HTP Mod Con 300 HL Installation & Maintenance Manual Download

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Summary of Contents for Mod Con 300 HL

Page 1: ...t 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 substantial property damage severe personal injury or death NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature ...

Page 2: ... THIS OR ANY OTHER APPLIANCE WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be provided by a qualified installer service ...

Page 3: ...system and additional publications including the National Fuel Gas Code ANSI Z223 1 2002 be reviewed in their entirety before beginning any work Installation should be made in accordance with the regulations of the local code authorities and utility companies which pertain to this type of water heating equipment NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE FOR THE INSTALLER T...

Page 4: ...as manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition TABLE OF CONTENTS PART 1 GENERAL SAFETY INFORMATION 7 A PRECAUTIONS 7 B IMPROPER COMBUSTION 8 C GAS 8 D WHEN SERVICING THE BOILER 8 E BOILER OPERATION 8 F BOILER WATER 8 G FREEZE PROTECTION 8 PART 2 BEFORE YOU START 9 A WHAT S IN THE BOX 9 B HOW BOILER O...

Page 5: ...OVED MATERIALS FOR EXHAUST VENT AND INTAKE AIR VENT 29 D REQUIREMENTS FOR INSTALLATION IN CANADA 29 E EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION 32 F EXHAUST VENT AND INTAKE AIR VENT SIZING 34 G LONGER VENT RUNS 34 H EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION 35 I BOILER REMOVAL FROM A COMMON VENT SYSTEM 35 J SIDEWALL VENTING DIAGRAMS 37 K VERTICAL VENTING DIAGRAMS 39 PART 6 GAS PIPING 41 A...

Page 6: ...ON 56 A CHECK CONTROL WATER CHEMISTRY 56 B FREEZE PROTECTION WHEN USED 56 C FILL AND TEST WATER SYSTEM 57 D PURGE AIR FROM WATER SYSTEM 57 E CHECK FOR GAS LEAKS 58 F CHECK THERMOSTAT CIRCUIT S 58 G CONDENSATE REMOVAL 58 H FINAL CHECKS BEFORE STARTING BOILER 59 I CASCADE SYSTEM 59 PART 9 START UP PROCEDURE 60 A OPERATING INSTRUCTIONS 61 B ADJUSTING THE SET POINT 61 C STATUS MENU 62 D TEST MODE 63 P...

Page 7: ...Refer to user s information manual for your reference Have this boiler serviced inspected by a qualified service technician annually FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDERWATER Immediately call a qualified service technician Replace any part of the control unit t...

Page 8: ... damage damage to boiler and or serious personal injury may result Continual fresh make up water will reduce boiler life Mineral buildup reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen by make up water can cause internal corrosion in system components Leaks in the boiler or piping must be repaired at once If you have an old system with cast ...

Page 9: ...tegrated control system monitors the system and regulates fan speed to control boiler output This allows the boiler to deliver only the amount of heat energy required and nothing more The system can be further enhanced by installing with 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 sys...

Page 10: ...e is a built in trap which seals the combustion system from the connected drain This condensate should be neutralized to avoid damage to the drainage system or piping Flow Protection The optional flow switch is designed to protect the boiler in the event of low flow conditions The boiler control will also monitor flow through the heat exchanger by monitoring the return and supply sensors and will ...

Page 11: ...ea around boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free of combustible materials liquids and vapors can result in substantial property damage severe personal injury or death 3 Gas control system components must be protected from dripping water during operation and service 4 If the boiler is to replace an existing boiler chec...

Page 12: ... the condensate to properly flow out of the collection system the area where you locate the boiler must be level The boiler comes equipped with leveling feet Should you find the floor beneath the boiler is uneven adjust the leveling feet with a wrench ...

Page 13: ...13 Figure 2 ...

Page 14: ... injury or death D RESIDENTIAL GARAGE INSTALLATION PRECAUTIONS If the boiler is located in a residential garage per ANSI Z223 1 Mount the bottom of the boiler a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor Locate or protect the boiler so it cannot be damaged by a moving vehicle E EXHAUST VENT AND INTAKE AIR VENT Vents must be properly...

Page 15: ... air will damage the boiler resulting in possible substantial property damage severe personal injury or death PRODUCTS TO AVOID AREAS LIKELY TO HAVE CONTAMINANTS Spray cans containing fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chlo...

Page 16: ...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 shoul...

Page 17: ...lectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler Failure to follow this instruction can lead to premature failure of the boiler system Such failures ARE NOT covered by warranty Plumbing of this product should only be done by a qualified licensed plumber in accordance with all local plumbing codes A GENERAL PIPING INFORMATION The building pipin...

