HTP Mod Con 300 LPHL, Mod Con 850 HL, Mod Con 500 LPHL, Mod Con 850 LP, Mod Con 500 LP Installation & Maintenance Manual

...

Mod Con

This manual must only be used by a qualified heating installer/service technician. Read all could result in substantial pr o p erty damage, severe personal injury, or death.

INSTALLATION

START-UP

MAINTENANCE

PARTS

Mod Con Models

300 / 500 / 850

LP / HL / LPHL

instructions in this manual before installing. Perform steps in the order given. Failure to comply

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held

liable for typographical errors in literature.

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

LP- 205 REV. 3.18.11

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 GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY 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, service agency, or the gas supplier.

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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 substantial property damage, severe personal injury, or death.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the appliance. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publicat ions incl ud ing the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entir e t y bef ore beginn ing 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.

FOR THE INSTALLER

this manual before installing. Perform steps in the order given. Failure to comply could result in

This appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Va lley Road, Cleveland, OH 44131.

In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the Instal lat ion of Heat Prod uc ing Applia nc es (lates t version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas 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 OPERATES................................................................................................................... 9

C. OPTIONAL EQUIPMENT ................................................................................................................... 10

PART 3 – PREPARE BOILER LOCATION ............................................................................................... 11

A. BEFORE LOCATING THE BOILER ................................................................................................... 11

B. LEVELING AND DIMENSIONS .......................................................................................................... 12

C. CLEARANCES FOR SERVICE ACCESS .......................................................................................... 14

D. RESIDENTIAL GARAGE INSTALLATION ......................................................................................... 14

E. EXHAUST VENT AND INTAKE AIR VENT ........................................................................................ 14

F. PREVENT COMBUSTION AIR CONTAMINATION ........................................................................... 15

G. REMOVING A BOILER FROM A COMMON VENT SYSTEM ........................................................... 15

H. UNCRATING AND MOVING BOILER ................................................................................................ 16

PART 4 – BOILER PIPING......................................................................................................................... 17

A. GENERAL PIPING INFORMATION ................................................................................................... 17

B. RELIEF VALVE ................................................................................................................................... 17

C. BACKFLOW PREVENTER ................................................................................................................. 18

D. SYSTEM WATER PIPING METHODS ............................................................................................... 18

E. CIRCULATORS .................................................................................................................................. 19

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS .............. 19

G. BOILER PIPING DETAILS ................................................................................................................. 21

H. CIRCULATOR SIZING ........................................................................................................................ 25

I. FILL AND PURGE HEATING SYSTEM ............................................................................................... 26

J. FREEZE PROTECTION FLUIDS ........................................................................................................ 27

K. ZONING WITH ZONE VALVES .......................................................................................................... 27

L. ZONING WITH CIRCULATORS ......................................................................................................... 28

M. MULTIPLE BOILERS ......................................................................................................................... 28

PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ........................................... 28

A. INSTALLING EXHAUST VENT AND INTAKE AIR VENT .................................................................. 28

B. GENERAL ........................................................................................................................................... 29

C. APPROVED 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. GAS CONNECTION ........................................................................................................................... 41

B. GAS PIPING ....................................................................................................................................... 41

C. GAS TABLE ........................................................................................................................................ 42

D. CHECK INLET GAS PRESSURE ....................................................................................................... 42

E. GAS VALVE ........................................................................................................................................ 44

PART 7 – FIELD WIRING ........................................................................................................................... 46

A. INSTALLATION MUST COMPLY WITH: ............................................................................................ 46

B. FIELD WIRING .................................................................................................................................... 46

C. LINE VOLTAGE WIRING.................................................................................................................... 46

D. ALARM CONNECTIONS .................................................................................................................... 47

E. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER .......................................................... 47

F. THERMOSTAT .................................................................................................................................... 48

G. OUTDOOR SENSOR ......................................................................................................................... 49

H. INDIRECT SENSOR ........................................................................................................................... 49

I. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL ...................................................................... 49

J. OPTIONAL HIGH GAS PRESSURE SWITCH .................................................................................... 49

