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This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing.
Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
120 Braley Rd. P.O. Box 429
Mod Con VWH
East Freetown, MA 02717-0429
INSTALLATION
MAINTENANCE
LP / HL / LPHL
Heat Exchanger Bears the ASME "H" Stamp
www.htproducts.com
LP- 276 REV. 9.4.14
START-UP
PARTS
VWH Models
300 / 500 / 850
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Table of Contents
Related Manuals for HTP VWH300LP
Summary of Contents for HTP VWH300LP
- Page 1 Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
- Page 2 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 •...
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Page 3: For The Installer
In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician. -
Page 4: Table Of Contents
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. The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death. - Page 5 C. SYSTEM WATER PIPING METHODS ............................. 16 D. CIRCULATOR PUMPS ................................16 E. INSTALLATION OF THE FLOW SWITCH ..........................17 F. SCALDING ....................................19 G. HIGH VELOCITY CIRCULATOR PUMP ..........................20 H. WATER CHEMISTRY ................................20 I. PIPING DIAGRAMS ................................... 22 PART 5 –...
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Page 6: Part 1 - General Safety Information
BOILER START-UP REPORT ..............................68 MAINTENANCE REPORT ................................. 68 MAINTENANCE NOTES .................................. 72 HTP CUSTOMER INSTALLATION RECORD FORM........................73 PART 1 – GENERAL SAFETY INFORMATION A. PRECAUTIONS This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Front must have room for service, 24”... -
Page 7: Improper Combustion
FAILURE TO PIPE THE UNIT PROPERLY WILL VOID THE WARRANTY. NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty. PART 2 – BEFORE YOU START VWH units must be connected to a storage tank. - Page 8 VWH Recovery Ratings with Storage Tanks and 40 F Inlet Temperature Mod Con 300 VWH Outlet Recovery Gallons Per First Hour Rating With 80 First Hour Rating With 119 First Hour Rating With 175 Temperature Hour Gallon Gallon Gallon Table 1 – Mod Con 300 VWH Recovery Ratings with Storage Tanks and 40 F Inlet Temperature Mod Con 500 VWH Outlet...
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Page 9: What's In The Box
Mixing factor → M = 140 – 40 = 1.43 First Hour Rating = 1,000,000 x .94 .75 x 160 x 1.43 (140 – 40) x 8.31 First Hour Rating = 940,000 + 120 x 1.43 First Hour Rating = 1,131 + 120 x 1.43 First Hour Rating =... -
Page 10: Optional Equipment
Indirect Tank Sensor (optional) – Monitors storage tank temperature. C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP: • Indirect Tank Sensor (Part # 7250P-325) •... -
Page 11: Leveling And Dimensions
The service life of the boiler’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other boiler components. - Page 12 Figure 2 – Dimensions and Specifications LP- 276 REV. 9.4.14...
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Page 13: Clearances For Service Access
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. Space must be provided with combustion/ventilation air openings correctly sized for all appliances located in the same space as the boiler. -
Page 14: Removing A Boiler From A Common Vent System
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... -
Page 15: Uncrating And Moving Boiler
Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler is designed to be connected to a storage tank to supply domestic hot water. HTP offers 80/119/175 gallon size storage tanks in either Stainless Steel or Glass lined construction. -
Page 16: Relief Valve
B. RELIEF VALVE Connect discharge piping to a safe disposal location according to the following guidelines. 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. •... -
Page 17: Installation Of The Flow Switch
The boiler is designed to be connected to a storage tank to supply domestic hot water. HTP offers storage tanks that are 80/119/175 gallon size storage tanks constructed in either stainless steel or glass-lined construction. These storage tanks connect directly to the boiler supply and return connections. - Page 18 5. Feed green ground wire into boiler through the wire access. 6. From the front of the boiler, feed the ground wire up into the control box. 7. Once into the control box, attach the green ground to the ground bus connection. 8.
