot There should be no more than 2 vents and 2 intakes then a space of 36 to the next set of vents Note There must be a minimum of 36 spacing between every 2 kit grouping Multiple V Series Vents 36 Minimum Exhaust Intake Fig 6 5 Multiple Stainless Steel Horizontal Vent Kit Installation Front View 29 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen E EXHAUST VENT AND INTAKE AIR VENT SIZING 1 The exhaust vent and intake air vent pipes are 4 for the Mod Con 300 and 500 and 6 for the Mod Con 850 2 The total combined equivalent length of exhaust vent and intake air pipe should not exceed 200 feet a he equivalent length of elbows tees and other fittings are listed in the Friction Loss Table 6 8 Table 6 8 Friction Loss Equivalent for Stainless or Plastic Piping and Fittings Fitting Description e e _ Gom o W _ Wemeeoh o w Friction loss for long radius elbow is 1 foot less b For example If the exhaust vent has two short 90 elbows and 10 feet of PVC pipe we Will calculate Exhaust Vent Pipe Equivalent Length 2x3 4 10 16 feet Further if the intake air vent pipe has two 90 elbows one 45 elbow and 10 feet of PVC pipe the following calculation applies Intake Air Vent Pipe Equivalent Length 2x3 1 10 17 feet c The intake air vent pipe and the exhau
99. termine correct action that is needed to provide proper gas pressure to the unit If Gas Pressure is within normal range proceed to next step 6 Exit Service mode then turn power off and shut off gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device Tighten the screw on the pressure tap tightly and turn gas on and checks for leaks with soapy solution It is recommended that a soapy solution be used to detect leaks Bubbles will appear on the pipe to indicate a leak is present The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 w c 87 kPa the meter regula tor or gas line is undersized or in need of serv ice You can attach a manometer to the incom ing gas drip leg by removing the cap and installing the manometer The gas pressure must remain between 3 5 87 kPa and 14 3 5 kPa during stand by static mode and while in operating dynamic mode If an in line regula 36 12121 GAS FIRED BOILER PART 7 GAS PIPING continuen tor is used it must be a minimum of 10 feet from the Mod Con It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition fail ure This problem is esp
100. the device it is connected to See the instruction manual of the connected devices for further information G OUTDOOR SENSOR There is no connection required if an outdoor sensor is not used in this installation If using an Outdoor Sensor Connect wires for sensor to the terminals marked OUTDOOR SEN shown in Figure 8 1 in the electrical junction box Caution should be used to ensure neither of these terminals become connected to ground Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions H INDIRECT SENSOR 2 43 There is indirect sensor connection required if an indirect water heater is not used in the installation The MOD CON boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank or an HTP 7250P 325 tank sensor When a tank sensor is used the MOD CON control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user settable set point by more than the user selectable offset The demand will continue until the sensor measures that the indirect water heater temperature is above the set point Co
101. to its normal readout when the condition 15 corrected or it may be the result of a condition that the controller has eval uated as not safe to restart the boiler In this case the boiler control will be locked out requiring the maintenance person to manually reset the control by pressing the but ton for more than 1 second Typically if the dis play has a code beginning with F followed by 2 numbers the ModCon Boiler is locked out If the display has a 3 letter code it is the result of a temporary condition B BOILER ERROR When an error condition occurs the controller will display an error code on the display module These error codes and several suggested cor rective actions are included in Table 12 1 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 The alarm output will also be activated Most fault conditions will also cause the CH pump to run in an attempt to cool the boiler 2 Note the fault code and refer to Table 12 2 for an explanation of the fault code along with several suggestions for corrective actions 3 Press the reset key to clear the fault and resume operation Be sure to observe the operation of the unit for a period of time to assure correct operation and no re occurrence of fault codes Boiler Manual WARNING When servicing or replacing any components of this boiler be certain that
102. ubstantial property damage e To avoid severe burns allow boiler to cool before performing maintenance BOILER OPERATION Do not block flow of combustion or ventilation air to boiler WARNING WHAT TO DO IF YOU SMELL GAS e Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not try to light any appliance Do not touch any electric switch do not use any phone in your building mmediately call your gas supplier from a neighbors phone Follow the gas suppliers instructions e f you cannot reach your gas supplier call the fire department Do not use this boiler if 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 under water BOILER WATER f you have an old system with cast iron radiators thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment HTP recommends a suction strainer in this type of system Do not use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage Donotuse homemade cures or boil
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104. urn The control adjusts the boiler firing depending on how close the return water temperature is to the supply water temperature Temperature and Pressure Gauge Allows the user to monitor the system temperature and pressure Electrical field connections with terminal strips he electrical cover allows easy access to the line voltage and low voltage terminals strips which are clearly marked to PART 3 PREPARE BOILER LOCATION A BOILER LOCATION SHOULD BE LEVEL Before considering the Boiler location there are 7 13 14 Boiler Manual facilitate wiring of the boiler Condensation Collection System This boiler is a high efficiency appliance therefore the boiler will produce condensate The collection system has a float switch to monitor the condensation level to prevent condensation from backing up into the combustion system Inside the collection system there is a built in trap to seal the combustion system to the connected drain This condensate should be neutralized to avoid damage to the drainage system or piping Outdoor Sensor The outdoor sensor will monitor the outdoor temperature and adjust the unit s set point to provide greater efficiency C OPTIONAL EQUIPMENT Below is the list of optional equipment available for Mod Con Boiler System Sensor Part 7250P 324 Indirect Sensor Part 7250P 325 4 Stainless Steel Outside Termination Vent Kit V3000 6 Stainless Steel Outsid
