HTP Mod Con 300 VWH Installation And Maintenance Instructions Manual Download | Manualshive

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120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

LP- 276 REV. 9.4.14

Mod Con VWH

INSTALLATION

START-UP

MAINTENANCE

PARTS

VWH Models

300 / 500 / 850

LP / HL / LPHL

Heat Exchanger Bears the ASME “H” Stamp

NOTICE:

HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors

in literature.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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 substantial property damage, severe personal injury, or death.

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Summary of Contents for Mod Con 300 VWH

Page 1: ...to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 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 substantial ...

Page 2: ...CINITY OF 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...

Page 3: ...department building official or electrical inspector or others having statutory authority In some circumstances the property owner or his her agent assumes the role and at government installations the commanding officer or departmental official may be the AHJ NOTE HTP Inc reserves the right to modify product technical specifications and components without prior notice FOR THE INSTALLER This applia...

Page 4: ...ments 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 ...

Page 5: ...T SYSTEM 35 I SIDEWALL VENTING DIAGRAMS 36 J VERTICAL VENTING DIAGRAMS 38 PART 6 GAS PIPING 40 A GAS CONNECTION 40 B GAS PIPING 40 C GAS TABLE 41 D CHECK INLET GAS PRESSURE 41 E GAS VALVE 42 PART 7 FIELD WIRING 44 A INSTALLATION MUST COMPLY WITH 44 B FIELD WIRING TERMINATIONS 44 C FIELD WIRING CONSIDERATIONS 44 D LINE VOLTAGE WIRING 45 E ALARM CONNECTIONS 45 F LOW VOLTAGE CONNECTIONS FOR STANDARD ...

Page 6: ...72 HTP CUSTOMER INSTALLATION RECORD FORM 73 PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This appliance is for indoor installations only Clearance to combustible materials 0 top bottom sides and back Front must have room for service 24 recommended A combustible door or removable panel is acceptable front clearance This appliance has been approved for closet installation Do not install this appl...

Page 7: ... BOILER To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before servicing E BOILER WATER Do not use petroleum based cleaning or sealing compounds in a boiler system These products may damage gaskets and seals in the system This can result in substantial property damage Do not use homemade cures or boiler patent medicines ...

Page 8: ...87 716 752 140 o 564 624 653 689 150 o 513 573 602 638 160 o 470 530 559 595 170 o 434 494 523 559 180 o 403 463 492 528 Table 2 Mod Con 500 VWH Recovery Ratings with Storage Tanks and 40 o F Inlet Temperature Mod Con 850 VWH Outlet Temperature Recovery Gallons Per Hour First Hour Rating With 80 Gallon First Hour Rating With 119 Gallon First Hour Rating With 175 Gallon 80 o 2 397 2 457 2 486 2 522...

Page 9: ...ance of the system Control The integrated 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 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...

Page 10: ...firing rate of the connected boilers Indirect Tank Sensor optional Monitors storage tank temperature C OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP Indirect Tank Sensor Part 7250P 325 4 Stainless Steel Outside Termination Vent Kit V2000 6 Stainless Steel Outside Termination Vent Kit V3000 High and Low Gas Pressure Switch Kit with Manual Reset Part 7350P 600 U L 353 C...

Page 11: ... supply piping Electrical power Condensate drain 3 Check area 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 4 Gas control system components must be protected from dripping water during operation and se...

Page 12: ...12 LP 276 REV 9 4 14 Figure 2 Dimensions and Specifications ...

Page 13: ...gorized as direct vent sealed combustion Note To prevent combustion air contamination see Table 4 in this section when considering exhaust vent and intake air vent termination Intake and exhaust vents must terminate near each other and may be vented vertically through the roof or out a side wall Intake and exhaust venting methods are detailed in the Venting Section Do not attempt installation usin...

Page 14: ...xisting boiler the following steps must be followed 1 Seal any unused openings in the common venting system 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 common venting system and other...