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Page 19: Scalding
F. SCALDING APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS More than 5 minutes When raising tank temperature, you increase the risk of 1 ½ to 2 minutes scalding. Please use a water tempering or mixing valve and About 30 seconds extreme caution when raising tank temperature to lessen About 10 seconds the chance of scalds. -
Page 20: High Velocity Circulator Pump
Table 8 – Mod Con Heat Exchanger Pressure Drop G. HIGH VELOCITY CIRCULATOR PUMP Every VWH system requires special attention to pump size in order to overcome the pressure drop through the boiler and its related piping. All circulators installed on the VWH system must be designed for a potable water system. Water temperature above 140 F requires the circulator pump to run continuously and water hardness between 5 and 7 grains. - Page 21 pH of Water pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water pH. The pH scale ranges from 0 to 14. Water with a pH of 7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water pH higher than 7 is considered alkaline.
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Page 22: Piping Diagrams
I. PIPING DIAGRAMS Figure 6 LP- 276 REV. 9.4.14... - Page 23 Figure 7 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3.
- Page 24 Figure 8 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3.
- Page 25 Figure 9 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3.
- Page 26 Figure 10 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3.
- Page 27 Figure 11 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3.
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Page 28: Part 5 - Venting, Combustion Air And Condensate Removal
Figure 12 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Boiler circulator(s) must be rated for open loop applications. Do not use cast-iron circulators. 3. -
Page 29: Approved Materials For Exhaust And Intake Air Vents
1. Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment. 2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes. -
Page 30: Requirements For Installation In Canada
When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the boiler vent connection, and at the termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer. -
Page 31: Exhaust Vent And Intake Air Vent Pipe Location
Figure 13 D. EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION You must insert the provided intake and exhaust screen at your vent termination to prevent blockage caused by debris or birds. NOTE: SEE ADDITIONAL REQUIREMENTS FOR MASSACHUSETTS IN THE BACK OF THIS MANUAL. 1. - Page 32 Condensate from the boiler is slightly acidic with a pH of 3.2 - 4.5. To avoid long term damage to the drainage system and to meet local code requirements, HTP recommends neutralizing the condensate with a Condensate Neutralizer Kit (Part # 7350P-611). The neutralizer kit connects to the drain system and contains marble chips that neutralize the pH level of the water vapor.
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Page 33: Exhaust Vent And Intake Air Vent Sizing
Figure 14 – Condensate Piping NOTE: Blow water into the condensate collector to remove any foreign matter that may block the line. NOTES: 1. Condensate line must be pitched at least 1/4" per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, you must increase the condensate line to a minimum of 1”... -
Page 34: Longer Vent Runs
2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 200 feet. a. The equivalent length of friction loss in elbows, tees, and other fittings are listed in Table 11. FRICTION LOSS EQUIVALENT FOR STAINLESS OR PLASTIC PIPING AND FITTINGS FITTING DESCRIPTION 4”... -
Page 35: Boiler Removal From A Common Vent System
NOTE: For Canadian Installations, it is required that Non Metallic Vent Installations conform to ULC S636. Where plastic venting is not allowed, HTP recommends AL294C Stainless Steel Venting be used for Exhaust venting installations and “B” vent for intake air. -
Page 36: Sidewall Venting Diagrams
I. SIDEWALL VENTING DIAGRAMS Figure 16 – Sidewall Venting Diagrams All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. Exhaust connection insertion depth should be a minimum of 2 ½” for models 300/500 and 3” for 850. When placing support brackets on vent piping, the first bracket must be within 1’... - Page 37 Figure 17 – Sidewall Venting with Tee and Coupling All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. Exhaust connection insertion depth should be a minimum of 2 ½” for models 300/500 and 3” for 850. When placing support brackets on vent piping, the first bracket must be within 1’...
