Professional Documents
Culture Documents
Manual
• Installation
• Startup
• Maintenance
• Parts
n WARNING
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
severe personal injury, death or substantial property damage.
NOTICE
Heat Transfer Products, Inc., reserves the right to make product changes or updates without
notice and will not be held liable for typographical errors in literature.
GAS-FIRED BOILER Boiler Manual
WARNING
If the information in this manual is not followed Do not store or use gasoline or other flammable
exactly, a fire or explosion may result causing vapors and liquids in the vicinity of this or any
property damage, personal injury or loss of life. other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance. gas supplier's instructions.
• Do not touch any electrical switch: • If you cannot reach your gas
do not use any phone in your supplier, call the fire department.
building. Installation and service must be
• Immediately call your gas supplier performed by a qualified installer,
from a neighbor's phone. Follow the service agency or the gas supplier.
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GAS-FIRED BOILER Boiler Manual
CONTENTS
Part 1 – Product and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Part 2 – Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
A. What’s In The Box
B. How The Boiler Operates
C. Optional Equipment
Part 3 – Prepare Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
A. Boiler Location Should Be Level
B. Installations Must Comply With:
C. Before Locating Boiler
D. Clearances for Service Access
E. Residential Garage Installation
F. Exhaust Vent and Intake Air Vent
G. Prevent Combustion Air Contamination
H. When Removing a Boiler from an Existing Common Vent System
Part 4 – Prepare Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Part 5 – Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
A. Relief Valve
B. General Piping Information
C. Backflow Preventer
D. System Water Piping Methods
E. Circulators
F. Hydronic Piping with Circulators, Zone Valves and Multiple Boilers
G. Boiler Piping Details
H. Circulator Sizing
I. Fill and Purge Heating System
J Zoning with Zone Valves
K. Zoning with Circulators
L. Multiple Boilers
Part 6 – Venting, Combustion Air & Condensate Removal . . . . . . . . . . . . . . . . . . . . . 24-34
A. Installing Exhaust Vent and Intake Air Vent
B. General
C. Approved Materials for Exhaust Vent and Intake Air Vent
D. Exhaust Vent and Intake Air Vent Pipe Location
E. Exhaust Vent and Intake Air Vent Sizing
F. Longer Vent Runs
G. Exhaust Vent and Intake Air Pipe Installation
H. Heater Removal from a Common Vent System
I. Diagrams for Sidewall Venting
J. Diagram for Vertical Venting
Part 7 – Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-39
A. Gas Connection
B. Gas Piping
C. Gas Table
D. Check Inlet Gas Pressure
E. Dungs Gas Valve
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GAS-FIRED BOILER Boiler Manual
CONTENTS (CONT’D)
Part 8 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
A. Installation Must Comply With
B. Field Wiring
C. Line Voltage Wiring for Standard Boiler
D. Alarm Connections
E. Low Voltage Connections for Standard Boiler
F. Thermostat
G. Outdoor Sensor
H. Indirect Sensor
I. Optional 0-10 Volt Building Control Signal
J. Optional High Gas Pressure Switch
K. Optional Low Gas Pressure Switch
L. Optional UL353 Low Water Cutoff Switch
M. Wiring of Cascade System Communication Bus
Part 9 – Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-52
A. Check/Control Water Chemistry
B. Freeze Protection (when used)
C. Fill and Test Water System
D. Purge Air from Water System
E. Check for Gas Leaks
F. Check Thermostat Circuit(s)
G. Condensate Removal
H. Final Checks Before Starting Boiler
I. Cascade System
Part 10 – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-54
A. Operating Instructions
B. Adjusting the Set Point
C. Status Menu
D. Test Mode
Part 11 – Start-Up Procedures for the Installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57
A. Programming for the Installer
B. Program Access
C. Program Navigation
Part 12 – Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-61
A. Mod Con Error Code
B. Boiler Error
C. Boiler Fault
Part 13 – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-71
A. Maintenance Procedures
B. Combustion Chamber Coil Cleaning Instructions for Mod Con 300/500 Only
Inspection and Maintenance Start-Up Charts
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GAS-FIRED BOILER Boiler Manual
DEFINITIONS
n DANGER n CAUTION
DANGER indicates an imminently hazardous CAUTION Indicates a potentially hazardous
situation which, if not avoided, will result in situation which, if not avoided, may result in
death or serious injury. minor or moderate injury.
n WARNING CAUTION
WARNING indicates a potentially hazardous CAUTION used without the safety alert symbol
situation which, if not avoided, could result in indicates a potentially hazardous situation which,
death or serious injury. if not avoided, may result in property damage.