Page 15: ...ious injury or death Plumbing of this product should only be done by a qualified licensed plumber in accordance with all local plumbing codes The boiler is designed to be connected to a storage tank to supply domestic hot water HTP offers 80 119 175 gallon size storage tanks in either Stainless Steel or Glass lined construction These storage tanks will be directly connected to the Boiler supply an...

Page 16: ...e 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 ANSI Z21 22 CSA4 4 FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VA...

Page 17: ...ll 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 Section H Piping Diagrams Then connect your hot water outlet located on the storage tank to your hot water plumbing lines Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or b...

Page 18: ...ow switch to boiler wire harness 9 When installation is complete power up the boiler and use the control to access installer parameter 20 and change the default value to 2 see Part 11 in this manual When done create a demand and observe boiler function to verify the installation is working properly Please note that these illustrations are meant to show system piping concept only The installer is r...

Page 19: ...the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications The table 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 syst...

Page 20: ... are those water quality parameters which need to be met in order for the system to operate efficiently for many years Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other imbalance IS NOT covered by the warranty Water Hardness Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water The concentration of these salts...

Page 21: ...s in your system Total dissolved solids in excess of 2 000 ppm will accelerate lime and scale formation in the heat exchanger Heat exchanger failure due to total dissolved solids in excess of 2 000 ppm is a non warrantable condition Failure of a water heater due to lime scale build up on the heating surface IS NOT covered by the warranty Hardness 7 grains Chloride levels 100 ppm pH levels 6 8 TDS ...

Page 22: ...22 LP 276 REV 9 4 14 I PIPING DIAGRAMS Figure 6 ...

Page 23: ...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 valves 8 Install a vacuum relief valve in accordance with local code requirements 9 Multiple boilers and storage tanks shall be installed with reverse return...

Page 24: ...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 valves 8 Install a vacuum relief valve in accordance with local code requirements 9 Multiple boilers and storage tanks shall be installed with reverse return...

Page 25: ...ves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install a vacuum relief valve in accordance with local code requirements 9 Multiple boilers and storage tanks shall be installed with reverse return piping as shown 10 Mixing valves are recommended on all tanks if hot water temperature is above 119o F 11 Expansion...

Page 26: ...ves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install a vacuum relief valve in accordance with local code requirements 9 Multiple boilers and storage tanks shall be installed with reverse return piping as shown 10 Mixing valves are recommended on all tanks if hot water temperature is above 119o F 11 Expansion...

Page 27: ...ves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install a vacuum relief valve in accordance with local code requirements 9 Multiple boilers and storage tanks shall be installed with reverse return piping as shown 10 Mixing valves are recommended on all tanks if hot water temperature is above 119o F 11 Expansion...

Page 28: ...the tank or system pipe sensor connected to the DHW sensor terminals on the follower boiler addressed as 1 14 The system pipe sensor must be placed on common piping to the tank as close to the tank as possible 15 The system pipe sensor is wired to the system sensor terminals on the master boiler PART 5 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL The boiler must be vented as detailed in this Vent...

Page 29: ...e to do so could result in property damage severe personal injury or death Due to the extreme flammability of most glues cements solvents and primers used to join plastic exhaust and intake air pipes explosive solvent vapors must be cleared from all vent piping before start up Avoid using excess cement or primer as this may pool in the vent pipes Vent assemblies should be allowed to cure for a per...

Page 30: ...ent piping All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of per foot back to the boiler to allow drainage of condensate Failure to properly support vent piping and follow the information in this statement could result in product damage severe personal injury or death For closet and alcove installations CPVC polypropylene or stainless steel venting materi...

Page 31: ...system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 m 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 r...

Page 32: ...condensate collection system with an internal float switch monitors the condensate level to prevent it from backing up into the combustion system There is a sweat connection provided to connect the outlet of the collection system to a drain or condensate pump See Table 10 for approved condensate piping material APPROVED PLASTIC CONDENSATE PIPING MATERIAL MATERIAL STANDARDS FOR INSTALLATION IN UNIT...

Page 33: ...side It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage Damages due to frozen or blocked condensate lines ARE NOT covered by warranty 4 Support of the condensate line may be necessary to avoid blockage of the condensate flow The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or i...