K. OPTIONAL LOW GAS PRESSURE SWITCH .................................................................................... 50

L. OPTIONAL FLOW SWITCH ................................................................................................................ 50

M. OPTIONAL UL353 LOW WATER CUTOFF INTERFACE KIT ........................................................... 50

N. WIRING OF THE CASCADE SYSTEM COMMUNICATION BUS ..................................................... 51

O. CASCADE MAST ER PU MP AN D SE N SOR WIRING ....................................................................... 52

P. CASCADE FOLLOWER PUMP AND SENSOR WIRING ................................................................... 53

PART 8 – START-UP PREPARATION ...................................................................................................... 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

PART 10 – START-UP PROCEDURES FOR THE INSTALLER .............................................................. 63

A. PROGRAMMING FOR THE INSTALLER ........................................................................................... 63

B. PROGRAM ACCESS .......................................................................................................................... 64

C. PROGRAM NAVIGATION .................................................................................................................. 64

PART 11 – TROUBLESHOOTING ............................................................................................................. 67

A. ERROR CODE .................................................................................................................................... 67

B. BOILER ERROR ................................................................................................................................. 67

C. BOILER FAULT .................................................................................................................................. 67

PART 12 – MAINTENANCE ....................................................................................................................... 70

INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.

USER – This manual is for use only by a qualified heating installer/service technician. Refer to user’s technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL

PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the boiler is exposed to the following, do not operate until all corrective steps have been made

company by the consignee.

installations greatly reduce the likelihood of boiler oversizing.

A. MAINTENANCE PROCEDURES ....................................................................................................... 70

B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR HEATER ............................... 71

BOILER START-UP REPORT ................................................................................................................... 78

MAINTENANCE REPORT .......................................................................................................................... 79

MAINTENANCE NOTES ............................................................................................................................ 82

HTP CUSTOMER INSTALLATION RECORD FORM ........................................................................ 83

PART 1 – GENERAL SA FETY IN FO RMATIO N

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 appliance directly on carpeting. This appliance may be installed on combustible flooring. For use with Category IV vent systems only.

information manual for your reference. Have this boiler serviced/inspected by a qualified service

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician. Replace any part of the control un it that has been und er water .

by a qualified serviceman:

• FIRE

• DAMAGE

• WATER

Any claims for damage or shortage in shipment must be filed immediately against the transportation

Due to low water content of the boiler, improperly sizing the boiler in regard to heating system load will result in excessive boiler cycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made poisonous if consumed, and can cause injury or death.

Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation.

WHAT TO DO IF YOU SMELL GAS

provided by a qualified installer, service agency, or the gas supplier.

B. IMPROPER COMBUSTION

C. 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 gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department. Installation and service must be

Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the appliance.

D. WHEN SERVICING THE BOILER

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before servicing.

E. BOILER OPERATION

• Do not block flow of combustion or ventilation air to boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical

supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and replace any part of the control system and any gas control that has been under water.

F. 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”. Substantial property 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 iron radiators, thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

G. FREEZE PROTECTION

for hydronic (non-potable) systems. These chemicals can attack gaskets and seals in water boilers, are

Consider piping and install atio n when determining boiler location .

PART 2 – BEFORE YOU START

A. WHAT’S IN THE BOX

Also included with the boiler:

• Pressure and Temperature Gauge

• Outdoor Sensor

• Intake PVC Tee with Screens

• Exhaust PVC Coupling with Screens

• Installation Manual

• Warranty

• CSD-1 Form

• H-3 Data Sheet

B. HOW BOILER OPERATES

Mod Con condensing technology intelligently delivers highly efficient hydronic heating while maximizing efficiency by measuring data from the heating system. Outlined below are the features of the system and how they operate:

Stainless Steel Heat Exchanger - The highly efficient stainless steel heat exchanger is designed to use the cold return water from the system and extract the last bit of heat before it is exhausted.

Modulating Combustion System - The combustion system will modulate 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.

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 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 system is capable of connecting up to eight boilers together in such a way that they function as one boiler system. This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize efficiency.