This appliance must be installed by qualified and licensed personnel in accordance with
local codes, or in the absence of local codes, by the national fuel gas code, ANSI Z223.1-
2002. This appliance is for indoor installations only. Clearance to combusitble 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. For
installation on combustible flooring directly. Category IV vent systems only.
4
GAS-FIRED BOILER Boiler Manual
5
GAS-FIRED BOILER Boiler Manual
CAUTION
Consider piping and installation when
determining boiler location.
6
GAS-FIRED BOILER Boiler Manual
7
GAS-FIRED BOILER Boiler Manual
n CAUTION
When preparing the boiler location, make sure the area where you are placing the boiler is level. In order
for the condensate properly to flow out of the collection system, the boiler must be level to assure proper
flow direction. The Mod Con Boiler comes equipped with leveling feet. Should you find the floor beneath
the boiler is uneven, with a wrench, adjust the leveling feet.
INCORRECT CORRECT
INCORRECT CORRECT
8
GAS-FIRED BOILER Boiler Manual
DIMENSIONS
&2/':$7(5
,1/(7
.
$
% ) * -
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9
GAS-FIRED BOILER Boiler Manual
n WARNING n WARNING
Failure to keep boiler area clear and free of The space must be provided with combus-
combustible materials, gasoline and other tion/ventilation air openings correctly sized for
flammable liquids and vapors can result in all other appliances located in the same space as
severe personal injury, death or substantial the Mod Con Boiler. The boiler cover must be se-
property damage. curely fastened to the boiler to prevent the boil-
er from drawing air from inside the boiler room.
3. T h e M o d C o n G a s C o n t r o l S y s t e m This is particularly important if the boiler is lo-
components must be protected from dripping cated in the same room as other appliances.
water during operation or service. Failure to comply with the above warnings could
result in severe personal injury, death or sub-
4. If the Mod Con Boiler is to replace an existing stantial property damage.
boiler, check for and correct any existing
system problems such as:
• System leaks.
10
GAS-FIRED BOILER Boiler Manual
11
GAS-FIRED BOILER Boiler Manual
12
GAS-FIRED BOILER Boiler Manual
,16(57%/$&.,5213,3(:,7+7((6
25/,)7,1*675$36
,172/,)7,1*5,1*63529,'('
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n WARNING
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 valve discharge.
• Discharge line must be as short as possible and be 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
where any discharge will be clearly visible.
• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of
375 °F or greater.
• Do not pipe the discharge to any place where freezing could occur.
• No shutoff valve shall 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 valve after filling and pressurizing 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.
• Failure to comply with the above guidelines could result in failure of the relief valve to operate,
resulting in possibility of severe personal injury, death or substantial property damage.
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GAS-FIRED BOILER Boiler Manual
CAUTION n CAUTION
All piping methods shown in this manual use DO NOT install automatic air vents on closed-
primary/secondary connection to the boiler loop. type expansion tank systems. Air must remain
This is to avoid the possibility of inadequate flow in the system and return to the tank to provide
through the boiler. For other piping methods, its air cushion. An automatic air vent would
consult your local Heat Transfer Products cause air to leave system, resulting in water-
representative or refer to separate Mod Con logging the expansion tank.
Boiler piping details in this manual (Part 5).
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GAS-FIRED BOILER Boiler Manual
15
GAS-FIRED BOILER Boiler Manual
%$//9$/9(
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NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. Piping shown is Primary/Secondary
5. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
LP-205-L Rev. 5/14/08
16
GAS-FIRED BOILER Boiler Manual
%$//9$/9( 3,3(',$0(7(5
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NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
4. Piping shown is Primary/Secondary
5. Reference Figure 5-2 to determine manifold pipe sizing.
6. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
17
GAS-FIRED BOILER Boiler Manual
%$//9$/9( 3,3(',$0(7(5
7<3,&$/ 63$&,1*0$;,080
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9$/9(
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9$/9(
NOTES:
1. This drawing is meant to show system piping concept only.
2. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
3. Piping shown is Primary/Secondary
6. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
18
GAS-FIRED BOILER Boiler Manual
%$//9$/9(
7<3,&$/ 3,3(',$0(7(5
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*$8*( 35(6685(5(/,()
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NOTES:
1. This drawing is meant to show system piping concept only.
2. An Anti-Scald mixing valve is recommended if the DHW temperature is set above the factory setting
of 119°F.