Page 18: ...way is clear If valve does not operate turn the boiler off and call a plumber immediately Take care whenever operating relief valve to avoid scalding injury or property damage For boilers installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with Relief Valves for Hot Water Supply Systems A...

Page 19: ...l The boiler circulator location is selected to ensure adequate flow through the boiler Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insufficient flow SIZING SPACE HEAT SYSTEM PIPING 1 In all diagrams the space heating system is isolated from the boiler loop by the primary secondary connection 2 Size the piping and components in the space h...

Page 20: ...hat the system fluid is checked for the correct glycol concentration and inhibitor level The system should be tested at least once a year and as recommended 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 glycol solution expands 4 8 in volume for the temperature increase from 32 o F to 180 o F while ...

Page 21: ...ors 4 Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees 5 Piping shown is Primary Secondary 6 The minimum pipe size for connecting an HTP indirect fired water heater is 1 7 The minimum pipe size for connecting a Mod Con boiler is 1 for the 300 and 2 for the 500 and 850 8 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 9 In...

Page 22: ...tting of 119 o F 3 Install a minimum of 12 diameters of straight pipe upstream of all circulators 4 Piping shown is Primary Secondary 5 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 6 Installations must comply with all local codes 7 In Massachusetts a vacuum relief valve must be installed on the cold water line per 248 CMR 8 Reference Multiple Boiler Manifold Pipin...

Page 23: ... comply with all local codes 3 Install a minimum of 12 diameters of straight pipe upstream of all circulators 4 Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees 5 The minimum pipe size for connecting a Mod Con boiler is 1 for the 300 and 2 for the 500 and 850 6 Piping shown is Primary Secondary ...

Page 24: ...ream of all circulators 4 Piping shown is Primary Secondary 5 Reference Multiple Boiler Manifold Piping chart Part 5 Section H The boiler should not be operated as a potable hot water heater The boiler should not be used as a direct hot water heating device Basic steps are listed below that will guide the installation of the boiler 1 Connect the system return marked Boiler Return 2 Connect the sys...

Page 25: ... relating to expansion tank installation Size the expansion tank for the required system volume and capacity 8 Install an air elimination device on the system supply 9 Install a drain valve at the lowest point of the system NOTE The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 PSI 10 The relief valve is installed at the factory A pipe discharge l...

Page 26: ...ply add up the number of boilers and the required flow rates for the system design temperature Example 5 Mod Con 300 boilers with a design of 30 o F temperature rise with each boiler having an individual flow rate of 20 GPM To correctly size the manifold feeding these boilers you would need a pipe size of 3 Figure 12 Multiple Boiler Manifold Piping I FILL AND PURGE HEATING SYSTEM Attach the hose t...

Page 27: ...ck gaskets and seals used in hydronic systems Glycol mixtures should not exceed 50 1 Glycol in hydronic applications is specially formulated for this purpose and 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 2 The glycol solution should be tested at least o...

Page 28: ...e above 140 o F requires the circulator pump to run continuously and water hardness between 5 and 7 grains Hardness above 7 grains will damage the heat exchanger and shorten the service life of the boiler PART 5 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL A INSTALLING EXHAUST VENT AND INTAKE AIR VENT The boiler must be vented as detailed in this section Verify that the exhaust and intake piping ...

Page 29: ...f 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 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 substantial property damage severe personal injury or death Ce...

Page 30: ...AKE VENTING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN UNITED STATES CANADA B GAS VENT U L LISTED U L LISTED GALVANIZED U L LISTED U L LISTED Table 9 Approved Metallic Venting Material APPROVED STAINLESS STEEL VENT ADAPTERS AND TERMINATIONS Mod Con 300 500 HTP PART NUMBER Boiler Adapter 4 7250P 732 Horizontal Vent Terminal 4 7350P 607 Vertical Rain Cap 4 7350P 609 Mod Con 850 HTP PART NUMBER ...

Page 31: ...31 Figure 13 ...

Page 32: ...cal 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 boiler 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 terminals at l...

Page 33: ...ished if necessary When replacing the marble chips take care to ensure chips are no smaller than to avoid blockage in condensate piping refer to Figure 14 for piping of the condensate neutralizer It is very important that the condensate piping be no smaller than You must use a tee at the condensate connection with a branch vertically up and open to the atmosphere so as not to cause a vacuum that c...

