HTP MODCON1000 - Page 5

LP-428 Rev. 6.6.16
5
N. Multiple Boilers 18
O. Applications 19
Part 5 - Venting and Condensate Removal 23
A. General 23
B. Approved Materials for Exhaust Vent and Intake Pipe 24
C. Additional Requirements for Installation in Canada 24
D. Exhaust Vent and Intake Pipe Location 25
E. Exhaust Vent and Intake Pipe Sizing 26
F. Exhaust Vent and Intake Pipe Installation 26
G. Applications 27
1. Direct Vent Installation of Exhaust and Intake 27
2. Room and Indoor Combustion Ventilation Requirements
29
H. Condensate Removal System 30
Part 6 - Wiring 31
A. Installation Must Comply With 31
B. Field Wiring Terminations 31
C. Field Wiring 31
D. Line Voltage Wiring 32
E. Alarm Connections (Top Boiler Connection) 32
F. Low Voltage Connections for Standard Boiler 32
G. Thermostat 32
H. Outdoor Sensor 32
I. Indirect Sensor (Top Boiler Connection) 32
J. Optional 0-10 Volt Building Control Signal 32
K. Optional High Gas Pressure Switch 33
L. Optional Low Gas Pressure Switch 33
M. Optional Flow Switch 34
N. Optional UL353 Low Water Cut-O Interface Kit 35
O. Wiring of Cascade System Communication Bus 35
Part 7 - Gas Connections 36
A. Gas Piping 36
B. Gas Table 37
C. Check Inlet Gas Pressure 37
D. Boiler Gas Valve 38
Part 8 - Start-Up Preparation 39
A. Check / Control Water Chemistry 39
B. Check for Gas Leaks 39
C. Freeze Protection (When Used) 39
D. Condensate Removal 39
E. Fill and Test Water System 40
F. Purge Air from Water System 40
G. Check Thermostat Circuit(s) 40
H. Condensate Removal 41
I. Final Checks Before Starting Boiler 41
J. Cascade System - MODCON1000 and 1700 Models 41
Part 9 - Start-Up Procedure 42
A. Control Overview 42
B. Navigation of the Display 42
C. Operating Instructions 42
D. Programming Boiler Settings 43
E. Programming the System Setting 43
F. System Setting Program Navigation 43
G. Resetting the Maintenance Schedule 46
Part 10 - Start-Up Procedures for the Installer 46
A. Boiler Control Status Menu 46
B. Cascade Menu 48
C. Boiler Test Mode 49
Part 11 - Troubleshooting 49
A. Boiler Error and Fault Codes 49
B. Boiler Error 49
C. Boiler Fault 49
D. User Interface Display 50
Part 12 - Maintenance 55
A. Procedures 55
B. Combustion Chamber Coil Cleaning Instructions 55
C. Cleaning Water Side of Heat Exchanger 56
Part 13 - Installation Checklist 62
Part 14 - Maintenance Report 62
Limited Warranty 66
Maintenance Notes 68
Customer Installation Record Form 69
Part 1 - General Safety Information
This boiler is approved for indoor installations only. Clearance to
combustible materials: 0” top, bottom, sides, and back. Left side
has all boiler mechanical connections. Boiler must have room for
service: 24” front is minimum recommended service clearance.
(A combustible door or removable panel is acceptable front
clearance.) This boiler has been approved for closet installation
and installation on combustible ooring. Do not install directly on
carpeting. Install the boiler in a location where temperature and
pressure relief valve discharge or a leak will not result in damage
to the surrounding area. If such a location is not available, install
an auxiliary catch pan. Use only Category IV vent systems.
Installer - Read all instructions in this manual before installing.
Perform steps in the given order.
User - This manual is for use only by a qualied heating installer /
service technician. Have this boiler serviced / inspected annually
by a qualied service technician.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE
CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE,
SEVERE PERSONAL INJURY, OR DEATH.
NOTE: If the boiler is exposed to the following, do not operate.
Immediately call a qualied service technician.
1. Fire
2. Damage
3. Water
Failure to follow this information could result in property
damage, severe personal injury, or death.
DO NOT USE THIS BOILER IF ANY PART HAS BEEN
SUBMERGED IN WATER. Immediately call a qualied
service technician. The boiler MUST BE replaced if it has been
submerged. Attempting to operate a boiler that has been
submerged could create numerous harmful conditions, such as
a potential gas leakage causing a re and/or explosion, or the
release of mold, bacteria, or other harmful particulates into
the air. Operating a previously submerged boiler could result in
property damage, severe personal injury, or death.
NOTE: Boiler damage due to ood or submersion is considered
an Act of God, and IS NOT covered under product warranty.
NOTE: Obey all local codes. Obtain all applicable permits before
installing the boiler.
NOTE: Install all system components and piping in such a
manner that does not reduce the performance of any re rated
assembly.