3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.
6. System Flow (Secondary Loop) must be greater than the boiler’s primary loop flow.
19
GAS-FIRED BOILER Boiler Manual
20
GAS-FIRED BOILER Boiler Manual
90
80
70
60
FLOW OF GPM
50
40
30
20
10
0
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
FRICTION IN FEET OF HEAD
Figure 5-1
The chart below represents the various system design temperature rise through the Mod Con along
with their respective flows and friction loss which will aid in circulator selection.
SYSTEM TEMPERATURE RISE CHART
20°Δt 25°Δt 30°Δt 35°Δt 40°Δt 45°Δt
Friction Flow Friction Flow Friction Flow Friction Flow Friction Flow Friction Flow
Model Feet GPM Feet GPM Feet GPM Feet GPM Feet GPM Feet GPM
Mod Con 300 19’ 30 12’ 24 9’ 20 7’ 17 6’ 15 5’ 14
Mod Con 500 19’ 50 11’ 40 8’ 33 6’ 28 5’ 25 4’ 23
Mod Con 850 35’ 85 26’ 65 18’ 54 12’ 45 10’ 40 8’ 36
LP-205-E Rev. 12/5/07
21
GAS-FIRED BOILER Boiler Manual
Combined
Multiple BoilerBoiler Pipe Sizing
Manifold Piping
7
5
Pipe Diameter Size (Inches)
0
0 100 200 300 400 500 600 700 800
Combined Boiler Water Flow (GPM)
Figure 5-2
I. FILL AND PURGE HEATING SYSTEM • Manually operate fill valve regulator. When
water runs out of the hose, while it’s
• Attach the hose to balance and purge hose connected to the balance and purge valve or
connector or drain valve and run hose to drain you will see a steady stream of water
nearest drain (without bubbles). Close balance and purge
• Close the other side of the balance and purge valve or drain to stop the water from flowing.
valve or the shut off valve after the drain. Disconnect the hose and connect it to next
zone to be purged.
• Open first zone balance and purge or drain
valve to let water flow out the hose. If zone • Repeat this procedure for additional zones
valves are used, open the valves one at a (one at time).
time manually. (Note: You should check valve
manufacturer’s instruction prior to opening
valves manually, so as not to damage the
valve.)
22
GAS-FIRED BOILER Boiler Manual
23
GAS-FIRED BOILER Boiler Manual
24
GAS-FIRED BOILER Boiler Manual
25
GAS-FIRED BOILER Boiler Manual
26
GAS-FIRED BOILER Boiler Manual
27
GAS-FIRED BOILER Boiler Manual
6:($739&7((
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Fig. 6-2 LP-205-W Rev. 5/7/08
CAUTION NOTICE
The condensate line must remain unobstructed, When installing a condensate pump, select one
allowing free flow of condensate. If condensate approved for use with condensing boilers and
is allowed to freeze in the line or if the line is furnaces. The pump should have an overflow
obstructed in any other manor, condensate can switch to prevent property damage from
exit from the boiler tee, resulting in potential condensate spillage.
water damage to property. Condensate from the Mod Con Boiler will be
slightly acidic (typically with a pH from 3.2 to
4.5). Install a neutralizing filter if required by
local codes.
28
GAS-FIRED BOILER Boiler Manual
Fig. 6-5 Multiple Stainless Steel Horizontal Vent Kit Installation – Front View
29
GAS-FIRED BOILER Boiler Manual
30
GAS-FIRED BOILER Boiler Manual
31
GAS-FIRED BOILER Boiler Manual
9(17.,7
6((&+$57
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&283/,1*
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/(9(/25:+,&+(9(5,6*5($7(5&+(&.:,7+/2&$/
&2'(5(48,5(0(176
Figure 6-9 LP-205-E Rev. 5/15/08 Figure 6-10 LP-205-F Rev. 5/15/08
GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the
appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.