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Page 38: Vertical Venting Diagrams
J. VERTICAL VENTING DIAGRAMS Figure 18 – Two Pipe Roof Venting with Tee and Coupling All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. - Page 39 Figure 19 – Roof and Sidewall Venting with Stainless Steel All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the boiler to allow drainage of condensate. Exhaust connection insertion depth should be a minimum of 2 ½” for models 300/500 and 3” for 850. When placing support brackets on vent piping, the first bracket must be within 1’...
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Page 40: Part 6 - Gas Piping
PART 6 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" w.c. (3.5 kPa), and a minimum of 3.5" w.c. (.87 kPa). The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5"... -
Page 41: Gas Table
Never use an open flame (match or lighter) to check for gas leaks. Use a soapy solution to test connection. Failure to use a soapy solution test or check gas connection for leaks could result in substantial property damage, severe personal injury, or death. Use a two-wrench method when tightening gas piping near the boiler and its piping connection: One wrench to prevent the boiler gas line connection from turning;... -
Page 42: Gas Valve
The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop. The gas meter and regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1" w.c. (.87 kPa), the meter, regulator or gas line may be undersized or in need of service. - Page 43 Figure 22 – Mod Con 850 Gas Valve Do not do a gas conversion on this boiler without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the boiler to fire on Natural or LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.
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Page 44: Part 7 - Field Wiring
PART 7 – FIELD WIRING To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death. -
Page 45: Line Voltage Wiring
use of a pipe sensor will be somewhat less accurate than using a sensor in the tank, and has the disadvantage of requiring the boiler pump(s) to run continuously so the sensor is always measuring the tank water temperature. In a multiple Mod Con VWH installation, where the boilers are connected for cascade operation, a system sensor is needed in addition to the tank or pipe sensor described above. -
Page 46: Low Voltage Connections For Standard Boiler
Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet. -
Page 47: Vwh Cascade Master Pump And Sensor Wiring
Figure 25 – LP-205-JJ Figure 26 – Cascade Resistor Plug Installation Detail M. VWH CASCADE MASTER PUMP AND SENSOR WIRING 1. Place the cascade master overlay sticker onto the field connection board on the boiler designated as the cascade master. 2. -
Page 48: Vwh Cascade Follower Pump And Sensor Wiring
Figure 27 – Mod Con VWH Cascade Master and Follower N. VWH CASCADE FOLLOWER PUMP AND SENSOR WIRING 1. If it is desired to have the boiler control the boiler pump, connect the boiler pump to the BOILER HOT, BOILER NEUT, and BOILER GND terminals. - Page 49 Figure 28 – Mod Con Internal Connection Diagram – LP-255 LP- 276 REV. 9.4.14...
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Page 50: Part 8 - Start-Up Preparation
PART 8 – START-UP PREPARATION A. CHECK / CONTROL WATER CHEMISTRY It is recommended that you test your water quality prior to installation. Listed below are some guidelines. Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. -
Page 51: Check For Gas Leaks
If the condensate outlet on the boiler is lower than the drain, you must use a condensate removal pump, available from HTP (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow, which, if not corrected, could cause property damage. -
Page 52: Setting Up A Cascaded System
When a demand for hot water is received, the control begins the following demand sequence. The boiler first turns on the pump (if it is not wired to run continuously). Once the pump is running, the control will display FL and wait for the water flow in the system to increase to an acceptable level determined by the flow switch on the outside of the boiler. -
Page 53: Part 9 - Start-Up Procedure
d. Verify that parameter 15 is set to 0. This makes the master boiler address 0. NOTE: The Master Boiler MUST be addressed as 0. e. Change parameter 23 from 0 to 1. f. Exit the installer menu. NOTE: The temperature set point of the master must match the follower boiler set point in order for the system to operate properly. 3. -
