Heat Transfer MODCON VWH 300 HL Installation & Maintenance Download Page 4

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GAS-FIRED HOT WATER SUPPLY BOILER

Boiler Manual

CONTENTS

(CONT’D)

Part 8 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-51

Installation Must Comply With

Field Wiring Terminations

Field Wiring Considerations

Line Voltage Wiring for ModCon VWH

Alarm Connections

Low Voltage Connections for Standard Boiler

Tank Sensor or Mechanical Control

System/Pipe Sensor

Optional High Gas Pressure Switch

Optional Low Gas Pressure Switch

Flow Switch

Wiring of Cascade System Communication Bus

M. ModCon VWH Cascade Master Pump and Sensor Wiring

ModCon VWH Cascade Follower Pump and Sensor Wiring

Part 9 –

Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-54

Single Mod Con VWH Boiler

Multiple Mod Con VWH Boilers

Check for Gas Leaks

Condensate Removal

Final Checks Before Starting Boiler

Cascade System

Part 10 –

Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57

Operating Instructions

Adjusting the Operating Set Points of the VWH Display

Status Menu

Test Mode

Part 11 –

Start-Up Procedures for the Installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59

Programming for the Installer

Program Access

Program Navigation

Part 12 –

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-63

Mod Con Error Code

Boiler Error

Boiler Fault

Part 13 –

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-78

Maintenance Procedures

Combustion Chamber Coil Cleaning Instructions for the Mod Con

Maintenance Procedure to Clean Heat Exchanger

Inspection and Maintenance Start-Up Charts

Summary of Contents for MODCON VWH 300 HL

Page 1: ...his manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Installation Startup Maintenance Parts 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 Installation Manual Installation Ma...

Page 2: ...w the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier 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 ...

Page 3: ...e Boiler 13 14 Part 5 Boiler Piping 14 27 A Relief Valve B General Piping Information C System Water Piping Methods D Circulator Pumps E Installation of Flow Switch F Scalding G High Velocity Circulator Pump H Boiler Piping Details Part 6 Venting Combustion Air Condensate Removal 28 38 A Installing Exhaust Vent and Intake Air Vent B General C Approved Materials for Exhaust Vent and Intake Air Vent...

Page 4: ... and Sensor Wiring Part 9 Start Up Preparation 52 54 A Single Mod Con VWH Boiler B Multiple Mod Con VWH Boilers C Check for Gas Leaks D Condensate Removal E Final Checks Before Starting Boiler F Cascade System Part 10 Start Up Procedure 55 57 A Operating Instructions B Adjusting the Operating Set Points of the VWH Display C Status Menu D Test Mode Part 11 Start Up Procedures for the Installer 57 5...

Page 5: ... 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 DEFINITIONS 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 Z223 1 2002 This app...

Page 6: ...cian 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 property damage n WARNING Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage n WARNING WHAT ...

Page 7: ...0 403 463 492 528 ModCon 300 VWH Inlet Temperature Outlet Temperature Recovery Gallons Per Hour First Hour Rating With 80 Gallon First Hour Rating With 119 Gallon First Hour Rating With 175 Gallon 40 80 846 906 935 971 40 90 677 737 766 802 40 100 564 624 653 689 40 110 483 543 572 608 40 120 423 483 512 548 40 130 376 436 465 501 40 140 338 398 427 463 40 150 308 368 397 433 40 160 282 342 371 40...

Page 8: ...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 change by internal or external signals which enhance the overall performance of the system 3 Control The integrated control system monitors the system and regulates the fan speed to control the boilers output This allows the boiler to deliver only the amount o...

Page 9: ...lectrical field connections with terminal strips The electrical cover allows easy access to the line voltage and low voltage terminals strips which are clearly marked to facilitate wiring of the boiler 13 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 condensate level to ...

Page 10: ...boiler is uneven adjust the leveling feet with a wrench INCORRECT CORRECT INCORRECT CORRECT GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 9 PART 3 PREPARE BOILER LOCATION A BOILER LOCATION DIMENSIONS Before considering the Boiler location there are 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 time and...

Page 11: ...TS DO NOT INCLDE ADJUSTABLE LEGS VWH MODEL A B C D D F J G H K L M N MOD CON 300 20 00 6 25 10 25 14 50 26 00 5 15 35 75 20 50 36 00 25 50 8 25 10 50 26 50 MOD CON 500 20 00 6 25 13 25 14 50 33 30 5 15 41 75 20 50 36 00 25 50 8 25 10 50 34 00 MOD CON 850 20 00 6 75 16 25 18 75 43 50 20 00 66 75 20 50 36 00 25 50 8 25 10 50 57 50 VWH MODEL BTU HR INPUT LOW FIRE Gross Output BTU hr Net I B R BTU hr ...