32
GAS-FIRED BOILER Boiler Manual
0,1 0,1
7((
29(50$;,080
612:/(9(/25
:+,&+(9(5,6*5($7(5
(;+$867
9(17
5,*+76,'(9,(: (;7(5,25:$//
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9(17
Figure 6-11 LP-205-G Rev. 5/6/08
NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the
appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.
GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
33
GAS-FIRED BOILER Boiler Manual
29(50$;,080
612:/(9(/25
:+,&+(9(5,6*5($7(5
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NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the
appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily
accessible for visual inspection for the first three feet from the boiler.
GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
34
GAS-FIRED BOILER Boiler Manual
35
GAS-FIRED BOILER Boiler Manual
Refer to Table 7-1 to size the supply piping to Maximum Capacity of Pipe in Cubic Feet of Gas
minimize pressure drop between meter or per Hour for Gas Pressures of 0.5 w.c. or Less and
regulator and unit. a Pressure Drop of 0.3 Inch w.c.
Table 7-1
NATURAL GAS SUPPLY PIPING CAPACITY CHART
(0.6 specific gravity gas; 0.5” WC pressure drop)
*Schedule 40 iron pipe size in nominal inch size
Boiler Model 1 Boiler 2 Boilers 3 Boilers 4 Boilers 5 Boilers 6 Boilers 7 Boilers 8 Boilers
Cubic Ft. Hr. 300 600 900 1200 1500 1800 2100 2400
ModCon 300 @ 100’ of pipe 1 1/4” 1 1/2” 2” 2 1/2” 2 1/2” 2 1/2” 3” 3”
ModCon 300 @ 250’ of pipe 1 1/2” 2” 2 1/2” 3” 3” 3” 4” 4”
Boiler Model 1 Boiler 2 Boilers 3 Boilers 4 Boilers 5 Boilers 6 Boilers 7 Boilers 8 Boilers
Cubic Ft. Hr. 500 1000 1500 2000 2500 3000 3500 4000
ModCon 500 @ 100’ of pipe 1 1/2” 2” 2 1/2” 3” 3” 3” 4” 4”
ModCon 500 @ 250’ of pipe 2” 2 1/2” 3” 3” 4” 4” 4” 4”
Boiler Model 1 Boiler 2 Boilers 3 Boilers 4 Boilers 5 Boilers 6 Boilers 7 Boilers 8 Boilers
Cubic Ft. Hr. 850 1700 2550 3400 4250 5100 5950 6800
ModCon 850 @ 100’ of pipe 2” 2 1/2” 3” 4” 4” 4” 4” 5”
ModCon 850 @ 250’ of pipe 2 1/2” 3” 4” 4” 5” 5” 5” 5”
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GAS-FIRED BOILER Boiler Manual
THROTTLE ADJUSTER
NOTE: IF FOR ANY REASON THE THROTTLE
NEEDS TO BE ADJUSTED, IT IS VERY IMPORTANT
THAT A "COMBUSTION ANALYZER" BE USED TO
GAS OUTLET ENSURE SAFE AND PROPER OPERATION.
TURN THE ADJUSTER TO THE (+) TO INCREASE
THE GAS OR (-) TO DECREASE THE GAS SUPPLY.
THIS ADJUSTMENT COULD AFFECT CO/CO%
GAS OUTLET LEVELS. MAKE SURE THE LEVELS CORRESPOND
TO THE CHART IN COMBUSTION SETTINGS.
PRESSURE TAP (FIG. 10-1)
DETAIL A
SCALE 2 : 3
A
OFFSET ADJUSMENT
GAS VALVE CAUTION: DO NOT REMOVE THIS SCREW
OR ATTEMPT TO MAKE ANY ADJUSTMENT TO
THIS SCREW WITHOUT A COMBUSTION
ANALYZER
GAS INLET
PRESSURE TAP
GAS INLET
GAS SHUT-OFF
VALVE
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GAS-FIRED BOILER Boiler Manual
GAS INLET
PRESSURE TAP GAS PRESSURE
SWITCH BLOCK
GAS INLET
GAS SHUT-OFF
VALVE
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GAS-FIRED BOILER Boiler Manual
THROTTLE ADJUSTER
NOTE: IF FOR ANY REASON THE THROTTLE NEEDS TO BE
ADJUSTED, IT IS VERY IMPORTANT THAT A COMBUSTION
ANALYZER BE USED TO ENSURE SAFE AND PROPER
OPERATION. TURN THE ADJUSTER TO THE (+) TO INCREASE
GAS SUPPLY OR TO THE (-) TO DECREASE GAS SUPPLY.
