HTP MODCON1000 - Condensate Removal; Final Checks before Starting Boiler; Cascade System - MODCON1000 and 1700 Models

LP-428 Rev. 6.6.16
41
I. Final Checks Before Starting Boiler
1. Read Startup Procedures within this manual for proper
steps to start boiler. (See Startup Report to record steps for
future reference.)
2. Verify the boiler and system are full of water and all system
components are correctly set for operation.
Ensure the boiler is full of water before ring the burner.
Failure to do so will damage the boiler. Such damage IS NOT
covered by warranty, and could result in property damage,
severe personal injury, or death.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and securely
J. Cascade System - MODCON1000 and 1700 Models
This boiler assembly is shipped factory preset to operate as a
common vented cascaded unit. If the boiler is meant to be used
as a common vented cascaded unit and additional boilers are
not to be added to the system, skip this section.
Programming the Master Boiler:
a. Pick one of the bottom boilers to be the Master Boiler.
b. Make sure there is no demand for heat being supplied to
the boiler.
c. Apply power to the Master Boiler.
d. Enter the system setting program navigation following
instructions in Part 10 of this manual.
e. Verify that cascade address function 15 is set to 0. This
makes the master boiler address 0. NOTE: The Master Boiler
MUST be addressed as 0. This establishes the unit as the
master in a cascaded system.
f. Change Function 23 to the total number of boilers in the
system (4 BOILERS for a four boiler system, 6 BOILERS for a
six boiler system, etc.)
g. 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.
Additional Connected MODCON1000 and 1700 Follower
Boilers:
NOTE: READ THE NOTES BELOW BEFORE PROGRAMMING
FOLLOWER BOILERS
• If one of the follower boilers has an indirect red water
heater connected directly to it, the address of this boiler
must be 2 or greater.
• It is recommended but not necessary to address boilers in
the order that they are wired.
• No two boilers can have the same address.
• Maximum amount of boilers in a cascaded system is eight
(8), equal to four (4) double-stacked units.
a. Make sure there is no demand for heat being supplied to
the master boiler
b. Apply power to the follower boiler you are working on.
c. Enter system settings following instructions in Part 10 of
this manual
d. Set cascade address parameter 15 to 1 for the rst follower,
2 for the second follower, etc. depending which boiler you
are programming based on the above notes. This establishes
the boiler as a follower in a cascaded system and enables
data to be transferred as needed for the system to function
at full capability.
NOTE: DO NOT select number 8.
NOTE: The top boiler in a MODCON1000 and 1700 assembly
is factory preset to 1.
e. Change “CASCADE MODE” Function 23 to COMMON
FLUE on all boilers EXCEPT the Master Boiler. This is the
default setting on the top boiler in a MODCON1000 or 1700
unit.
2. Connect a voltmeter across these two incoming wires
with power supplied to the thermostat circuits. Close each
thermostat, zone valve and relay in the external circuit one at
a time and check the voltmeter reading across the incoming
wires.
3. There should NEVER be a voltage reading.
4. If a voltage reading does occur under any condition, check
and correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the boiler low voltage terminal strip. Allow the
boiler to cycle.
H. Condensate Removal
1. The boiler is a high eciency condensing boiler. Therefore,
the unit has a condensate drain. Condensate uid is nothing
more than water vapor, derived from combustion products,
similar to that produced by an automobile when it is initially
started.
Condensation is slightly acidic (typically with a pH of 3 to 5)
and must be piped with the correct materials. Never pipe the
condensate using steel, copper, brass or other materials that
will be subject to corrosion. Plastic PVC or CPVC pipe are the
only approved materials.
A condensate neutralizer, if required by local authorities,
can be made up of lime crystals, marble or phosphate chips
that will neutralize the condensate. This may be done by the
installer or you may purchase a condensate neutralizer from
HTP (7350P-611).
2. The boiler is equipped with a ¾ female socket weld tting
connection that must be piped to a local drain. It is very
important that the condensate line is sloped downward away
from the boiler to a suitable inside drain. If the condensate
outlet on the appliance 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 overow, which, if not corrected, could cause
property damage.
3. If a long horizontal run is used, it may be necessary to create
a vent in the horizontal run to prevent a vacuum lock in the
condensate line.
4. Do not expose the condensate to freezing temperatures.
5. It is very important you support the condensation line to
assure proper drainage.
attached.
5. Inspect exhaust vent and intake piping for signs of deterioration
from corrosion, physical damage or sagging. Verify exhaust vent
and intake piping are intact and correctly installed per Venting
Section and local codes.
6. Ensure both boiler power switches are activated before
running the unit.