Page 12: ... national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 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 C BEFORE LOCATING THE BOILER 1 Check for nearby connections t...

Page 13: ...r 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 pipe intake air vent near a swimming pool Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants Products to avoid Spray...

Page 14: ...maining 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 previous conditions of use g Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition Correct by resizing to ap...

Page 15: ...lve 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 res...

Page 16: ...f future service If there is a back flow preventer or any type of no return valve in the system then you must install an additional tee for a suitable potable hot water expansion tank Connect the Storage tank return line to the return connection located on the Mod Con VWH shown in Piping details this section Then connect your hot water outlet located on the storage tank to your hot water plumbing ...

Page 17: ... nipple using pipe dope 3 Thread switch into Tee using pipe dope making certain the Flow Arrow points in the correct direction 4 Disconnect red wire on the Low Water Cut off Probe and connect it to the red wire from the wire harness included in kit n WARNING Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler n WARNING When raising t...

Page 18: ...ess to the red wire connection on the flow switch 9 Now that the installation is complete power up the boiler and use the control to access the Installer Parameter 20 and change the default value to 2 See Mod Con Installation Manual Part 11 Program Navigation When done create a demand and observe the boiler s function to verfiy the installation is working proeprly Please note that these illustrati...

Page 19: ...ng the safest water temperature for your applications APPROXIMATE TIME TEMPERATURE RELATIONSHIPS IN SCALDS 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1 2 seconds 155 F About 1 second F SCALDING This water heater can deliver scalding tempera ture water at any faucet in the system ...

Page 20: ...EM TEMPERATURE RISE CHART 20 Δt 25 Δt Model Friction Feet Flow G P M Friction Feet Flow G P M Mod Con 300 VWH 19 30 12 24 Mod Con 500 VWH 19 50 11 40 Mod Con 850 VWH 35 85 26 65 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 Example 5 Mod Con 300 Boilers with a desi...

Page 21: ...le buildup Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section Part 13 of this manual NOTICE Water temperature above 140 requires the circulator pump to run continuously and must have a water hardness of between 5 to 7 grains Hardness above 7 grains will damage the heat exchanger and shorten the service life of the boiler Piping components Water heating system p...

Page 22: ...aded check valve hose bib boiler drain diaphragm type expansion tank for potable water anti scald rated mixing valve pressure gauge pressure relief valve or P T relief valve union Mod Con Boiler vacuum breaker T P temperature pressure gauge flow switch Superstor Ultra Storage Tank GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 21 H BOILER PIPING DETAILS ...

Page 23: ...PART 5 BOILER PIPING CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 22 ...

Page 24: ...PART 5 BOILER PIPING CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 23 ...

Page 25: ...PART 5 BOILER PIPING CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 24 ...

Page 26: ...PART 5 BOILER PIPING CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 25 ...

Page 27: ... inch 5 The minimum pipe size for connecting a MOD CON boiler is 1 5 inches for MOD CON 300 VWH and 2 inches for MOD CON 500 800 6 All pumps are shown with isolation flanges or full port ball valves for isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check v...

Page 28: ...27 GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual PART 5 BOILER PIPING CONTINUED ...

Page 29: ...systems or unlisted pipe fittings Cellular foam core piping may be used on air inlet piping only PART 6 VENTING COMBUSTION AIR CONDENSATE REMOVAL n 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 mechanical draft systems operating under positive pressure Follow these venting ins...

Page 30: ...IMER MATERIAL APPROVED PLASTIC INTAKE VENTING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN UNITED STATES CANADA ULC S636 PVC SCHEDULE 40 80 APPROVED PLASTIC EXHAUST VENTING MATERIAL STANDARDS FOR INSTALLATION IN UNITED STATES CANADA MATERIAL CPVC SCHEDULE 40 80 ANSI ASTM D2665 ANSI ASTM F441 APPROVED PLASTIC CONDENSATE PIPING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN UNITED STATES CANADA ...

Page 31: ... 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 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 pr...

Page 32: ...ralizing the condensate with a Condensate Neutralizer Kit p n 7350P 611 that can 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 sh...

Page 33: ...uld have an overflow switch to prevent property damage from condensate spillage 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 3 3 1 5 66 0 6 25 6833257 225 5 1 39 6 7 3 3 1 77 1 6 25 217 1 6 0867 167 7 3 7 2 3 5 227 1 287 3257 6 7 39 7 23 1 72 70263 5 21 16 7 1 875 5 21 16 7 1 875 5 7 287 3803...