Page 54: Adjusting The Operating Set Points Of The Vwh Display
pressing on top of the plastic cover over the red reset button. You will note that the yellow LED has gone out. Press and hold the {S4} key on the control panel for 4 seconds to begin normal operation. 4. If the tank water temperature is below the tank set point temperature (tank differential temperature) the boiler will ignite. 5. -
Page 55: Test Mode
|d4| — Not used. |d5| — Not used. |d6| — Actual fan speed multiplied by 10 (Example: If fan speed displayed is |410| RPM x 10 = 4100 actual fan speed) |d7| — Actual ionization current read from flame rectification probe |d8| —... -
Page 56: Part 10 - Start-Up Procedures For The Installer
MOD CON FAN SPEEDS MODEL IGNITION 3000 1250 5500 3000 1250 6930 3000 1500 5400 Table 16 – Fan Speeds PART 10 – START-UP PROCEDURES FOR THE INSTALLER A. PROGRAMMING FOR THE INSTALLER This section describes each parameter the installer can access to customize the settings of the VWH boiler for a particular installation. These system limits should not be changed by the user. -
Page 57: Part 11 - Troubleshooting
Flow switch. Do not change. 0 = none, 1 = water pressure switch, 2 = flow switch, 3 = low water cut-off N/A (no change required) This parameter can be adjusted to lower the maximum boiler output. Default = 100%. 100% Ex: 500 boiler setting at 80% will go to 400,000 BTU/hr max rather than 500,000 BTU/hr. -
Page 58: Boiler Fault
1. Check line voltage. Must be between 100 – 128 volts. 2. If available, connect a PC and, using HTP service software, check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be greater than 250. Use this as a troubleshooting guide as you follow the steps below. - Page 59 System sensor 1. Check wiring to system sensor. Repair as necessary. failure 2. Check sensor resistance. Compare to the resistance table in this manual. Replace if not correct. (Cascade Master only) Low water flow 1. Check to see if boiler circulator is functioning. Repair as necessary. (Users with 2.
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Page 60: Part 12 - Maintenance
1. Check condensate lines for obstructions. Condensate cup is full 2. Check float switch in condensate reservoir. 3. Check wiring from condensate reservoir to 926 control and repair as necessary. Parameters programmed Press {S4} reset for at least 1 second. Program parameter error Control must be re-programmed. -
Page 61: Combustion Chamber Coil Cleaning Instructions For Heater
The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”... -
Page 62: Cleaning Water Side Of Heat Exchanger
f. Replace the (4) screws on the aluminum connector on the gas valve. Turn the gas back on. (IMPORTANT: CHECK FOR GAS LEAKS BEFORE TURNING THE APPLIANCE ON!) g. Turn the boiler power back on and create a demand on the boiler. When boiler is lit, observe condensate flow from the boiler. - Page 63 Figure 31 LP- 276 REV. 9.4.14...
- Page 64 Figure 32 LP- 276 REV. 9.4.14...
- Page 65 Figure 33 – NOTE: Ceramic Refractory Part # 7250P-162 LP- 276 REV. 9.4.14...
- Page 66 Figure 34 LP- 276 REV. 9.4.14...
- Page 67 Figure 35 LP- 276 REV. 9.4.14...
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Page 68: Boiler Start-Up Report
BOILER START-UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED ________________ 1) Fill the Check all piping and gas connections, verify all are heating system tight Pressurize system ____ PSI Add water to prime condensate cup Verify near heater piping is properly supported 2) Check gas Leak test using locally approved methods (consult pipe... - Page 69 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING YEAR YEAR YEAR YEAR* Near heater piping Check heater and system piping for any sign of leakage; make sure they are properly supported. Vent Check condition of all vent pipes and joints. Check for any obstructions at intake and exhaust termination points.
- Page 70 LP- 276 REV. 9.4.14...
- Page 71 LP- 276 REV. 9.4.14...
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Page 72: Maintenance Notes
MAINTENANCE NOTES LP- 276 REV. 9.4.14... -
Page 73: Htp Customer Installation Record Form
HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
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