Mod Con 850 Installation Manual
  1. Manuals
  2. Brands
  3. Mod Con Manuals
  4. Boiler
  5. 850
  6. Installation manual

Mod Con 850 Installation Manual

Gas-fired boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 850 and is the answer not in the manual?

Questions and answers

Related Manuals for Mod Con 850

Summary of Contents for Mod Con 850

  • Page 1 Installation Installation Manual Manual • Installation • Installation • Startup • Startup • Maintenance • Maintenance • Parts • Parts 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.
  • Page 2 Boiler Manual GAS-FIRED BOILER 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.

  • Page 3: Table Of Contents

    Boiler Manual GAS-FIRED BOILER CONTENTS Part 1 – Product and Safety Information........4-6 Part 2 –...
  • Page 4 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...

  • Page 5: Part 1: Product And Safety Information

    Boiler Manual GAS-FIRED BOILER PART 1: PRODUCT AND SAFETY INFORMATION SPECIAL ATTENTION BOXES The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the product. DEFINITIONS DANGER CAUTION...
  • Page 6 Due to the low water content of the boiler, mis- Installer — Read all instructions in this manual, sizing of the boiler with regard to the heating and Mod Con Venting section, before installing. system load will result in excessive boiler Perform steps in the order given.

  • Page 7: Part 2: Before You Start

    PART 2: BEFORE YOU START change by internal or external signals which A. WHAT’S IN THE BOX enhance the overall performance of the Also included with the Mod Con are: system. 3. Control – The integrated control system • Pressure and Temperature Gauge monitors the system and regulates the fan •...

  • Page 8: Optional Equipment

    • Boiler Caster Kit (Part # 7350P-404) and pressure. • Mod Con Condensate Neutralizer (Part # 7350P-611) 12. Electrical field connections with terminal strips – The electrical cover allows easy These additional options may be purchased access to the line voltage and low voltage through your HTP Distributor.
  • Page 9 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.
  • Page 10 Boiler Manual GAS-FIRED BOILER DIMENSIONS Figure 2-1 LP-205-C Rev. 5/6/08...

  • Page 11: Installations Must Comply With

    Failure to comply with the above warnings could water during operation or service. 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: •...

  • Page 12: Residential Garage Installation

    E. RESIDENTIAL GARAGE INSTALLATION G. PREVENT COMBUSTION AIR CONTAMINATION Precautions Install intake air piping for the Mod Con Boiler as Take the following special precautions when described in the Venting section. Do not termi- installing the boiler in a residential garage. If the...

  • Page 13: When Removing A Boiler From An Existing Common Vent System

    Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will Do not install the Mod Con Boiler into a common operate at maximum speed. Do not operate vent with any other appliance. This will cause a summer exhaust fan.

  • Page 14: Part 5: Boiler Piping

    You must have at least two individuals to handle the boiler properly to avoid damage as care should be taken as the Mod Con is very heavy. The Mod Con is also equipped with leveling feet that can be used to level the boiler properly if the surface location is not level.

  • Page 15: General Piping Information

    This type of failure is NOT ZONE VALVES AND MULTIPLE BOILERS covered by warranty. The Mod Con Boiler is designed to function in a 2. The expansion tank must be located as closed loop Hydronic System. We have also in-...
  • Page 16 Mod Con Boiler. It is control valves or other devices must be installed to important to note that the Mod Con Boiler has a prevent gravity circulation of boiler water in the minimal amount of pressure drop and must be cal- coils during the cooling cycle.

  • Page 17: Boiler Piping Details

    PART 5: BOILER PIPING (CONTINUED) G. BOILER PIPING DETAILS Single Mod Con Boiler Space Heating with Indirect Priority 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 .
  • Page 18 Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) Cascade Multiple Mod Con Boilers with Indirect Priority on One Boiler 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 .
  • Page 19 Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) Single Mod Con Boiler Space Heating 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.
  • Page 20 Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) Cascade Mod Con Boilers Space Heating Only 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 .

  • Page 21: Circulator Sizing

    CAUTION 7. Install an Expansion Tank on the system The Mod Con Boiler should not be operated as supply. Consult the tank manufacturer’s a potable Hot Water Heater. It should not be instruction for specific information relating to used as a direct Hot Water Heating Device.
  • Page 22 MODCON 300 MODCON 500 MODCON 850 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...
  • Page 23 Combined Boiler Water Flow (GPM) Figure 5-2 MULTIPLE BOILER MANIFOLD PIPING Flow rate 30 90 100 120 150 170 180 200 210 240 250 255 300 340 350 400 425 510 595 680 Pipe Dia. 2” 2½” 2½” 3” 3”...