THIS ADJUSTMENT COULD AFFECT CO/CO% LEVELS.
MAKE SURE THE LEVELS CORRESPOND TO THE CHART IN THE
COMBUSTION SETTINGS SECTION (FIG. 10-1)
DETAIL A
SCALE 2:1.5
GAS VALVE
GAS PRESSURE
SWITCH BLOCK
INTERMEDIATE
PRESSURE TAP
GAS SHUT OFF
VALVE GAS PRESSURE
SWITCH BLOCK
OFFSET ADJUSTMENT
CAUTION: DO NOT REMOVE THIS SCREW OR ATTEMPT TO
DETAIL B MAKE ANY ADJUSTMENT TO THIS SCREW WITHOUT USING
A COMBUSTION ANALYZER.
SCALE 2:1.5
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GAS-FIRED BOILER Boiler Manual
UNUSED COMMUNICATION
B JACK AVAILABLE TO
CONNECT TO VISION 2.
UNUSED COMMUNICATION
BUS JACK AVAILABLE TO
CONNECT TO VISION 2.
45
GAS-FIRED BOILER Boiler Manual
NOTE:
You must place the
Cascade Master
label (included in
shipping envelope)
on top of the
Standard Mod Con
Control
MOD CON CASCADE MASTER PUMP AND 5. Connect the boiler pump to the terminals
SENSOR WIRING marked BOILER HOT, BOILER NEUT, and
BOILER GND
1. Place the Cascade Master Overlay Sticker
6. Connect the system pipe sensor to the
(included) onto the field connection board on
terminals marked SYS SENSOR.
the boiler designated as the Cascade Master
Only. 7. Connect the outdoor sensor (if used) to the
terminals marked OUTDR. SEN
2. Connect the system pump hot wire to the
terminal marked SYS PUMP. 8. Connect the signal to start the system to the
terminals marked THERMOSTAT.
3. Connect the system pump neutral to the
BOILER NEUT terminal and the pump ground NOTE: This signal can come from a room
wire to the BOILER GND terminal. thermostat or a dry contact closure. No power of
any voltage should be fed into either of these
4. Connect a jumper wire from the 120 VOLT
terminals.
terminal to the SYS PUMP PWR terminal.
46
GAS-FIRED BOILER Boiler Manual
MOD CON CASCADE FOLLOWER PUMP To connect an alarm device, connect the power
AND SENSOR WIRING for the device to the ALARM COM terminal.
Connect the alarm device hot wire to the
1. Connect the boiler pump to the terminals ALARM NO terminal. Connect the neutral or
labeled BOILER HOT, BOILER NEUT, BOILER return of the alarm device to the neutral or
GND. return of the power for the alarm device.
2. If you are using an indirect fired water tank To connect a device that should be powered off
connected directly to the follower boiler during a boiler lockout condition, follow the
connect the pump for it to the DHW, HOT same instructions as above except use the
DHW NEUT, and DHW GND terminals. ALARM NC terminal rather than the ALARM NO
terminal.
If you desire, an alarm bell or light can be con-
nected to the alarm contacts of the follower boil- Note that in a cascade system the alarm output
er. Optionally the normally closed alarm contact of the Boiler addressed as #1 will also be active
may be used to turn a device off if the boiler if the master boiler has a lockout condition. The
goes into lockout mode. The alarm contacts are alarm output of Boilers addressed as 2-7 will
rated 5 amps at 120 VAC. only sound if a lockout condition occurs on that
specific boiler.
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GAS-FIRED BOILER Boiler Manual
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To start, press down and hold the {S/3} and {S/4} 5 7ºF Allows the installer to change the
simultaneously for three seconds. You will notice differential in the Indirect Fired
that the display will change to |000|. Then, with Water Heater (Does not apply if
your {S1/–} key on the display press down until used with a Mechanical Control)
you see |925|. This is the pass code. To confirm Range: 1ºF to 18ºF
that the pass code is correct, you will need to 6 0 Min. Allows the installer to change
press and hold the {S3/Program} for 1 second to the Indirect Circulator Post Purge
confirm. If the pass code is entered incorrectly,
Time once the sensor is satisfied
the controller program function will be cancelled
and the control returns to normal operation. If the (Note: it is recommend that
code is entered correctly, the control will switch Circulator Post Purge Time be
off the gas valve and purge fan while showing a set no greater than 5 minutes).