Page 34: ... 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 Fig 6 5 Multiple Stainless Steel Horizontal Vent Kit Installation Front View Fig 6 3 Multiple Vents PART 6 VENTING COMBUSTION AIR CONDENSATE REMOVAL CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 33 Fig 6 6 Multiple Conce...

Page 35: ...he 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 32 feet from the boiler 16 ft inlet 16 ft exhaust 32 ft combined with transition total of 245 ft upsize piping for longer vent runs G EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION 1 Use only solid PVC or CPVC schedule 40 or 80 pipe and AL294...

Page 36: ... 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 If 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 dryer...

Page 37: ... leading edge before inserting into the boiler adapter to prevent damage to internal o ring seal Do not use any Liquids or Petroleum based products that could damage the o ring seal It is recommended you use talcum powder to assist in inserting pipe into adapter 2 Tighten clamp to a maximum of 50 inch pounds to avoid reforming connected PVC which may cause combustion leaks I DIAGRAMS FOR SIDEWALL ...

Page 38: ... be glued properly supported and the exhaust must be pitched a minimum of a per foot back to the heater to allow drainage of condensate Exhaust connection insertion depth should be a minimum of 2 for models 300 500 and 3 for 850 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 venti...

Page 39: ...first three feet from the boiler GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 38 WHICHEVER IS GREATER 12 OVER MAXIMUM SNOW LEVEL OR 24 10 0 MIN SUPPORT BRACKETS 6 Z FLEX 2SVSRC06 4 Z FLEX 2SVSRCF04 ROOF EXHAUST RAIN CAP STAINLESS STEEL AIR INTAKE GALVANIZED B VENT 24 MIN A D C MULTIPLE BOILERS SINGLE BOILER RIZONTAL VENTING E CODE REQUIREMENTS LEVEL OR 24 WHICHEVER IS GREATER CHECK WITH LOCAL N...

Page 40: ... and install manual shutoff valves in ac 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 is 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 approved for ga...

Page 41: ...e 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...

Page 42: ...NT COULD AFFECT CO CO LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHART IN COMBUSTION SETTINGS FIG 10 1 Fig 7 2 LP 205 AA Rev 6 3 08 MOD CON 300 GAS VALVE 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 ...

Page 43: ...ENT CAUTION DO NOT REMOVE THIS SCREW GAS PRESSURE SWITCH BLOCK A DETAIL A SCALE 2 3 THROTTLE ADJUSTER NOTE IF FOR ANY REASON THE THROTTLE NEEDS TO BE ADJUSTED IT IS VERY IMPORTANT THAT A COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE ADJUSTER TO THE TO INCREASE THE GAS OR TO DECREASE THE GAS SUPPLY THIS ADJUSTMENT COULD AFFECT CO CO LEVELS MAKE SURE THE LEVELS CORRESPOND ...

Page 44: ...10 1 THROTTLE ADJUSTER NOTE IF FOR ANY REASON THE THROTTLE NEEDS TO BE ADJUSTED IT IS VERY IMPORTANT THAT A COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE ADJUSTER TO THE TO INCREASE GAS SUPPLY OR TO THE TO DECREASE GAS SUPPLY GAS INLET PRESSURE TAP DETAIL A SCALE 2 1 5 OFFSET ADJUSTMENT CAUTION DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW WITH...

Page 45: ...e stor age tank for the best temperature control If mul tiple tanks are used in the installation it is rec ommended to put a mechanical aquastat in each tank and wire them in series to provide temper ature control of the tanks See piping sensor dia grams in Part 5 section G for reference The con trol in the MODCON VWH will read either the temperature of the tank sensor or the status of the aquasta...

Page 46: ...GE WIRING FOR MODCON VWH Connect the incoming power wiring to the line voltage terminal strip in the electrical junction box at terminals LINE 120V Neutral Ground Shown in Fig 8 1 A line voltage fused discon nect switch may be required to be externally mounted and connected according to local wiring codes that may apply If the pump used for the boiler operates at 120 volt and less than 3 amps is r...

Page 47: ...MOD CON VWH CONTROL Fig 8 1 LP 248 VWH Rev 7 17 09 PART 8 FIELD WIRING CONTINUED GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 46 ...

Page 48: ...to the Master Boiler terminals on the low voltage strip as shown on figure 8 3 I OPTIONAL HIGH GAS PRESSURE SWITCH 1 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 5 w c on the outlet side 2 Locate the two pigtails hanging from the electrical box inside of the boiler cabin...

Page 49: ...lers 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 3 Route the communication cables through one of the knockouts in the cabinet 4 Co...