  • Page 24: J Zoning With Zone Valves

    Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) CAUTION CAUTION For installation that incorporates standing iron It is highly recommended that you carefully radiation and systems with manual vents at the follow the glycol manufacturer’s recommended high points. Follow previous section and concentrations, expansion requirements and starting with the nearest manual air vent, open maintenance recommendations (pH additive...

  • Page 25: Part 6: Venting, Combustion Air & Condensate Removal

    Failure to do so could result DANGER in severe personal injury, death or substantial property damage. The Mod Con Boiler must be vented as detailed in this section. Ensure the exhaust and intake piping comply with these instructions regarding REQUIREMENTS FOR INSTALLATION the venting system.
  • Page 26 "B" GAS VENT U.L. LISTED U.L. LISTED GALVANIZED U.L. LISTED U.L. LISTED Table 6-7 APPROVED STAINLESS STEEL VENT ADAPTERS AND TERMINATIONS Mod Con 300 & 500 HTP PART NUMBER Z-FLEX PART NUMBER Boiler Adapter 4" 7250P-732 2SVSMK04 Horizontal Vent Terminal 4" 7350P-607 2SVSRTF04 Rain Cap 4"...

  • Page 27: Exhaust Vent And Intake Air Vent Pipe Location

    Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) removal may be necessary to maintain WARNING clearance. You must not use “B” Vent in an exhaust • Provide 4 feet horizontal clearance from application. ‘B’ vent is for intake applications electrical meters, gas meters, gas only.
  • Page 28 Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) Products recommends neutralizing the CAUTION condensate with a Condensate Neutralizer Kit (p/n 7350P-611) that can be added to your It is very important that the condensate piping system to avoid long term damage to the be no smaller than ¾”...
  • Page 29 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.
  • Page 30 Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Fig. 6-3 Multiple Vents Fig. 6-4 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot.

  • Page 31: Exhaust Vent And Intake Air Vent Sizing

    1. The exhaust vent and intake air vent pipes of both exhaust vent and intake air vent pipe are 4" for the Mod Con 300 and 500, and 6" equally. However, the transitions should for the Mod Con 850.

  • Page 32: Heater Removal From A Common Vent System

    Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) 4. Horizontal lengths of exhaust vent must slope 2. Visually inspect the venting system for proper back towards the boiler not less than ¼" per size and horizontal pitch to determine if there foot to allow condensate to drain from the is blockage, leakage, corrosion or other defi- vent pipe.

  • Page 33: Diagrams For Sidewall Venting

    Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) I. DIAGRAMS FOR SIDEWALL VENTING SIDEWALL VENTING W/TEE (INTAKE) SIDEWALL VENTING WITH KIT AND COUPLING (EXHAUST) Figure 6-9 Figure 6-10 LP-205-E Rev. 5/15/08 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"...

  • Page 34: Diagram For Vertical Venting

    Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) J. DIAGRAM FOR VERTICAL VENTING ROOF VENT WITH TEE (INTAKE) AND COUPLING (EXHAUST) 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.
  • Page 35 Boiler Manual GAS-FIRED BOILER PART 6: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) Figure 6-12 LP-205-Y Rev. 5/28/08 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.

  • Page 36: Part 7: Gas Piping

    NOTICE The gas connection on the Mod Con is 1-1/4” for the Mod Con 300, 1-1/2” for the Mod Con 500 CSA or UL listed Flexible gas connections can and 2” for the Mod Con 850. It is mandatory that be used when installing The Mod Con Boiler.

  • Page 37: Gas Piping

    5 Boilers 6 Boilers 7 Boilers 8 Boilers Cubic Ft. Hr. 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”...

  • Page 38: Dungs Gas Valve

    10 feet from NEW LP installations and also in empty tank sit- the Mod Con. It is very important that the gas uations. This can also occur when a utility com-...
  • Page 39 Boiler Manual GAS-FIRED BOILER PART 7: GAS PIPING (CONTINUED) MOD CON 500 GAS VALVE THROTTLE ADJUSTER GAS PRESSURE NOTE: IF FOR ANY REASON THE THROTTLE SWITCH BLOCK NEEDS TO BE ADJUSTED, IT IS VERY IMPORTANT THAT A "COMBUSTION ANALYZER" BE USED TO ENSURE SAFE AND PROPER OPERATION.
  • Page 40 Boiler Manual GAS-FIRED BOILER PART 7: GAS PIPING (CONTINUED) MOD CON 850 GAS VALVE 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.