The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a cascade system sensor and a cascade pump in addition to its own boiler pump. Each of the follower boilers has an individual pump.

System Display and Operational LED Light Indicators – The display allows the user to change the system parameters and monitor system outputs.

Gas Valve – Senses suction from the blower, allowing gas to flow only if powered and combustion air is flowing.

All Metal Integrated Venturi – Controls air and gas flow into the burner.

Burner – Constructed of high grade stainless steel, the burner uses premixed air and gas fuel to provide a wide range of firing rates.

Spark Ignition – The burner is ignited by applying high voltage through the system spark electrode. This causes the spark from the electrode to ignite mixed gas from the burner.

Supply Water Temperature Sensor – This sensor monitors the boiler outlet water temperature (System Supply). The control adjusts the boiler firing rate so the supply temperature will match the boiler set point.

Return Water Temperature Sensor – This sensor monitors the boiler return water temperature (System Return).

Temperature and Pressure Gauge – Allows the user to monitor system temperature and pressure. Electrical 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. Condensation Collection Syste m – This boiler is a high efficiency appliance, therefore the boiler will

produce condensate. The collection system has a float switch which monitors the condensation level and prevents condensation from backing up into the combustion system. Inside the collection system there 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 shut down the burner before overheating occurs.

Outdoor Sensor – This sensor monitors outdoor temperature. Data from this sensor is monitored by the control, which adjusts the unit set point to provide greater efficiency.

Indirect Tank Sensor (optional) – Monitors storage tank temperature.

C. OPTIONAL EQUIPMENT

Below is a list of optional equipment available from HTP. These additional options may be purchased through your HTP distributor.

• System Sensor (Part # 7250P-324)

• 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 Compliant Low Water Cut-Off Interface Kit with Manual Reset (Part # 7450P-225)

• Alarm System (Part # 7350P-602) (to monitor any failure)

• Stacking Kit (Part # 7350P-603)

• PC Connection Kit (Part # 7250P-320)

• Condensate Neutralizer (Part # 7350P-611)

• Caster Kit (Part # 7350P-604)

• Flow Switch Kit (Part # 7350P-606 for Mod Con 300, Part # 7350P-605 for Mod Con 500/850)

Consider piping and install ation when determining boiler location.

substantial property damage, severe personal injury, or death.

PART 3 – PREPARE BOILER LOCATION

Before considering location, there are many factors to be addressed. Piping, Venting, and Condensation Removal are just a few of the important issues covered in detail in this manual. Please read the entire manual before attempting installation. Doing so could save time and money.

A. BEFORE LOCATING THE BOILER

1. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

2. 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

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, check for and correct any existing system problems, such as:

• System leaks

• Location that could cause the system and boiler to freeze and leak.

• Lack of freeze protection in boiler water which will cause system and boiler to freeze and leak.

• Excessive glycol which will af f ec t boiler system operat i on.

5. Clean and flush system when reinstalling a boiler.

In order for the condensate to properly flow out of the collection system, the area where you locate the boiler is uneven, adjust the leveling feet with a wrench.

B. LEVELING AND DIMENSIONS

Figure 1

boiler must be level. The boiler comes equipped with leveling feet. Should you find the floor beneath the

Figure 2

Space must be provided with combustion/ventilation air openings correctly sized for all appliances located

severe personal injury, or death.

Vents must be properly supported. The boiler intake and exhaust connections are not designed to carry

Figure 3

C. CLEARANCES FOR SERVICE ACCESS

See Figure 3 for recommended service clearances. If you do not provide the minimum clearances shown, it might not be possible to service the boiler without removing it from the space.

in the same space as the boiler. The boiler venting cover must be securely fastened to prevent it from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage,

D. RESIDENTIAL GARAGE INSTALL AT IO N

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

heavy weight. Vent support brackets must be within 1’ of the boiler and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’ from the boiler.

The boiler is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent), and requires a special vent system designed for pressurized venting.

You must pipe outside air to the boiler intake. Ensure that the intake air will not contain any of the

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 chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops Adhesives used to fasten building products

NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY.

