51
GAS-FIRED BOILER Boiler Manual
PART 9. START-UP PREPARATION (CONTINUED)
F. CHECK THERMOSTAT CIRCUIT(S)
1. Disconnect the two external wires connected
to the boiler thermostat terminals (low
voltage terminal strip).
2. Connect a voltmeter across these two
incoming wires with power applied to
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 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 boiler low voltage terminal strip
Allow the boiler to cycle.
G. CONDENSATE REMOVAL
1. The Mod Con Boiler is a high efficiency
condensing boiler, therefore, the unit has a
condensate drain. Condensate fluid is
nothing more than water vapor, derived from
combustion products, similar to an
automobile when it is initially started. The
condensation is slightly acidic (typically with
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 filter, 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 Heat Transfer
Products, Inc. (P/N S7350-025)
2. The Mod Con Boiler is equipped with a ¾ FPT
connection that must be piped to a local drain.
It is very important that the condensate line is
sloped downward away from the Mod Con to
a suitable inside drain. If the condensate
outlet on the Mod Con is lower than the drain,
you must use a condensate removal pump,
available from Heat Transfer Products
(#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.
3. If a long horizontal run is used, it may be
necessary to create a vent in the horizontal 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.
H. 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.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and
securely attached.
5. Inspect intake piping and exhaust piping for
signs of deterioration from corrosion, physical
damage or sagging. Verify intake piping and
exhaust piping are intact and correctly
installed per Venting section and local code.
I. CASCADE SYSTEM
1. If the boiler is used in a stand alone
configuration, skip this section.
2. Programming The Master Boiler
1. Make sure there is no demand for heat
being supplied to the boiler
2. Apply power to the boiler
n
WARNING
Propane boilers only — Your propane supplier
mixes an odorant with the propane to make its
presence detectable. In some instances, the
odorant can fade, and the gas may no longer
have an odor. Before startup (and periodically
thereafter), have the propane supplier verify the
correct odorant level in the gas.
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