Mod Con MODCON500 Installation Manual Download Page 58 | Manualshive

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LP-446-r4 Rev. 10.12.16

58

Figure 36 - 700/850 Models Combustion System Replacement Parts

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Summary of Contents for MODCON500

Page 1: ...personal injury or death HTPreservestherighttomakeproductchangesorupdateswithoutnoticeandwillnotbeheldliablefortypographical errors in literature NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTUR...

Page 2: ...VICINITY OFTHIS OR ANY OTHER APPLIANCE WHATTO DO IFYOU 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 su...

Page 3: ...dividual such as a fire chief fire marshal chief of a fire prevention bureau labor department or health department building official or electrical inspector or others For the Installer This boiler mus...

Page 4: ...ating System 5 D BoilerWater 6 E Freeze Protection 6 F High Elevation Installations 6 G WaterTemperature Adjustment 6 Part 2 BeforeYou Start 7 A What s in the Box 8 B How the Boiler Operates 8 C Optio...

Page 5: ...e boiler warranty and could result in property damage personal injury or death This boiler has been designed to heat potable water ONLY Using this boiler to heat non potable fluid WILL VOID product wa...

Page 6: ...utes 125oF 1 1 2 to 2 minutes 130oF About 30 seconds 135oF About 10 seconds 140oF Less than 5 seconds 145oF Less than 3 seconds 150oF About 1 1 2 seconds 155oF About 1 second Table 1 ApproximateTime T...

Page 7: ...StorageTanks Contact HTP for Available StorageTanks 40o 1414 859 883 894 1980 1206 1217 1260 2404 1449 1459 1502 50o 1131 872 902 915 1584 1225 1238 1292 1923 1467 1481 1534 60o 943 884 920 937 1320 1...

Page 8: ...oilers Each cascaded boiler will have its own pump to provide maximum flow and control heat exchanger flow rate Text Display and Operational LED Light Indicators The display allows the user to change...

Page 9: ...y damage severe personal injury or death A Locating the Boiler Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk Ensure that the installation locatio...

Page 10: ...orrect operating conditions IS NOT covered by product warranty Use extreme care not to drop the boiler or cause bodily injury while lifting the boiler Gas conversion should be performed BEFORE the boi...

Page 11: ...orted Boiler exhaust and intake connections are not designed to carry heavy weight Vent support brackets must be within 1 of the boiler and the balance at 4 intervals Boiler must be readily accessible...

Page 12: ...15 cm below the space ceiling the other 6 15cm above the space floor Each opening should have a free area of one square inch per 1 000 BTU hr 22cm2 kW of the total input of all appliances in the space...

Page 13: ...G of ANSI Z223 1 Figure 4 CO Warning Label I Water Chemistry Requirements Chemicalimbalanceofthewatersupplymayaffectefficiencyand cause severe damage to the boiler and associated equipment HTP recomme...

Page 14: ...in property damage severe personal injury or death Dielectric unions or galvanized steel fittings must not be used in a system with this boiler Doing soWILLVOID the warranty Useonlycopper brass orsta...

Page 15: ...al location following the guidelines below entire length Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making discharge clearly visible The discharge...

Page 16: ...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 insufficie...

Page 17: ...ve flows and friction loss This is provided to aid in circulator selection SystemTemperature Rise Chart 20 t 25 t 30 t Model Friction Ft Flow Rate GPM Friction Ft Flow Rate GPM Friction Ft Flow Rate G...

Page 18: ...ion must be replaced The manufacturer of the boiler has no control of water quality especially TDS levels in your system Total dissolved solids in excess of 2 000 ppm will accelerate lime and scale fo...

Page 19: ...rect tank sensor or system pipe sensor mounted on common return to the boiler 12 Aquastat or system pipe sensor connects to DHW sensor input on boiler 13 The minimum storage tank size for a 500VWH is...

Page 20: ...oiler Manifold Piping Chart this manual 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 separat...

Page 21: ...for connecting a boiler is 2 When sizing and installing a multiple boiler system see Multiple Boiler Manifold Piping Chart this manual 6 All pumps are shown with isolation flanges or full port ball va...

Page 22: ...contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors NOTE If exhaust vent pipe system passes through an unheated space such as an alcove or...

Page 23: ...d vent system must not be interchanged with other vent systems or unlisted pipe fittings Cellular foam core piping may be used on air inlet piping only DO NOT mix components from different venting sys...

Page 24: ...er to center Minimum distance between exhaust vents and intake pipes on multiple boilers is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above g...

Page 25: ...am core piping may be used on air inlet piping only 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use onl...

Page 26: ...given in theVenting section of this manual When installing a combustion air intake from outdoors care must be taken to utilize uncontaminated combustion air NOTE To prevent combustion air contaminati...

Page 27: ...4 foot intervals on the vent pipe Venting must be readily accessible for visual inspection from the first three feet from the boiler NOTES A For every 1 of overhang the exhaust vent must be located 1...

Page 28: ...re meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes Figure 18 UnbalancedVenting Roof Exhaust and Sidewall Intake An unbalan...

Page 29: ...air is taken from the outdoors using a duct to deliver the air to the mechanical room each of the two openings should be sized based on a minimum free area of one square inch per 2000 BTU hr input See...

Page 30: ...structions could result in property damage or personal injury Combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the boil...

Page 31: ...he boiler prior to opening an electrical box within the unit Ensure the power remains off while any wiring connections are being made Failure to follow these instructions could result in component or...

Page 32: ...the tank then one sensor should be used on the pipe carrying water from the tank s to the boiler To minimize temperature loss in the piping this sensor should be placed as close to the tank s as possi...