Page 34: ...d by equally increasing the diameter of both the exhaust and intake air vent pipes However the transitions should begin a minimum of 32 combined equivalent feet from the boiler equally on both the intake and exhaust The maximum equivalent length for 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...

Page 35: ...determine if there is blockage leakage corrosion or other deficiencies that could cause an unsafe condition 3 If practical close all building doors windows and all doors between the common venting system 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 ...

Page 36: ...ck to the boiler 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 of the appliance and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler ...

Page 37: ...e boiler 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 of the appliance and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler ...

Page 38: ...r foot back to the boiler 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 of the appliance and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler...

Page 39: ...00 and 3 for 850 When placing support brackets on vent piping the first bracket must be within 1 of the appliance and the balance at 4 intervals on the vent pipe Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler Take extra precaution to adequately support the weight of vent pipes terminating through the roof Failure to properly support roof te...

Page 40: ...use an open flame match lighter etc to check gas connections B GAS PIPING 1 Run the gas supply line in accordance with all applicable codes 2 Locate and install manual shutoff valves in accordance 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 suppor...

Page 41: ...Before you connect to the inlet pressure shut off the gas and electrical power to unit 2 Loosen the pressure tap with a small screwdriver Refer to Figures 21 and 22 for locations 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 un...

Page 42: ...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 failure This problem is especially noticeable in NEW LP installations and empty tank situations This situation can also occur when a utility company shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with ...

Page 43: ...tion leading to fire explosion severe injury or death Strain on the gas valve and fittings may result in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO Fa...

Page 44: ...circulator pump to the controller if a tank sensor or mechanical control can be mounted to the storage tank otherwise circulator pumps must be wired to run continuously The circulator pump wired to the boiler control will have a default program of a 5 minute post purge to provide stabilization and post cleaning of the heat exchanger The boiler control is capable of supplying 120 volts at up to 3 a...

Page 45: ... Figure 24 A line voltage fused disconnect switch may be required to be externally mounted and connected according to local wiring codes If the pump used for the boiler operates at 120 volts and less than 3 amps is required it may be connected directly to the terminals marked BOILER HOT BOILER NEUT and BOILER GRD If the pump operates at a voltage other than 120 volts and or requires more than 3 am...

Page 46: ...essure 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 below 1 w c on the inlet side 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 jum...

Page 47: ... 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 and BOILER GND terminals 3 Connect the system sensor to the terminals marked SYS SENSOR 4 Do not connect anything to the OUTDOOR SENS or THERMOSTAT terminals 5 If 0 10 volt input is used connect to marked terminals ...

Page 48: ...rked TANK SENSOR 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 27 for wiring suggestions for this relay Note that ...

Page 49: ...49 LP 276 REV 9 4 14 Figure 28 Mod Con Internal Connection Diagram LP 255 ...

Page 50: ...sive Consult local water treatment companies for unusually hard water areas above 7 grains hardness pH of Water pH is a measure of relative acidity neutrality or alkalinity Dissolved minerals and gases affect water pH The pH scale ranges from 0 to 14 Water with a pH of 7 0 is considered neutral Water with a pH lower than 7 is considered acidic Water pH higher than 7 is considered alkaline A neutra...

Page 51: ... available from HTP 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 3 If a long horizontal run is used it may be necessary to create a vent in the horizontal run to prevent a vacuum lock in the condensate line 4 Do not expose the condensate t...

Page 52: ...ate command to that boiler until the system sensor temperature is at the tank set point temperature plus the supply offset 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 required temperature the master boiler control will then tell the next boiler in t...

Page 53: ...ELL GAS Do not try to light any boiler 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 Turn off gas shutoff valve located outside of the boiler so that the handle is crosswise to the gas pipe If the handle will not tu...

Page 54: ...esired tank temperature If you are using 0 10 volt control parameter dd should be set to the tank temperature corresponding to the 10 volt input signal Parameters sh and dh should both be set to the number of degrees below the desired tank temperature that you want the VWH boiler s to start firing at Settings when using a Mechanical Tank or Pipe Sensor The mechanical sensor should be set to the de...

