Download Installation Manual (.pdf) - Heat Transfer Products, Inc

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6D. FINAL CHECKS BEFORE STARTING BOILER ....................................................................................................................... 47E. CASCADE SYSTEM ................................................................................................................................................................. 47PART 9 – START-UP PROCEDURE ......................................................................................................................................... 48A. CONTROL OVERVIEW ............................................................................................................................................................ 48B. NAVIGATION OF THE DISPLAY .............................................................................................................................................. 49C. OPERATING INSTRUCTIONS ................................................................................................................................................. 49D. PROGRAMMING HEATER SETTINGS .................................................................................................................................... 49E. PROGRAMMING THE SYSTEM SETTING .............................................................................................................................. 50F. SYSTEM SETTING PROGRAM NAVIGATION......................................................................................................................... 51G. RESETTING THE MAINTENANCE SCHEDULE...................................................................................................................... 53PART 10 – START-UP PROCEDURES FOR THE INSTALLER ............................................................................................... 53A. HEATER CONTROL STATUS MENU ...................................................................................................................................... 53B. CASCADE MENU ..................................................................................................................................................................... 54C. HEATER TEST MODE ............................................................................................................................................................. 55PART 11 – TROUBLESHOOTING ............................................................................................................................................ 56A. HEATER ERROR CODE .......................................................................................................................................................... 56B. HEATER ERROR...................................................................................................................................................................... 56C. HEATER FAULT ....................................................................................................................................................................... 56D. USER INTERFACE DISPLAY .................................................................................................................................................. 57PART 12 – MAINTENANCE ...................................................................................................................................................... 62A. MAINTENANCE PROCEDURES .............................................................................................................................................. 62B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR HEATER ...................................................................... 62C. CLEANING WATER SIDE OF THE HEAT EXCHANGER ........................................................................................................ 63BOILER START-UP REPORT ................................................................................................................................................... 70MAINTENANCE REPORT ......................................................................................................................................................... 70MAINTENANCE NOTES .................................................................................................................................................................. 74HTP CUSTOMER INSTALLATION RECORD FORM...................................................................................................................... 75PART 1 – GENERAL SAFETY INFORMATIONA. PRECAUTIONSThis appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Front must haveroom for service, 24” recommended. (A combustible door or removable panel is acceptable front clearance.) This appliance has beenapproved for closet installation. Do not install this appliance directly on carpeting. This appliance may be installed on combustibleflooring. For use with Category IV vent systems only.INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.USER – This manual is for use only by a qualified heating installer/service technician. Refer to user’s information manual for yourreference. Have this boiler serviced/inspected by a qualified service technician annually.FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS BOILER SERVICED/INSPECTED ANNUALLYCAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.LP- 429 REV. 6.6.13
7DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician.The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could createnumerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or otherharmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury,or death.NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.NOTE: If the boiler is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman: FIRE DAMAGE WATERAny claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.Due to low water content of the boiler, improperly sizing the boiler in regard to potable water heating load will result in excessive boilercycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOToversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing.B. GASShould overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut offthe gas supply at a location external to the appliance.C. IMPROPER COMBUSTIONDo not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. Failure to keep theexhaust vent and intake pipe clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.D. WHEN SERVICING THE BOILER To avoid electric shock, disconnect electrical supply before performingmaintenance. To avoid severe burns, allow boiler to cool before servicing.E. BOILER OPERATION Do not block flow of combustion or ventilation air to boiler. Should overheating occur or gas supply fail to shut off, do not turn off ordisconnect electrical supply to circulator. Instead, shut off the gassupply at a location external to the appliance. Do not use this boiler if any part has been under water. Immediately calla qualified service technician to inspect the boiler and replace any partof the control system and any gas control that has been under water.F. BOILER WATER Do not use petroleum-based cleaning or sealing compounds in a boilersystem. These products may damage gaskets and seals in the system.This can result in substantial property damage. Do not use “homemade cures” or “boiler patent medicines”. Substantialproperty damage, damage to boiler, and/or serious personal injury mayresult.You must not have a direct connection of the potable water system into the heat exchanger. This could cause flow issues, short cycling,and an increase of mineral build-up in the unit. This system is designed to have incoming potable water flow through the storage tankfirst, then through the heat exchanger. 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, <strong>Inc</strong>. ARE NOT covered by warranty.LP- 429 REV. 6.6.13
Page 1 and 2: Mod Con VWHINSTALLATIONSTART-UPMAIN
Page 3 and 4: 3The following defined terms are us
Page 5: 5D. CIRCULATOR PUMPS ..............
Page 9 and 10: 9A. WHAT’S IN THE BOXAlso include
Page 12 and 13: 12D. CLEARANCES FOR SERVICE ACCESSS
Page 15 and 16: 7. Any improper operation of the co
Page 17 and 18: 17Never use dielectric unions or ga
Page 19 and 20: 19H. WATER CHEMISTRYChemical imbala
Page 21 and 22: 21I. PIPING DIAGRAMSFigure 5 - Pipi
Page 23 and 24: 23Figure 7 NOTES:1. This drawing is
Page 25 and 26: 25ItemExhaust vent or Intake pipean
Page 27 and 28: 27NOTE: Due to potential moisture b
Page 29 and 30: 29When installing a condensate pump
Page 31 and 32: 31I. SIDEWALL VENTING DIAGRAMSFigur
Page 34 and 35: 34Under no circumstances should the
Page 36 and 37: 36D. CHECK INLET GAS PRESSUREThe ga
Page 38 and 39: 38Figure 19 - Mod Con 1700 Gas Valv
Page 40 and 41: 40use of a pipe sensor will be some
Page 42 and 43: 42Figure 21Figure 22 - Cascade Resi
Page 44 and 45: 44Figure 23 - Mod Con VWH Cascade M
Page 46 and 47: 46PART 8 - START-UP PREPARATIONA. C
Page 48 and 49: 48Additional Connected Mod Con 1000
Page 50 and 51: Heater Setting Program NavigationOn
Page 52 and 53: Function 21Error Outdoor SensorERRO
Page 54 and 55: 54The following 10 screens display
Page 56 and 57:
56PART 11 - TROUBLESHOOTINGA. HEATE
Page 58 and 59:
58Fault Code F01FLUE TEMP/WAT LV F0
Page 60 and 61:
60Fault Code F15APS OPEN F15 Flappe
Page 62 and 63:
62PART 12 - MAINTENANCEIn unusually
Page 64 and 65:
64Figure 26 - MOD CON 1000 External
Page 66 and 67:
66Figure 28LP- 429 REV. 6.6.13
Page 68 and 69:
68Figure 30LP- 429 REV. 6.6.13
Page 70 and 71:
70BOILER START-UP REPORTLIGHT OFF A
Page 72 and 73:
72LP- 429 REV. 6.6.13
Page 74 and 75:
74MAINTENANCE NOTESLP- 429 REV. 6.6
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