Do not install the boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

You must also install air intake piping from outdoors to the boiler flue adaptor. The resultant installation is categorized as direct vent (sealed combustion). NOTE: To prevent combustion air contamination, see Table 1 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 ven tin g m ethods ar e detailed in the Ve nti ng S ect ion . Do not attempt installation using any other means. Be sure to locate the boiler so intake and exhaust vent piping can be routed through the building and properly terminated. The air intak e and exhaust vent piping lengths, routing and termination method must all comply with methods and limits given in the venting section.

F. PREVENT COMBUSTION AIR CONTAM INATION

Install intake piping for the boiler as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

contaminants below. For example, do not pipe intake vent near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death.

Table 1 – Contaminants

(Refer to the limited warranty for complete terms and conditions).

G. REMOVING A BOILER FROM A COMMON VENT SYSTEM

Uncrating Boiler – Any claims for damage in shipment must be filed immediately against the transportation company by the consignee.

Cold Weather Handling – If boiler has been stored in a very cold location (below 0oF) before installation, handle with care until the plastic components come to room temperature.

Figure 4 - CO Warning Label

Figure 5 - CO Warning Label

When removing an existing 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 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 speed. Do not operate a summer exhaust fan. Close all fireplace dampers.

4. Place in operation the applianc e bei ng insp ec ted.

Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of 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 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 determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

H. UNCRATING AND MOVING BOILER

ARE NOT covered by warranty.

The building piping system must meet or exceed the piping requirements in this manual.

The control module uses temperature sensors to provide both high limit protection and modulating the heat exchanger. Some codes/jurisdictions may require additional external controls.

Figure 6

Remove all sides of the shipping crate in order to allow the boiler to be lifted into its installation location. Pick the boiler up by the lift rings to avoid damage to the boiler enclosure. Use either a solid ¾” diameter black iron pipe or lifting straps to lift the boiler off of its shipping crate. The boiler is very heavy. At least two individuals are needed to handle the boiler properly. If the location is not level, adjust the boiler’s leveling feet to ensure a level boiler and proper flow

of condensate. If surface flooring is rough, care should be taken not to catch the leveling feet and damage the boiler when sliding it into position.

PART 4 – BOILER PIPING

Never use dielectric 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

Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes.

A. GENERAL PIPING INFORM ATION

temperature control. The control module also provides low water protection by sensing the water level in

B. RELIEF VALVE

Connect discharge piping to a safe disposal location following the guidelines on the following page.

SEVERE PERSONAL INJURY, OR DEATH.

All piping methods shown in this manual use primary/secondary connection to the boiler loop. This is to HTP representative, or refer to Boiler Piping Details in this manual, Part 4, Section G.

BOILER WATER VOLUME

300

2.9 Gallons

500

4.2 Gallons

850

5.8 Gallons

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and run to a safe place of disposal.

• Terminate the discharge line in a manner that will prevent possibility of severe burns or property

damage should the relief valve discharge.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly visible.

• Discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of

F or greater.

375

• Do not pipe discharge to any location where freezing could occur.

• No shutoff valve may 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 relief valve after filling and pressurizing the 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.

• Test relief valve at least once annually to ensure the waterway 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, ANSI Z21.22 CSA4.4

•

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE,

C. BACKFLOW PREVENTER

Use a backflow preventer specifically designed for hydronic boiler installations. This valve should be installed on the cold water fill supply line per local codes (see Boiler Piping Details, Part 4, Section G).

avoid the possibility of inadequate flow through the boiler. For other piping methods, consult your local

D. SYSTEM WATER PIPING METHODS

EXPANSION TANK AND MAKE-UP WATER

1. Ensure that the expansion tank is sized to correctly handle boiler and system water volume and temperature.

Table 2

Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water

IS NOT COVERED BY WARRANTY.

DO NOT install automatic air vents on closed type expansion tank systems. Air must remain in the system

system, resulting in improper operation of the expansion tank.