  • Page 41: Part 8: Field Wiring

    120 volts supplied, an external motor starter or MOD CON 500 and MOD CON 850 units and on contactor will be required. the right side of MOD CON 300 units. Multiple knockout locations are available to route field D.

  • Page 42: Low Voltage Connections For Standard Boiler

    Boiler Manual GAS-FIRED BOILER PART 8: FIELD WIRING (CONTINUED) mode and the other light will be on when the boiler is in lockout mode. E. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER 1. All low voltage cables should enter the electrical junction box through the provided knock out holes as shown below.

  • Page 43: Thermostat

    2. Mount the thermostat on an inside wall as electrical junction box (shown in figure 8-1) central as possible to the area being heated, Alternately, any dry contact closure across but away from drafts or heat producing these terminals will cause the MOD CON unit...

  • Page 44: Outdoor Sensor

    When the signal is between 0 and 1 SEN (shown in Figure 8-1) in the electrical volt, the MOD CON Boiler will be in stand by junction box. Caution should be used to mode, not firing. When the signal rises above ensure neither of these terminals become 1 volt, the MOD CON Boiler will ignite.

  • Page 45: Optional Low Gas Pressure Switch

    Boiler Manual GAS-FIRED BOILER PART 8: FIELD WIRING (CONTINUED) connected to a gas pressure switch, remove K. OPTIONAL LOW GAS PRESSURE the jumper plug from the end of the pigtail SWITCH and place the jumper plug into the mating connector coming from the LWCO control 1.
  • Page 46 Boiler Manual GAS-FIRED BOILER PART 8: FIELD WIRING (CONTINUED) 4. Connect the boilers in a daisy chain are interchangeable so you can use either configuration as shown below. It is best to one or both in any order to connect the cable wire the boilers using the shortest wire runs to.
  • Page 47 Standard Mod Con Control Fig. 8-3 LP-205-JJ1 Rev. 5/12/08 5. Connect the boiler pump to the terminals MOD CON CASCADE MASTER PUMP AND marked BOILER HOT, BOILER NEUT, and SENSOR WIRING BOILER GND 1. Place the Cascade Master Overlay Sticker 6.
  • Page 48 MOD CON Cascade Follower Fig. 8-4 LP-205-JJ1 Rev. 5/12/08 To connect an alarm device, connect the power MOD CON CASCADE FOLLOWER PUMP for the device to the ALARM COM terminal. AND SENSOR WIRING Connect the alarm device hot wire to the ALARM NO terminal.
  • Page 49 Boiler Manual GAS-FIRED BOILER PART 8: FIELD WIRING (CONTINUED) Fig. 8-3 LP-205-X Rev. 3/30/08...

  • Page 50: Part 9. Start-Up Preparation

    Boiler Manual GAS-FIRED BOILER PART 9. START-UP PREPARATION ically due to degradation of inhibitors over time. A. CHECK/CONTROL WATER CHEMISTRY Follow all fluid manufacturer’s instructions. WARNING B. FREEZE PROTECTION (WHEN USED) Do not use petroleum-based cleaning or sealing WARNING compounds in boiler system. Damage to elastomer seals and gaskets in system could NEVER use automotive or standard glycol occur, resulting in substantial property damage.

  • Page 51: Purge Air From Water System

    Boiler Manual GAS-FIRED BOILER PART 9. START-UP PREPARATION (CONTINUED) perature of the water in the boiler. Press WARNING the { S 1/-} and { S 3} keys simultaneously and Eliminate all system leaks. Continual fresh hold for 1 second. The Display will begin make-up water will reduce boiler life.

  • Page 52: Check Thermostat Circuit(S)

    Products, Inc. (P/N S7350-025) Propane boilers only — Your propane supplier 2. The Mod Con Boiler is equipped with a ¾ FPT mixes an odorant with the propane to make its connection that must be piped to a local drain.

  • Page 53: Part 10. Start-Up Procedure

    • Do not touch any electric switch; do not water. use any phone in your building. 5. The Mod Con Boiler shall be installed so the • Immediately call your gas supplier from a gas ignition system components are neighbor's phone. Follow the gas protected from water (dripping, spraying, suppliers' instructions.

  • Page 54: Operating Instructions

    Changes are directly stored and the display (located on the left for the Mod Con 500 and returns to normal mode after one minute. on the right for the Mod Con 850). You will also see a yellow LED illuminated under the C.