Page 50: ...ASTER PUMP AND SENSOR WIRING 1 Place the Cascade Master Overlay Sticker onto the field connection board on the boiler designated as the Cascade Master 2 If it is desired to have the boiler control the boiler pump Connect the boiler pump to the BOILER HOT BOILER NEUT BOILER GND terminals 3 Connect the System sensor to the terminals marked SYS SENSOR 4 Do not connect anything to the OUTDOOR SENS or ...

Page 51: ...on the follower boiler addressed as 1 There are no connections to these terminals on other follower boilers in the system 3 Do not connect anything to the OUTDOOR SENS 0 10V or THERMOSTAT terminals 4 If it is desired to monitor the boiler system to detect a lockout condition a dry contact alarm relay is provided Please see Figure 8 4 for wiring suggestions for this relay Note that the alarm output...

Page 52: ...PART 8 FIELD WIRING CONTINUED Fig 8 5 LP 255 Rev 11 09 09 GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 51 ...

Page 53: ...any other boilers are present and if there are boilers present the mas ter control determines their boiler address The master boiler control will re check the bus every few seconds as long as it is powered up to update the status of the connected boilers The control in the master boiler is the one that processes all heat demands and dictates which of the follower boilers should light and at what f...

Page 54: ...ary to create a vent in the horizontal to prevent a vacuum lock in the condensate line 4 Do not expose the condensate to freezing temperatures 5 It is very important you support the condensation line to assure proper drainage E FINAL CHECKS BEFORE STARTING BOILER 1 Read Startup Procedures within this manual for proper steps to start boiler See Startup Report to record steps for future reference 2 ...

Page 55: ...se 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 f...

Page 56: ... gas follow the next steps 1 Turn on all electric power to appliance 2 Adjust the temperature setpoint of the Mod Con VWH 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 may note a lock out code of F01 This is a low gas pressure switch lock out from the factory installed ...

Page 57: ...rent status of the Munchkin parameters by pressing S4 Reset key for 3 seconds Once activated the display will show d1 alternating value of the actu al outlet temperature Actual values are displayed for each function To view the next value simply press the S 4 key to go to the next displayed value Listed below are the values which can be displayed These values cannot be changed To exit this menu si...

Page 58: ...ION SETTINGS ON ALL MODELS Natural Gas Propane LP Fan Speed low high low high Carbon Monoxide CO 0 20 ppm 70 ppm 135 ppm 0 20 ppm 80 ppm 150 ppm Carbon Dioxide CO2 8 9 8 9 9 10 9 10 Fig 10 1 B PROGRAM ACCESS To start press down and hold the S 3 and S 4 simultaneously for three seconds The display will change to 000 Then with your S1 key on the display press down until you see 925 This is the pass ...

Page 59: ...18 6 5 Min Circulator Post Purge Time after tank sensor is satisfied that the pump will run Note it is recom mend that Circulator Post Purge Time be set no greater than 5 min utes Range 0 to 10 minutes Function Default Function Number Value Description 7 68 N A No change required 8 5 N A No change required 9 180 N A No change required 10 68 N A No change required 11 95 N A No change required 12 68...

Page 60: ...unction Default Function Number Value Description 23 0 Cascade configuration default 0 Change this to 1 if the boiler is in a cascade system Range 0 1 24 24 Power on hours for cascade prior ity change over 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 Range 0 240 25 0 Not applicable must be at 0 26 27 0 Parameter...

Page 61: ...ode beginning with F followed by 2 numbers the Mod Con 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...

Page 62: ... 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 4 If LOU only occurs when burner tries to light check gas valve for excessive current draw 5 If LOU is present with the low voltage harness disconnected from the 926 control board re ...

Page 63: ...ing steps in F02 F06 Return Inlet Temperature Exceeded 230 F 1 Check circulation pump operation 2 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 thermistor to the supply thermistor 3 Check direction of flow on boiler circulator See Piping Details in this manual 4 Troubleshoot thermistor by followin...

Page 64: ...ts with a qualified heating con tractor for periodic maintenance of the heater Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition n WARNING BEFORE EACH HEATING SEASON A trained and qualified service technician should perform the inspections as per the boiler inspection and maintenance schedule in the back of manual Fa...

Page 65: ...s brush do not use steel and scrub coils to remove any buildup then vacuum the debris from the coils WARNING Follow precautions above 4 Spray 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 water runs from the conden sate At this point the Mod C...