Page 34: ...bow 1 1 1 Coupling 0 0 0 Tee intake only 0 0 0 V Series Vent Kit 1 1 1 AL20 4C Vent Terminal 1 1 1 Pipe All Materials 1 1 1 Table 11 Friction Loss in Equivalent Feet Friction loss for long radius elbow is 1 less b For example If the exhaust vent has two short 90 o elbows and 10 feet of PVC pipe we will calculate Exhaust Vent Pipe Equivalent Length 2x3 10 16 feet Further if the intake air vent pipe...

Page 35: ... piping should be a minimum of PVC rigid piping pitched a minimum of per foot away from the boiler See Figure 14 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 th...

Page 36: ...oors 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 to the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determine...

Page 37: ...37 J SIDEWALL VENTING DIAGRAMS Figure 16 Sidewall Venting with Tee and Coupling ...

Page 38: ...38 Figure 17 Sidewall Venting Diagrams ...

Page 39: ...39 K VERTICAL VENTING DIAGRAMS Figure 18 Two Pipe Roof Venting with Tee and Coupling ...

Page 40: ...40 Figure 19 Roof and Sidewall Venting with Stainless Steel ...

Page 41: ...ious injury or death The gas connection on the boiler is 1 1 4 for the Mod 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 fabricated 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 boiler is no smaller than the unit supplied c...

Page 42: ...when installing the 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 adequate for the job Follow local codes for proper installation and service requirements C GAS TABLE Refer to Table 13 to size the supply piping to minimize pressure drop between the meter or r...

Page 43: ... gas on and check for leaks with a soapy solution If a leak is present bubbles will appear on the pipe The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop The gas meter and 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 regulator or gas line may be undersized or in need of service ...

Page 44: ...44 E GAS VALVE Figure 21 ...

Page 45: ...45 Figure 22 ...

Page 46: ...in standard mode and 3 pumps when configured as a cascade master boiler When configured as a standard unit each pump output can provide a maximum of 3 amps at 120 volts If pumps used 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...

Page 47: ...ent 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 24 show two 120 volt lights connected to the alarm terminals One light will be on when the boiler is in normal mode and the other light will turn on whe...

Page 48: ...t closure across these terminals will cause the boiler to run Caution should be taken to ensure neither of the terminals becomes connected to ground 2 Mount the thermostat on an inside wall as centrally as possible to the area being heated but away from drafts or heat producing devices such as television sets that could influence the ability of the thermostat to measure room temperature ...

Page 49: ...user selected set point by more than the user selected offset The demand will continue until the sensor measures that the indirect water heater temperature is above the set point 3 Connect the indirect tank sensor 7250P 325 to the terminals marked DHW SENSOR shown in Figure 24 in the electrical junction box Caution should be used to ensure neither of these terminals becomes connected to ground I O...

Page 50: ... wire from the wire harness included in kit 5 Feed green ground wire into boiler through the wire access 6 From the front of the boiler feed the ground wire up into the control box 7 Once into the control box attach the green ground to the ground bus connection 8 Connect red wire from flow switch to boiler wire harness 9 When installation is complete power up the boiler and use the control to acce...

Page 51: ...NG OF THE CASCADE SYSTEM COMMUNICATION BUS 1 Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers Use standard straight through cables for these connections These cables are readily available at any office supply computer electronic department or discount home supply store in varying lengths DO NOT use crossover cables 2 It is recomme...

Page 52: ...R GND terminal 4 Connect a jumper wire from the 120 VOLT terminal to the SYS PUMP PWR terminal 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 OUTDOOR SEN 8 Connect the signal to start the system to the terminals marked THERMOSTAT ...

Page 53: ... DHW HOT DHW NEUT and DHW GND terminals If desired an alarm bell or light can be connected to the alarm contacts of the follower boiler 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 To connect an alarm device connect the power for the device to the ALARM COM terminal Connect the alarm device ho...

Page 54: ... ALARM NC terminal rather than the ALARM NO terminal NOTE 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 2 7 will only sound if a lockout condition occurs on that specific boiler Figure 27 Mod Con Cascade Follower ...

Page 55: ...55 Figure 28 Mod Con Internal Connection Diagram ...

Page 56: ... the boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buildup or corrosion due to sediment build up 2 For zoned systems flush each zone valve separately through a purge valve If purge valves and isolation valves are not already installed install them to properly clean the system 3 Flush system until water runs clean and you are sure piping is free of sedimen...

Page 57: ...at exchanger failure Such failure IS NOT covered by warranty 5 The system may have residual substances that could affect water chemistry After the system has been filled and leak tested verify that water pH and chlorine concentrations are acceptable by sample testing It is important to purge the system of air to avoid damage to the boiler D PURGE AIR FROM WATER SYSTEM 1 Purge air from system a Con...

