Table of Contents
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Installation
Installation
Manual
Manual
• Installation
• Installation
• Startup
• Startup
• Maintenance
• Maintenance
• Parts
• Parts
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.
n
WARNING
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Table of Contents
Related Manuals for Mod Con 500
Summarization of Contents
Part 1: Product and Safety Information
Special Attention Boxes
Defines terms for hazards and important information.
Definitions
Explains DANGER, WARNING, and CAUTION terms used in the manual.
Part 2: Before You Start
A. What's in the Box
Lists items included with the Mod Con boiler.
B. How Boiler Operates
Explains the Mod/Con condensing technology and its features.
C. Optional Equipment
Lists available optional equipment for the Mod Con Boiler.
Part 3: Prepare Boiler Location
A. Boiler Location Should Be Level
Discusses leveling requirements for proper condensate flow.
B. Installations Must Comply With:
Lists codes and regulations for boiler installation.
C. Before Locating the Boiler
Checks for nearby connections and potential hazards.
D. Clearances for Service Access
Details recommended clearances for maintenance access.
E. Residential Garage Installation
Special precautions for installing boilers in residential garages.
F. Exhaust Vent and Intake Air Vent
Requirements for installing exhaust and intake air vents.
G. Prevent Combustion Air Contamination
How to prevent contaminants from affecting combustion air.
H. When Removing a Boiler from an Existing Common Vent System
Steps for safely removing a boiler from a common vent system.
Part 5: Boiler Piping
A. Relief Valve
Guidelines for connecting discharge piping for the relief valve.
B. General Piping Information
Notes on control module usage and external controls.
C. Backflow Preventer
Specifics on installing a backflow preventer for hydronic installations.
D. System Water Piping Methods
Discusses expansion tank sizing and location.
E. Circulators
Notes on circulator usage and sizing for adequate flow.
F. Hydronic Piping with Circulators, Zone Valves and Multiple Boilers
Describes system design for hydronic piping with multiple components.
G. Boiler Piping Details
Illustrates piping concepts for single and multiple boiler setups.
H. Circulator Sizing
Guidance on sizing circulators considering boiler pressure drop.
I. Fill and Purge Heating System
Steps for filling and purging air from the heating system.
J. Zoning with Zone Valves
How to connect the boiler for zoning with zone valves.
K. Zoning with Circulators
How to connect the boiler for zoning with circulators.
L. Multiple Boilers
Guidelines for connecting multiple boilers in a system.
Part 6: Venting, Combustion Air & Condensate Removal
A. Installing Exhaust Vent and Intake Air Vent
Instructions for installing exhaust and intake air vent systems.
B. General
General installation requirements for venting systems.
C. Approved Materials for Exhaust Vent and Intake Air Vent
Lists approved materials for vent pipes.
D. Exhaust Vent and Intake Air Vent Pipe Location
Guidance on proper placement of vent terminals.
E. Exhaust Vent and Intake Air Vent Sizing
How to size exhaust and intake air vent pipes.
F. Longer Vent Runs
Considerations for extending vent runs and using transitions.
G. Exhaust Vent and Intake Air Pipe Installation
Proper installation procedures for vent pipes.
H. Heater Removal from a Common Vent System
Steps for safely removing a boiler from a common vent system.
I. Diagrams for Sidewall Venting
Illustrations of sidewall venting configurations.
J. Diagram for Vertical Venting
Illustration of vertical venting configuration.
Part 7: Gas Piping
A. Gas Connection
Requirements for connecting the gas supply to the boiler.
B. Gas Piping
Guidelines for running and supporting gas supply lines.
D. Check Inlet Gas Pressure
Steps to measure and verify inlet gas pressure.
E. Dungs Gas Valve
Details on the Dungs gas valve for Mod Con boilers.
Part 8: Field Wiring
A. Installation Must Comply With:
Lists electrical codes and regulations to follow.
B. Field Wiring
Overview of field wiring connections inside the junction box.
C. Line Voltage Wiring for Standard Boiler
How to connect incoming power and pump wiring.
D. Alarm Connections
How to connect an alarm output for lockout conditions.
E. Low Voltage Connections for Standard Boiler
How to route and connect low voltage wiring.
F. Thermostat
Instructions for connecting the room thermostat.
G. Outdoor Sensor
How to connect and install the outdoor sensor.
H. Indirect Sensor
How to connect the indirect water heater tank sensor.
I. Optional 0-10 Volt Building Control Signal
Connecting a signal from a building management system.
J. Optional High Gas Pressure Switch
Installing an optional high gas pressure switch.
K. Optional Low Gas Pressure Switch
Installing an optional low gas pressure switch.
L. Optional UL353 Low Water Cutoff Switch
Installing an optional low water cutoff switch.
M. Wiring of Cascade System Communication Bus
How to connect boilers in a cascade system.
Part 9: Start-Up Preparation
A. Check/Control Water Chemistry
Procedures for maintaining proper water pH and hardness.
B. Freeze Protection (When Used)
Guidelines for using freeze protection fluids.
C. Fill and Test Water System
Steps for filling the system with water and checking for leaks.
D. Purge Air from Water System
Methods for removing air from the hydronic system.
E. Check for Gas Leaks
Procedures for detecting gas leaks before startup.
F. Check Thermostat Circuit(s)
Verifying thermostat wiring and operation.
G. Condensate Removal
Proper piping and support for condensate removal.
I. Cascade System
Programming master and follower boilers for cascade operation.
Part 10: Start-Up Procedure
A. Operating Instructions
Initial steps for starting the boiler.
B. Adjusting the Setpoint
How to change the boiler's temperature setpoint.
C. Status Menu
How to view and navigate boiler status parameters.
D. Test Mode
Using test mode for gas valve adjustment.
Part 11: Start-Up Procedures for the Installer
A. Programming for the Installer
Setting system limits and heat curves.
B. Program Access
How to access the installer programming menu.
C. Program Navigation
How to navigate through programming functions.
Part 12: Troubleshooting
A. Mod Con Error Code
Understanding error codes displayed by the boiler.
B. Boiler Error
How error codes are displayed and what they mean.
C. Boiler Fault
Identifying and correcting fault conditions.
Part 13: Maintenance
A. Maintenance Procedures
Guidelines for annual boiler inspection and maintenance.
B. Combustion Chamber Coil Cleaning Instructions for Mod Con 300/500 Only
Steps for cleaning the combustion chamber coils.
Additional Installation Requirements for the Commonwealth of Massachusetts
5.08: Modifications to NFPA-54, Chapter 10
Specific modifications to NFPA-54 for Massachusetts installations.
1. Installation of Carbon Monoxide Detectors
Requirements for installing CO detectors in Massachusetts.
2. Approved Carbon Monoxide Detectors
Standards for approved carbon monoxide detectors.
3. Signage
Signage requirements for exhaust vent terminals.
4. Inspection
Inspector's role in verifying CO detectors and signage.
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