Page 33: ...l ignite As the signal continues to rise towards its maximum of 10 volts the boiler will increase in set point temperature See Part 10 for details on the setting of function 16 2 Connect a building ma...

Page 34: ...or to the terminals marked SYS SENSOR 4 Do not connect anything to the OUTDOOR SENS or THERMOSTAT terminals 5 If 0 10 volt positive going DC signal input is used connect to marked terminals O Cascade...

Page 35: ...LP 446 r4 Rev 10 12 16 35 Figure 29 Cascade Master and FollowerWiring...

Page 36: ...SWITCH FOR VWH APPLICATION OPTIONAL FOR STANDARD BOILER APPLICATION LOW WATER LEVEL APPLICATION FOR STANDARD BOILER ONLY NOT FOR VWH X6 5 FLAME RECTIFICATION PROBE BVPS FUSE THERMAL X5 4 926 CONTROL X...

Page 37: ...rtant to support gas piping as the unit is not Support gas supply piping with hangers not by the boiler or its accessories The boiler gas valve and blower will not support the weight of the piping Mak...

Page 38: ...upply at the manual gas valve before disconnecting the hose from the gas monitoring device Tighten screw on the pressure tap and turn gas on Check for leaks with soapy solution Bubbles will appear on...

Page 39: ...death Strainonthegasvalveandfittingsmayresult in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death Adjustments to the t...

Page 40: ...al 1 The 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 that prod...

Page 41: ...set temperature installer 4 or that boiler is at high firing rate If the command from the master boiler control gets to the high firing rate of the follower boiler but the system sensor is below the r...

Page 42: ...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 Turn off the gas shutoff valve...

Page 43: ...the user to adjust the ignition differential set point from 1oF to 36oF Factory Default 7oF Degrees below set point must be equal to or below tank differentials TANK SETPOINT 120 oF Adjusts the tank s...

Page 44: ...set point that the burner will maintain its outlet water temperature while there is a demand for heat Factory Default is 20oF Range 1oF to 45oF Function 6 VWH Post PumpTime VWH POST PUMP TIME 0 MINUTE...

Page 45: ...a connected and powered Modbus communication adapter p n 7350P 629 will result in improper appliance operation Service calls associated with this ARE NOT covered by warranty Table 19 System Setting Pr...

Page 46: ...ting press ENTER Press the and v keys to make adjustments Press ENTER when reset is complete Part 10 Start Up Procedures for the Installer A Boiler Control Status Menu The boiler control also has the...

Page 47: ...ate and time that the fault occurred Press v once FAULT HISTORY 4 08 28 2009 Fr 5 19A This screen displays the fourth oldest boiler control lockout fault The top line will alternate between the words...

Page 48: ...tom line shows the status of the system pump output contacts Press v once CASCADE PWR 100 PRESENT 01234567 This screen displays overall cascade power output The range of this value is the number of bo...

Page 49: ...mp to run in an attempt to cool the boiler 2 Note the displayed fault code and refer to Section D for an explanation of the message along with several suggestions for corrective actions 3 Press RESET...

Page 50: ...n FLU error Faulty switch MUST be replaced Failure to follow this instruction could result in serious personal injury or death 24 VOLT LOW LOU PUMP ON LOU indicates the 24 volt power supply on the con...

Page 51: ...h the boiler or b poor heat transfer from the water to the load 5 If no switches are tripped push RESET on the boiler If the boiler tries to ignite or ignites and only runs for a short time and the F0...

Page 52: ...exists The boiler will not restart until a technician determines and repairs the cause of excessive temperature and pushes RESET on the display If the red FAULT light is not illuminated and this messa...

Page 53: ...he combustion chamber the refractory wall may be damaged and should be replaced 5 Turn the gas on at the service valve after corrective action is taken 6 If the refractory wall falls against the recti...

Page 54: ...for boiler operation FLUE TEMP HIGH E07 PUMP OFF TIME E07 indicates the flue sensor temperature is excessive and above 210oF When E07 is displayed the boiler will not respond to a demand for heat When...

Page 55: ...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...

Page 56: ...ers as shown in the piping diagrams in this manual Slowly open the ball valves and release pressure into a bucket Once pressure is released connect a hose to the water line to flush the boiler Scale r...

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 59: ...250P 152 7250P 152 O RING SILICONE 2 007 BARBED FITTING 22 7350P 605 7350P 605 FLOW SWITCH KIT FOR MOD CON VWH 07 28 16 ITEM MOD CON 500VWH MOD CON 700 VWH MOD CON 850VWH DESCRIPTION 1 7500P 033 7500P...

Page 60: ...LP 446 r4 Rev 10 12 16 60 Figure 38 Cabinet Replacement Parts All Models...

Page 61: ...If necessary convert the boiler to the proper fuel type Locate the stickers in the appropriate locations on the boiler Verify combustion settings after gas conversion Carbon Dioxide CO2 High Fire CO2...

Page 62: ...Ignitor and Flame Probe Check ionization in uA d7 in Status Menu in Start Up Procedures Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1stYear 2ndYear 3rdYe...

Page 63: ...ONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with...

Page 64: ...ENTING 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 instru...

Page 65: ...ating components must be maintained in good operating condition 3 All lines must be checked to confirm that all condensate drains properly from the unit 4 Operate the VWH at pressures not exceeding th...

Page 66: ...CEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION LIABILI...

Page 67: ...LP 446 r4 Rev 10 12 16 67 Maintenance Notes...

Page 68: ...of Installation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer P...

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