solid |---| in the display. The display will than Range: 0 to 10 minutes
show a |1| alternating to |de|. This first function ver- 7 68ºF Outdoor temperature that you
ifies that the control will address the require- wish the central heating should be
ments of the Superstor Indirect Fired Water disabled—(warm weather shut-
Heater.
off) Range: 41ºF to 122ºF
C. PROGRAM NAVIGATION *8 5ºF Allows the installer to change the
Next you will have to press the {S/3} key to move Minimum Outside Design
through each function. To increase or decrease Temperature. Range: –49ºF to
a value, you will need to press either the {S/1-} 32ºF (See Chart 11-1 to set out-
key or {S/2+} key to change the default values. If door reset curve)
there is no key action for 1 minute, the display *9 180ºF Allows the installer to change the
returns to normal operation. Changes are effec- Design Supply Water Temperature
tive immediately but not directly stored until the from the Mod Con based on the
{S/4} key is pressed down for 3 seconds then the Minimum Outside Design
new values are stored. Listed below are the vari- Temperature Range: 77ºF to 200ºF
ety of functions the installer can program into
the 926 Control. *10 68ºF Allows the installer to change the
Maximum Outside Design
CAUTION Temperature for Central Heating.
Range: 95ºF to 32ºF
The Boiler cannot be programmed while
there is a call for heat. *11 95ºF Allows the installer to change the
D e s i g n S u p p l y Wa t e r
NOTE: See Chart 11-1 in Part 11 to set outdoor Temperature from the Mod Con
reset curve. based on the Maximum Outside
Design Temperature. Range: 32ºF
to 200ºF
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GAS-FIRED BOILER Boiler Manual
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GAS-FIRED BOILER Boiler Manual
NOTICE
It is important to note that the user can adjust the heat curve down by adjusting the central heating
temperature to a lower setting.
203 203
201˚
194 194
185 185
158
SUPPLY OUTLET TEMPERATURE (F)
158
DEFAULT RESET CURVE
149 149
131 131
122 122
113 113
104 104
95 95
FUNCTION 11
86 86
77
FUNCTION 10
77
FUNCTION 8
68 68
59 59
50 50
41 41
32 32
0 0
-59 -41 -24 -9 9 27 45 63 81 99 -59 -41 -24 -9 9 27 45 63 81 99
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GAS-FIRED BOILER Boiler Manual
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GAS-FIRED BOILER Boiler Manual
F31 Program Parameter Error Control must be re-programmed. If pgramming does not solve problem, control must be replaced.
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GAS-FIRED BOILER Boiler Manual
02'&21
LP-205-A
Fig. 13-1 REV. 5/6/08
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GAS-FIRED BOILER Boiler Manual
02'&21
LP-205-V
Fig. 13-2 REV. 5/16/08
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GAS-FIRED BOILER Boiler Manual
02'&21
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GAS-FIRED BOILER Boiler Manual
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GAS-FIRED BOILER Boiler Manual
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LP-205-B
Fig. 13-5 REV. 5/20/08
68
69
BOILER START UP REPORT
Light Off Activities Date completed _______________
1) Fill the heating system Check all piping and gas connections, verify they are all tight
2) Check Gas Pipe Leak test using locally approved methods (consult jurisdictional code book)
Check incoming gas pressure (3.5" to 14" W.C.) ____in w.c. Static
What is the "drop" on light off (No more than 1" W.C.) ____in w.c. Dynamic
3) Record Ionization Current Check μA reading at d7 on the status menu (see start-up section) ____ μA High Fire ____ μA Low Fire
5) Check Combustion Check and adjust (if necessary) carbon dioxide content ____% CO2 High Fire ____%CO2 Low Fire
Check and adjust (if necessary) carbon monoxide content ____ppm CO High Fire ____ppm CO Low Fire
6) Record System Settings Record heating curve, record steps ____*8 ____*9 ____*10 ____*11
7) Indirect water heater Verify safety and operation of the Super-Stor Indirect water heater, record setttings ____de ____dh
Notes:
Boiler Manual
BOILER INSPECTION AND MAINTENANCE SCHEDULE
Inspection Activities Date last completed
Piping 1st Year 2nd Year 3rd Year 4th Year*
Near Heater Piping Check heater and system piping for any sign of leakage, verify proper support
Vent Check condition of all vent pipe and joints and supports. Note any deterioration and replace.