Page 55: ... P3 Follower Boiler 3 Alternating 0 100 Percentage firing rate P4 Follower Boiler 4 Alternating 0 100 Percentage firing rate P5 Follower Boiler 5 Alternating 0 100 Percentage firing rate P6 Follower Boiler 6 Alternating 0 100 Percentage firing rate P7 Follower Boiler 7 Alternating 0 100 Percentage firing rate NOTE If you toggle beyond parameters of connected boilers the display will go into the ne...

Page 56: ...minute the display returns to normal operation Changes are effective immediately but not directly stored until the S4 key is pressed down for 3 seconds then the new values are stored Listed below are the varieties of functions the installer can program The boiler cannot be programmed while there is a call for heat DEFAULT FUNCTION VALUE DESCRIPTION 1 dd N A no change allowed 2 149 o F N A no chang...

Page 57: ... Table 17 PART 11 TROUBLESHOOTING A VWH ERROR CODE If any of the sensors detect an abnormal condition or an internal component fails during the operation of the VWH boiler the display may show an error code This code may be the result of a temporary condition in which case the display will revert to its normal readout when the condition is corrected or it may be the result of a condition that the ...

Page 58: ... the boiler at the gas service valve 926 CONTROL BOARD ERROR CODES CODE DESCRIPTION CORRECTIVE ACTION E19 Line voltage frequency out of range Inspect power wiring to appliance and repair as necessary If connected to line voltage notify power company If connected to an alternate power source such as a generator or inverter make sure line voltage frequency supplied by the device is 60 Hz No reset is...

Page 59: ...ically Verify thermistor values by referencing chart in this manual 2 If connection is okay replace thermistor F03 Interrupted or shorted return inlet thermistor F05 Supply outlet temperature sensor exceeds 230o F 1 Check circulation pump operation 2 Assure there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50o F rise from the return therm...

Page 60: ...ration Failure to clean the heat exchanger as needed by the installation location could result in appliance failure property damage personal injury or death Such product failures ARE NOT covered under warranty The appliance requires minimal periodic maintenance under normal conditions However in unusually dirty or dusty conditions periodic vacuuming of the cover to maintain visibility of the displ...

Page 61: ...boiler by using the following steps a Close the gas valve shut down the unit and wait for the unit to be cool to the touch b Disconnect the condensate piping from the outside connection not from the boiler side so flow from condensate reservoir can be observed c Disconnect electrical connections from the gas valve spark electrode and flame rectification probe and combustion blower d Remove the 4 s...

Page 62: ...oiler Run water through the hot water system to assure it is below room temperature 2 Close isolation valves on the return and supply connections to the heaters as shown in the piping diagrams within 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 heater Scale removing solution may be used but must b...

Page 63: ...63 LP 276 REV 9 4 14 Figure 31 ...

Page 64: ...64 LP 276 REV 9 4 14 Figure 32 ...

Page 65: ...65 LP 276 REV 9 4 14 Figure 33 NOTE Ceramic Refractory Part 7250P 162 ...

Page 66: ...66 LP 276 REV 9 4 14 Figure 34 ...

Page 67: ...67 LP 276 REV 9 4 14 Figure 35 ...

Page 68: ...ombustion settings after gas conversion Carbon Dioxide ____ CO2 High Fire ____ CO2 Low Fire Verify combustion settings after gas conversion Carbon Monoxide ____ppm CO High Fire ____ppm CO Low Fire Mail in the conversion registration 8 System Setting Verify system settings ___ de ___ dh Check mixing valve Notes Table 21 MAINTENANCE REPORT In unusually dirty or dusty conditions care must be taken to...

Page 69: ...intenance section of manual Vacuum combustion chamber Replace any gaskets that show signs of damage 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 Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate hose Clean out dirt Fill with water to level...

Page 70: ...70 LP 276 REV 9 4 14 ...

Page 71: ...71 LP 276 REV 9 4 14 ...

Page 72: ...72 LP 276 REV 9 4 14 MAINTENANCE NOTES ...

Page 73: ...tallation Address 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...

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