DO NOT use the boiler circulator in any location other than the ones shown in this manual. The boiler caution could result in unreliab le performance and nuisance shutdowns from insufficient flow.

to be added. Eventual boiler failure can result due to excessive make-up water addition. SUCH FAILURE

2. The expansion tank must be located as shown in Part 4, Boiler Piping Details, or following recognized design methods. See expansion tank manufacturer’s instructions for details. Always install an expansion tank designed for potable water systems.

3. Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system.

4. Most chilled water systems are piped using a closed type expansion tank.

DIAPHRAGM (OR BLADDER) EXPANSION TANK

Always install an automatic air vent on top of the air separator to remove residual air from the system.

E. CIRCULATORS

and return to the tank to provide an air cushion. An automatic air vent would cause air to leave the

circulator location is selected to ensure adequate flow through the boiler. Failure to comply with this

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 heating system using recognized design methods.

F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS

The boiler is designed to function in a closed loop hydronic system. The included temperature and pressure gauge allows the user to monitor system pressure and outlet temperature from the boiler. It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators. Each boiler installation must have an air elimination device that will remove air from the system.

Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.). Allow clearance for basic service of the boiler circulator, valves, and other components. Observe minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by non-combustible materials.

On a boiler installed above radiation level, some states and local codes require a low water cut off device. This is provided standard on the Mod Con boiler. Check with local codes for additional requirements. If

Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank ARE NOT covered by warranty.

the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle. Chilled water medium must be piped in p ar allel with the boi ler.

Freeze protection for new or existing systems must use glycol specifically formulated for this purpose. This glycol must include inhibitors that will prevent it from attacking metallic system components. Make certain that 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 water expands 3% over the same temperature rise.

or boiler. Failure to follow this instruction can lead to premature failure of the boiler system. Such failures

F to 180oF, whil e

G. BOILER PIPING DETAILS

Figure 7 – Single Boiler Space Heating – Indirect Priority

FIGURE NOTES:

1. This drawing is meant to demonstrate system piping concept only.

2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119

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. 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 ½” 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. Installations must comply with all local codes.

10. In Massachusetts, a vacuum relief valve must be installed on the cold water line per 248 CMR.

Figure 8 – Cascade Multiple Boilers – Indirect Priority on One

FIGURE NOTES:

1. This drawing is meant to demonstrate system piping concept only.

2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119

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 Piping chart, Part 5, Section H.

Figure 9 – Single Boiler Space Heating

FIGURE NOTES:

1. This drawing is meant to demonstrate system piping concept only.

2. Installations must 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 ½” for the 300 and 2” for the 500 and 850.

6. Piping shown is Primary/Secondary.

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.

Figure 10 – Cascaded Boilers – Space Heating

FIGURE NOTES:

1. This drawing is meant to demonstrate system piping concept only.

2. Installations must comply with all local codes.

3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

4. Piping shown is Primary/Secondary.

5. Reference Multiple Boiler Manifold Piping chart, Part 5, Section H.

Basic steps are listed below that will guide the installation of the boiler.

1. Connect the system return marked “Boiler Return”.

2. Connect the system supply marked “Boiler Supply”.

3. Install purge and balance valve or shut off valve and drain on system return to purge air out of each zone.

4. Install a back flow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed make-up water line (15 PSI nominal on the system return). Check temperature and pressure gauge when operating. It should read a minimum pressure of 12 PSI.

6. Install a circulator as shown in piping details (this section). Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instructions for specific information 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 line should be installed to discharge 6” above the drain in the event of pressure relief. The pipe size must be the same size as the relief valve outlet. NEVER BLOCK THE OUTLET OF THE SAFETY RELIEF VALVE.

H. CIRCULATOR SIZING

The boiler heat exchanger does have a pressure drop which must be considered in system design. Refer to the graph in Figure 11 for pressure drop through the boiler heat exchanger.

Figure 11 – Heat Exchanger Pressure Drop Chart

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HTP Mod Con 300 LPHL, Mod Con 850 HL, Mod Con 500 LPHL, Mod Con 850 LP, Mod Con 500 LP Installation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

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