Gas Check gas piping, test for gas leaks and signs of aging, make sure all pipes are supported properly.
System
Visual Do a full visual inspection of all system components. Pay close attention to clearances of venting.
GAS-FIRED BOILER
Verify safe settings on Super-Stor indirect fired water heater or Anti-Scald Valve (see part 12 for related
Temperatures
safety warnings)
Temperatures Verify temperature settings programmed into the heating curve (See Part 13)
Electrical
Circuit breakers Check to see that the circuit breaker is clearly labeled, exercise circuit breaker
Switch and Plug Verify ON/OFF switch and convenience plug are both functional
Smoke and CO detector Verify devices are installed and working properly, change batteries if necessary
Chamber and Burner
Combustion Chamber Vacuum Debris from Combustion Chamber if Necessary
Combustion Chamber Check burner tube, and combustion chamber coils, clean according to maintenance section of manual
Spark Electrode Clean with Scotch Brite pad, Set gap at 1/4" (see Fig 14-2 Part 14 in Troubleshooting section)
Clean with Scotch Brite pad, Check flame current in μA (d7 on status menu in Start-up Procedures)
Flame Probe
record high fire (7-9 typical) and low fire (6-8 typical)
Boiler Manual
70
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS.
71
BOILER INSPECTION AND MAINTENANCE SCHEDULE (CONTINUED)
Inspection Activities Date last completed
Condensate Neutralizer Check condensate neutralizer, making sure there is a sufficient quantity. Replenish if necessary.
Disconnect condensate piping, clean out dirt, fill with water to level of outlet and re-install. Remove
Condensate System plug. Clean out, check for potential obstruction issues. (Note: You must verify the flow of condensate,
making sure that the cup is connected properly during final inspection.)
Gas
GAS-FIRED BOILER
Pressure Drop Measure drop in pressure on light off (no more than 1" W.C.)
Check gas pipe for leaks Check piping for leaks, and verify they are all properly supported
Combustion
Check levels of CO and CO2 in Exhaust (See start up section 12 fig 12-1 for ranges) record at high and
Check CO/CO2 Levels
low fire
Safeties
ECO (Energy Cut Out) Check continuity on Flue and Water ECO, replace if corroded
Thermistors Check wiring, verify through ohms reading (see chart part 14 Fig. 14-3)
Final Inspection
Verify that you have completed the entire check list WARNING: FAILURE TO DO SO COULD RESULT IN
Check List
DEATH OR SERIOUS INJURY.
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS. DATE DATE DATE DATE
ADDITIONAL INSTALLATION REQUIREMENTS
FOR THE COMMONWEALTH OF MASSACHUSETTS
Existing chimneys shall be permitted to have their use continued when a gas conversion
burner is installed, and shall be equipped with a manually reset device that will
automatically shut off the gas to the burner in the event of a sustained back-draft.
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
building or structure used in whole or in part for residential purposes, including those owned
or operated by the Commonwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting, including but not limited
to decks and porches, the following requirements shall be satisfied:
a. In the event that the side wall horizontally vented gas fueled equipment is installed
in a crawl space or an attic, the hard wired carbon monoxide detector with alarm
and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be
installed.
72
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the
exterior of the building at a minimum height of eight (8) feet above grade directly in line with
the exhaust vent terminal for the horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW, KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas
fueled equipment shall not approve the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed in accordance with the
provisions of 248 CMR 5.08 (2)(a) 1 through 4.
(b) EXEMPTIONS: the following equipment is exempt from 248 CMR 5.08 (2)(a) 1 through 4:
2. Product Approved side wall horizontally vented gas fueled equipment installed in a
room or structure separate from the dwelling, building or structure used in whole or in
part for residential purposes.
1. Detailed instructions for the installation of the venting system design or the venting
system components; and
2. A complete parts list for the venting system design or venting system.
1. The referenced “special venting system” instructions shall be included with the
appliance or equipment installation instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approval side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion
of the installation.
LP-172
REV. 2/16/06
73
MAINTENANCE NOTES
74
© 2008 Heat Transfer Products, Inc.
www.HTproducts.com LP-205 REV. 5/16/08