LP-446-r4 Rev. 10.12.16
4
J. Applications
19
Part 5 - Venting and Condensate Removal
22
A. General
22
B. Approved Materials for Exhaust Vent and Intake Pipe 23
C. Additional Requirements for Installation in Canada 23
D. Exhaust Vent and Intake Pipe Location
24
E. Exhaust Vent and Intake Pipe Sizing
25
F. Longer Vent Runs
25
G. Exhaust Vent and Intake Pipe Installation
25
H. Applications
26
1. Direct Vent Installation of Exhaust and Intake
26
2. Room and Indoor Combustion Ventilation Requirements
29
I. Condensate Removal System
30
Part 6 - Wiring
31
A. Installation Must Comply With
31
B. Field Wiring Terminations
31
C. Field Wiring
31
D. Line Voltage Wiring for Standard Boiler
32
E. Alarm Connections
32
F. Low Voltage Connections for Standard Boiler
33
G. Tank Sensor or Mechanical Control
33
H. System / Pipe Sensor
33
I. Optional 0-10 Volt Building Control Signal
33
J. Optional High Gas Pressure Switch
33
K. Optional Low Gas Pressure Switch
33
L. Flow Switch
33
M. Wiring of Cascade System Communication Bus
33
N. Cascade Master Pump and Sensor Wiring
34
O. Cascade Follower Pump and Sensor Wiring
34
Part 7 - Gas Connections
37
A. Gas Piping
37
B. Gas Table
38
C. Check Inlet Gas Pressure
38
D. Boiler Gas Valve
39
Part 8 - Start-Up Preparation
40
A. Check / Control Water Chemistry
40
B. Check for Gas Leaks
40
C. Condensate Removal
40
D. Final Checks Before Starting Boiler
40
E. Setting Up a Single Boiler
40
F. Setting Up a Cascaded System
41
G. Lockout Condition
41
H. Cascade System Programming
41
Part 9 - Start-Up Procedure
42
A. Control Overview
42
B. Navigation of the Display
42
C. Operating Instructions
43
D. Programming Boiler Settings
43
E. Programming the System Setting
44
F. System Setting Program Navigation
44
G. Resetting the Maintenance Schedule
46
Part 10 - Start-Up Procedures for the Installer
46
A. Boiler Control Status Menu
46
B. Cascade Menu
47
C. Boiler Test Mode
48
Part 11 - Troubleshooting
49
A. Boiler Error and Fault Codes
49
B. Boiler Error
49
C. Boiler Fault
49
Table of Contents
Part 1 - General Safety Information
5
A. Improper Combustion
5
B. Gas
5
C. When Servicing the Water Heating System
5
D. Boiler Water
6
E. Freeze Protection
6
F. High Elevation Installations
6
G. Water Temperature Adjustment
6
Part 2 - Before You Start
7
A. What’s in the Box
8
B. How the Boiler Operates
8
C. Optional Equipment
8
Part 3 - Prepare the Boiler
9
A. Locating the Boiler
9
B. Flooring
10
C. Leveling
10
D. Clearances for Service Access
10
E. Residential Garage and Closet Installations
11
F. Exhaust Vent and Intake Pipe
11
1. Direct Vent of Exhaust and Intake
12
2. Indoor Combustion Air in Confined or Unconfined Space 12
G. Prevent Combustion Air Contamination
12
H. Removing a Boiler from a Common Vent System
12
I. Water Chemistry Requirements*
13
Part 4 - Piping
14
A. General Plumbing Information
15
B. Relief Valve
15
C. Backflow Preventer
15
D. Potable Expansion Tank
15
E. Circulators
16
F. Scalding
16
G. High Velocity Circulator Pump
16
H. Water Chemistry
18
The CSD-1 ASME Code, Section CW-400 requires that hot
water heating and supply boilers have a) a UL 353 temperature
control device, b) at least one (1) temperature-actuated control
to shut off the fuel supply when system water reaches a preset
operating temperature, c) a high temperature limit control that
prevents the water temperature from exceeding the maximum
allowable temperature by causing a safety shutdown and
lockout, and d) its own sensing element and operating switch.
The temperature control system integrated into the 926
control provided with this heating appliance complies with
the requirements of CSD-1 Section CW-400 as a temperature
operation control. The control monitors the temperature
difference between the inlet and the outlet sensor, which is
affected by boiler water flow. If this temperature difference
exceeds 55°F (typically because of low water flow or very low
heat load), the control will reduce the maximum fan speed.
If the temperature difference exceeds 60°F, the control will
effectively sense there is little or no water flow or heat load and
shut the boiler down. The controller will restart automatically
once the temperature difference has dropped below 55°F and
the minimum off time (anti-cycle time) has expired. In addition,
if the control senses that the outlet water temperature has
reached 210°F, the boiler is put into a hard lockout and requires
manual reset to restart.
Summary of Contents for MODCON500
Page 35: ...LP 446 r4 Rev 10 12 16 35 Figure 29 Cascade Master and FollowerWiring...
Page 57: ...LP 446 r4 Rev 10 12 16 57 Figure 35 500 Model Combustion System Replacement Parts...
Page 58: ...LP 446 r4 Rev 10 12 16 58 Figure 36 700 850 Models Combustion System Replacement Parts...
Page 60: ...LP 446 r4 Rev 10 12 16 60 Figure 38 Cabinet Replacement Parts All Models...