105. verhangs Determine air intake vent location e Provide 1 foot clearance from the bottom of the intake air vent and the level of maximum snow accumulation Snow removal may be necessary to maintain clearances Do not locate intake air vent a parking area where machinery may damage the pipe Follow required minimum clearances located in Fig 6 3 6 4 6 5 Determine location of Condensate Piping This boiler is a high efficiency appliance therefore the boiler produces condensate Condensate is a by product of the boiler combustion process A condensate collection system with an internal float switch monitors the condensate level to prevent it from backing up into the combustion system There is 34 sweat connection provided to connect the outlet of the collection system to a drain or condensate pump See table 6 1 for approved condensate piping material 26 GAS FIRED BOILER Boiler Manual PART 6 VENTING COMBUSTION AIR amp CONDENSATE REMOVAL continuen CAUTION It is very important that the condensate piping be no smaller than 34 and you must use tee at the condensate connection with the branch vertically up and open to the atmosphere so it will not cause a vacuum that could obstruct the flow of condensate from the boiler The condensate piping should also be properly supported with pipe supports to prevent 4 27 sagging and to maintain the pitch of the piping Co
106. vide its air cushion An automatic air vent would cause air to leave system resulting in water logging the expansion tank All piping methods shown in this manual use primary secondary connection to the boiler loop This is to avoid the possibility of inadequate flow through the boiler For other piping methods consult your local Heat Transfer Products representative or refer to separate Mod Con Boiler piping details in this manual Part 5 A CAUTION DO NOT use the boiler circulator in any location other than the ones shown in this manual The boiler circulator is selected to ensure adequate flow through the Mod Con Boiler Failure to comply could result in unreliable performance and nuisance shut downs from insufficient flow D SYSTEM WATER PIPING METHODS Expansion tank and make up water 1 Ensure that the expansion tank size will handle boiler and system water volume and temperature Allow for boiler and its piping Mod Con 300 2 9 Gallons E Mod Con 500 4 2 Gallons Sizing space heat system piping 1 See Piping Details in this manual Part 5 In all diagrams the space heating system is isolated from the boiler loop by the primary secondary connection Mod Con 850 5 8 Gallons CAUTION Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through a fill valve Eventual boiler failure can result due to excessive make up water addition This type of failure is N
107. w the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at draft hood opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not In operation After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their a Seal any unused openings in the common previous conditions of use venting system Any improper operation of common venting b Visually inspect the venting system for system should be corrected so the proper size and horizontal pitch and determine that there is no blockage or restriction leakage corrosion or other installation conforms with the National Fuel Gas Code ANSI 7223 1 latest edition Correct by resizing to approach the minimum deficiencies which could cause an unsafe condition size as determined using the appropriate tables in Table 13 of NFPA54 ANSI 2223 1 2006 of that code Canadian installations must comply with B149 1 or B149 2 Installat
108. will go to 400000 BTU hr max rather than 500000 BTU hr Range 50 100 Cascade configuration default O Change this to 1 if the boiler is a cascade master Power on hours for cascade prior ity changeover This parameter is used to set how many power on hours will go by before the priori ty boiler will be rotated in the cas cade system Not applicable must be at 0 Only used on Master Boiler in a multiple boiler installation to pro vide system pump activation user defined temperature Adjus tment to the default setting can be made by pressing the key to increase temperature Activation point Range 40 F to 104 F Central Heating Curve Function The central heating demand 15 detected when the room thermostat closes When an outside sensor 15 also connected the supply temperature will depend on the factory default central heating curve which is sufficient for most applications To set your own custom heat curve you will have to set the following parameters Use graph Fig 11 1 and 11 2 to assist you the design of the curve 56 12171 GAS FIRED BOILER Boiler Manual PART 11 START UP PROCEDURES FOR THE INSTALLER continuen SUPPLY OUTLET TEMPERATURE F Fig 11 1 Minimum outside design temperature 3 Function 8 Design Supply water temperature at the 4 minimum design outside temperature Function 9 Maximum outside design temperature Function 10 Design Supply water temp
109. will switch off the gas valve and purge fan while showing a solid EE in the display The display will than show a alternating to This first function ver ifies that the control will address the require ments of the Superstor Indirect Fired Water Heater C PROGRAM NAVIGATION Next you will have to press the key to move through each function To increase or decrease a value you will need to press either the key or key to change the default values If there is no key action for 1 minute the display returns to normal operation Changes are effec tive immediately but not directly stored until the key is pressed down for 3 seconds then the new values are stored Listed below are the vari ety of functions the installer can program into the 926 Control CAUTION The Boiler cannot be programmed while there is a call for heat NOTE See Chart 11 1 in Part 11 to set outdoor reset curve 99 1 2 8 10 11 Function Default Number Value de 149 F 180 36 F 7 F 0 Min 68 F 180 68 95 F Function Description Not Applicable Not Applicable Maximum Domestic water heater delivery temperature allowed user menu Installer can set the maximum temperature that Not Applicable Allows the installer to change the differential in the Indirect Fired Water Heater Does not apply if used with a Mechanical Control Range 1 F to 18 F Allows the installer t

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