Page 66: ...t heater cool down to room temperature before opening both drain valves Please note the amount of water content in each unit varies see chart Mod Con 300 2 9 gallons water Mod Con 500 4 2 gallons water Mod Con 850 5 8 gallons water 4 Next pour lime scale remover into the bucket Rydlyme is an approved scale remover that is FDA approved and when circulated through the heater for a period of time wil...

Page 67: ...PART 13 MAINTENANCE CONTINUED Fig 13 1 LP 205 A REV 8 24 09 MOD CON 300 VWH GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 66 ...

Page 68: ...PART 13 MAINTENANCE CONTINUED Fig 13 2 LP 205 V REV 8 24 09 MOD CON 500 VWH GAS FIRED HOT WATER SUPPLY BOILER Boiler Manual 67 ...

Page 69: ...LWHP 3 0 00 6 6 6 5 352 752 WHP 1R 5HSODFHPHQW 3DUW HVFULSWLRQ 3 63 5 752 LQFOXGHV LWHP 3 675 7 2 6 3 6 9 9 3 137 1 33 3 263 7 2 7 3 137 5 2 3 137 1 33 3 263 7 2 7 3 56 0 1 211 725 3 6 9 9 LQFOXGHV LWHPV 1 2 5 1 1 3 137 1 3 0 080 2 5 675 725 1 1 0 00 6 5 6 1 3 6 35 6685 6 7 Z 2 5 1 237 21 3 5 8670 17 3257 3 2 6 35 6685 6 7 Z 2 5 1 237 21 3 6 3 3 66 6 87 2 36 36 3 5 8 1 283 1 3 2 9 17 35 6685 6 7 3...

Page 70: ...7350P 014 7350P 015 7350P 015 1 1 2 INLET OUTLET NIPPLE CLIP 300 ONLY 2 INLET NIPPLE CLIP 10 7350P 001 7350P 002 7350P 002 1 1 2 OUTLET NIPPLE W O RING 300 only 2 OUTLET NIPPLE W O RING 11 SN1018 SN1018 SN1018 3 4 NPT X 3 NIPPLE BRASS 12 7350P 065 7350P 065 7350P 065 150 RELIEF VALVE 3 4 NPT 13 7250P 733 7250P 733 7350P 094 Z FLEX EXHAUST ADAPTOR FOR PVC 14 7250P 739 7250P 739 7250P 739 FLUE ECO S...

Page 71: ...REWS 13 7350P 046 7350P 046 7350P 046 JACKET UPPER FRONT w MOD CON LABEL SCREWS 14 7500P 087 7500P 087 7500P 087 POWER SWITCH 15 7350P 009 7350P 009 7350P 009 926 DISPLAY PANEL w RIBBON CABLE 16 7500P 115 7500P 115 7500P 115 6 32 X 1 4 PAN HEAD SCREW DISPLAY BOARDS 17 7350P 042 7350P 042 7350P 042 ELECTRICAL BOX 18 7350P 008 7350P 008 7350P 008 926 CONTROL BOARD 19 7350P 070 7350P 070 7350P 070 FI...

Page 72: ...o more than 1 W C ____in w c Dynamic 3 Record Ionization Current Check μA reading at d7 on the status menu see start up section ____ μA High Fire ____ μA Low Fire 4 Verify System Operation Turn up aquastat on storage tank to verify wiring connections 5 Check Combustion Check and adjust if necessary carbon dioxide content ____ CO2 High Fire ____ CO2 Low Fire Check and adjust if necessary carbon mon...

Page 73: ...nnections make sure they are tight Circuit breakers Check to see that the circuit breaker is clearly labeled exercise circuit breaker Switch and Plug Verify ON OFF switch and convenience plug are both functional Smoke and CO detector Verify devices are installed and working properly change batteries if necessary Combustion Chamber Vacuum Debris from Combustion Chamber if Necessary Combustion Chamb...

Page 74: ... from 3 5 to 14 W C Pressure Drop Measure drop in pressure on light off no more than 1 W C Check gas pipe for leaks Check piping for leaks and verify they are all properly supported Check CO CO2 Levels Check levels of CO and CO2 in Exhaust See Start Up section Part 10 Fig 10 1 for ranges record at high and low fire ECO Energy Cut Out Check continuity on Flue and Water ECO replace if corroded Therm...

Page 75: ...LP 172 REV 2 16 06 74 ...

Page 76: ...LP 172 REV 2 16 06 75 ...

Page 77: ...MAINTENANCE NOTES 76 ...

Page 78: ...MAINTENANCE NOTES 77 ...

Page 79: ...MAINTENANCE NOTES 78 ...

Page 80: ... 2003 2009 Heat Transfer Products Inc www HTproducts com LP 276 REV 11 25 09 ...

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