  • Page 55: Test Mode

    This function is intended to simplify the gas valve adjustment if needed. Listed below are the rec- d14 — Total Domestic Hot Water Hours in ommended limits on each Mod Con Boiler and the Thousands (display will not read until 100 hrs) Combustion Settings. Automatic modulation does...

  • Page 56: Programming For The Installer

    Description This section allows the installer to set system Not Applicable limits and the heat curve for the Mod Con Boiler. 149ºF Not Applicable These system limits should not be changed by the user. It is important to document your set- 180˚...
  • Page 57 Allows the installer to set the con- 68º F Allows the installer to set the low- trol to display |FOU| error. If out- est temperature on the Mod Con door sensor is open or shorted for Central Heating. Range: 32ºF |FOU| error does not prevent boil- to 200ºF...
  • Page 58 Boiler Manual GAS-FIRED BOILER PART 11: START-UP PROCEDURES FOR THE INSTALLER (CONTINUED) 1. Minimum outside design temperature: 3. Maximum outside design temperature: Function 8 Function 10 2. Design Supply water temperature at the 4. Design Supply water temperature at the minimum design outside temperature: maximum outside temperature: Function 11 Function 9...

  • Page 59: Part 12: Troubleshooting

    Boiler Manual GAS-FIRED BOILER PART 12: TROUBLESHOOTING A. MOD CON ERROR CODE WARNING If any of the sensors detect an abnormal condi- When servicing or replacing any components of this boiler be certain that: tion or an internal component fails during the •...
  • Page 60 Boiler Manual GAS-FIRED BOILER PART 12: TROUBLESHOOTING (CONTINUED) Table 12-1 : 926 Control Board ERROR Codes Code Description Corrective Action Outside sensor shorted or Inspect wiring from outside sensor for damage or shorted connections repairing as necessary. temperature less than -40 Measure resistance of outdoor sensor and compare to resistance chart.
  • Page 61 Boiler Manual GAS-FIRED BOILER PART 12: TROUBLESHOOTING (CONTINUED) Table 12-2: 926 Control Board FAULT Codes Code Description Remedy 1. Check circulation pump operation 2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the return thermister to the supply thermister.

  • Page 62: Part 13: Maintenance

    Boiler Manual GAS-FIRED BOILER PART 12: TROUBLESHOOTING (CONTINUED) Resistance Tables System Sensor 7250P-324 Outdoor Sensor (7250P-319) Indirect Sensor Outside Temperature (°F) Resistance (ohms) Boiler Sensor (7250P-667) (72 50P-325) –22 171800 Water Temperature (°F) Resistance (ohms) –13 129800 32550 –4 98930 25340 76020 19870...

  • Page 63: Combustion Chamber Coil Cleaning Instructions For Mod Con 300/500 Only

    “CLR” (available at most hardware stores) – Gloves, eye protection 1. Shut down the Mod Con Boiler by using the fol- lowing steps: a. Close the gas valve, shut down the unit and wait for the unit to be cool to the...
  • Page 64 Turn the gas back on. (IMPORTANT: CHECK FOR GAS LEAKS) g. Turn the Mod Con Boiler power back on and create a demand on the boiler. When boiler is lit, observe condensate flow from the boiler. Be sure the boiler is oper- ating properly.
  • Page 65 Boiler Manual GAS-FIRED BOILER PART 13: MAINTENANCE (CONTINUED) LP-205-A Fig. 13-1 REV. 5/6/08...
  • Page 66 Boiler Manual GAS-FIRED BOILER PART 13: MAINTENANCE (CONTINUED) LP-205-V Fig. 13-2 REV. 5/16/08...
  • Page 67 Boiler Manual GAS-FIRED BOILER PART 13: MAINTENANCE (CONTINUED) LP-205-S Fig. 13-3 REV. 5/12/08...
  • Page 68 Boiler Manual GAS-FIRED BOILER PART 13: MAINTENANCE (CONTINUED) LP-205-H Fig. 13-4 REV. 5/12/08...
  • Page 69 Boiler Manual GAS-FIRED BOILER PART 13: MAINTENANCE (CONTINUED) LP-205-B Fig. 13-5 REV. 5/20/08...
  • Page 70 Boiler Manual GAS-FIRED BOILER...
  • Page 71 Boiler Manual GAS-FIRED BOILER...
  • Page 72 Boiler Manual GAS-FIRED BOILER...
  • Page 73 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 74 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.
  • Page 75 MAINTENANCE NOTES...
  • Page 76 © 2008 Heat Transfer Products, Inc. www.HTproducts.com LP-205 REV. 5/16/08...

Table of Contents