Page 58: ...as leak Repair any leaks at once PROPANE BOILERS ONLY Propane suppliers mix an odorant with the propane to make its presence 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 1 Disconnect the two external wires connecte...

Page 59: ...ECKS 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 Verify the boiler and system are full of water and all system components are correctly set for operation 3 Fill condensate trap with water 4 Verify electrical connections are correct and securely attached 5 Inspect intake piping and exh...

Page 60: ...nt of the follower must match the master boiler set point in order for the system to operate properly PART 9 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 sme...

Page 61: ...e control panel for 4 seconds to begin normal operation 4 Set the thermostat to the desired setting 5 If the appliance fails to start refer to Troubleshooting Part 11 B ADJUSTING THE SET POINT NOTE Before you can change the temperature from the factory setting of 180 o F make sure none of the thermostats are calling for heat The controller will not memorize a program setting while in a heating cyc...

Page 62: ...ill be visible d4 320 Not used d5 Actual temperature from the outdoor sensor if connected NC d6 Actual fan speed multiplied by 10 Example If fan speed displayed is 410 RPM x 10 4100 actual fan speed d7 Actual ionization current read from flame rectification probe d8 Actual status of the central heating circulator Off 0 On 1 d9 Actual status of the indirect fired circulator Off 0 On 1 d10 Actual st...

Page 63: ... not take place when the controller is in test mode only temperature limitation based on the boiler central heating set point The user can increase or decrease the fan speed by pressing either S1 or S2 To activate test mode press the S2 and S3 Program keys together for 1 second Once activated you will see in the display Ser and the actual fan speed The measurement of the combustion levels should a...

Page 64: ...N VALUE DESCRIPTION 1 de N A no change allowed 2 149 o F N A no change allowed 3 180 o F Allows the installer to set the maximum domestic water heater delivery temperature Range 95 o Fto 185 o F 4 36 o F N A no change allowed 5 7 o F Allows the installer to change the differential temperature dh in the indirect fired water heater does not apply if used with mechanical control Range 1 o F to 18 o F...

Page 65: ...iority appliance will be rotated in the cascade system Range 0 240 25 0 N A must be at 0 26 System pump freeze protection Default disabled Use this function on a cascade master to activate the system pump if the outdoor temperature drops below the set value Use the S2 key to increase from the default disabled upward to the desired temperature Range disabled to 104 o F 27 0 Parameter set on 0 then ...

Page 66: ...ature Function 9 3 Maximum outside design temperature Function 10 4 Design supply water temperature at the maximum outside temperature Function 11 NOTE The user can adjust the heat curve down by adjusting the central heating temperature to a lower setting Figure 29 Table 17 ...

Page 67: ... 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 19 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 correc...

Page 68: ...ce software check the 24v supply 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 3 Remove 10 pin Molex connector from customer connection board If LOU clears then the problem is with external sensor wiring Examine external sensor wiring for shorts to gr...

Page 69: ...hree attempts at ignition before the control goes into this lockout condition 1 Watch the igniter through the observation window provided 2 If there is no spark check the spark electrode for the proper gap 3 Remove any corrosion from the spark electrode and flame rectifier probe 4 If there is a spark but no flame check the gas supply to the boiler 5 If there is a flame check the flame sensor 6 Che...

Page 70: ...ng safely and efficiently The owner should make necessary arrangements with a qualified heating contractor 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 BEFORE EACH HEATING SEASON a trained and qualified service technician should perform the inspections as per the boiler ins...

Page 71: ...ated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air B COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR HEATER Before beginning this procedure you must have on hand the following items a nylon stainless steel or brass brush not steel lime scale removing solution approved for use with stainless steel gloves ...

Page 72: ...he combustion chamber with fresh water until it runs clear from the condensate At this point the boiler should be ready to be re assembled a Inspect gaskets b Re install the burner assembly c Replace and tighten the 6 10 mm nuts to the burner plate using staggered tightening sequence see detail d Re connect all wiring connections e Inspect the gas valve to assure the O ring is in place f Replace t...

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Page 78: ...nd adjust if necessary carbon monoxide content ____ppm CO High Fire ____ ppm CO Low Fire 4 Verify system operation Turn up aquastat on storage tank to verify wiring connections 5 Record ionization current Check uA reading at d7 on the status menu see start up section ____ uA High Fire ____ uA Low Fire 6 Indirect water heater Verify safety and operation of the indirect water heater record settings ...

Page 79: ...unctional CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Spark Electrode Clean Set gap at Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Clean out condensate neutralizer Use wet dry vacuum Check for all ...

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Page 82: ...82 MAINTENANCE NOTES ...

Page 83: ...Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please co...

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