HTP MODCON1000 Installation, Start-Up And Maintenance Instructions
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HTP MODCON1000 Installation, Start-Up And Maintenance Instructions

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Installation
Start-Up
Maintenance
Parts
Warranty
MODCON1000 / MODCON1700
"LP" Denotes Propane Gas Operation
"HL" Denotes Installed High and Low Gas
Pressure Switches
This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe
personal injury, or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause
property damage, severe personal injury, or death.
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.
272 Duchaine Blvd.
This Manual For Use With Boilers Manufactured After
New Bedford, MA 02745
Mod Con
August 13, 2013
Heat Exchanger Bears the ASME "H" Stamp
www.htproducts.com
LP-428 Rev. 6.6.16

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Summary of Contents for HTP MODCON1000

  • Page 1 Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death. 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 •...
  • Page 3 AHJ. levels or to important product information. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. DANGER indicates an imminently hazardous situation...

  • Page 4: Table Of Contents

    In accordance with Section 325 (f) (3) of the Energy Policy F. High Elevation Installations and Conservation Act, HTP, Inc. has provided this boiler with Part 2 - Before You Start multiple features designed to save energy by reducing the A.
  • Page 5 SUBMERGED IN WATER. Immediately call a qualified I. Final Checks Before Starting Boiler service technician. The boiler MUST BE replaced if it has been J. Cascade System - MODCON1000 and 1700 Models submerged. Attempting to operate a boiler that has been Part 9 - Start-Up Procedure submerged could create numerous harmful conditions, such as A.

  • Page 6: Improper Combustion

    Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in Altering any HTP, Inc. boiler with parts not manufactured by the system may be damaged, possibly resulting in HTP, Inc. WILL INSTANTLY VOID the boiler warranty and could substantial property damage.

  • Page 7: Optional Equipment

    Monitors storage tank temperature. powered and combustion air is flowing. C. Optional Equipment Integrated Venturi (1000 Models) or Swirl Plate (1700 Optional equipment available from HTP (and Part #): Models) • Remote System Sensor (7250P-324) Controls air and gas flow into the burner.

  • Page 8: Locating The Boiler

    If local building codes require additional clearance, if exposed to sustained temperatures below 32 F. Precautions these codes supersede HTP’s. It is recommended to make should be taken to protect the condensate trap and drain lines note of the boiler model and serial number before finalizing from sustained freezing conditions.

  • Page 9: Flooring

    NOTE: A combustible door or removable panel is acceptable front clearance. Gas conversion should be performed BEFORE the boiler is installed. Carefully follow the gas conversion instructions when performing the conversion. Failure to follow these The space must be provided with combustion / ventilation air instructions could result in property damage, severe personal openings correctly sized for all other appliances located in the injury, or death.

  • Page 10: Exhaust Vent And Intake Pipe

    Figure 2 - Recommended Service Clearances • When raising the boiler ensure the entire bottom and fully filled weight of the boiler are fully supported. Vents must be properly supported. Boiler exhaust and intake • Locate or protect the boiler so it cannot be damaged by connections are not designed to carry heavy weight.

  • Page 11: Direct Vent Of Exhaust And Intake

    1. Direct Vent of Exhaust and Intake If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake and Failure to provide an adequate supply of fresh combustion air can exhaust must terminate outdoors. There are three basic direct cause poisonous flue gases to enter the living space, resulting vent options detailed in this manual: 1.

  • Page 12: Water Chemistry Requirements

    HTP recommends having water quality 3. If practical, close all building doors, windows, and doors professionally analyzed to determine whether it is necessary between the space in which the boiler remains connected to to install a water softener.

  • Page 13: Part 4 - Piping

    The boiler may be connected to an indirect water heater to inadequate flow through the boiler. For other piping methods, supply domestic hot water. HTP offers indirect water heaters consult your local HTP representative, or refer to Boiler Piping in stainless steel or glass-lined construction. Details in this manual.

  • Page 14: Relief Valve

    Model Heat Exchanger Volume (Gallons) • Test T&P valve at least once annually to ensure the MODCON1000 waterway is clear. If valve does not operate, turn the MODCON1700 11.6 boiler “off” and call a plumber immediately. Table 2 - ModCon Heat Exchanger Volume •...

  • Page 15: Hydronic Piping With Circulators, Zone Valves, And Multiple Boilers

    Minimum boiler flow rates are listed in the table below. Minimum Boiler Flow Rates Model Minimum Flow (GPM) MODCON1000 MODCON1700 Table 3 - Minimum Flow Rates LP-428 Rev. 6.6.16...
  • Page 16 25°Δt 30°Δt Model Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM) MODCON1000 19’ 11’ 8’ MODCON1700 35’ 26’ 18’ Table 6 - Temperature Rise, Friction Ft, and Flow Rate The chart below represents the combined flow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit.

  • Page 17: Check / Control Water Chemistry

    through the boiler, causing inadvertent short cycling and poor H. Check / Control Water Chemistry system performance. NOTE: Boiler failure due to improper water chemistry is not Check Valves covered by warranty. Field supplied. Check valves are recommended for installation Water Chemistry* as shown in Applications.

  • Page 18: Freeze Protection Fluids

    water flow out the hose. If zone valves are used, open the L. Zoning with Zone Valves valves one at a time manually. (NOTE: You should check 1. When zoning with zone valves, connect the boiler to the the valve manufacturer’s instructions prior to opening system as shown in Applications.

  • Page 19: O. Applications

    5. Piping shown is Primary/Secondary. 6. The minimum pipe size for connecting an HTP indirect fired water heater is 1”. 7. The minimum pipe size for connecting a Mod Con boiler is 3” for both the 1000 and 1700 models.
  • Page 20 5. Piping shown is Primary/Secondary. 6. The minimum pipe size for connecting an HTP indirect fired water heater is 1”. 7. The minimum pipe size for connecting a Mod Con boiler is 3” for both the 1000 and 1700 models. See Multiple Boiler Manifold Piping chart, this manual, when sizing and installing a multiple boiler system.
  • Page 21 Figure 7 - Space Heating FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees. 4.
  • Page 22 Figure 8 - Cascaded Space Heating FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 3. Install a minimum of 6 diameters of straight pipe up and downstream of all closely spaced tees. 4.

  • Page 23: Part 5 - Venting And Condensate Removal

    Part 5 - Venting and Condensate Removal The boiler must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual.

  • Page 24: Approved Materials For Exhaust Vent And Intake Pipe

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada PVC Schedule 40/80 ANSI / ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV* ANSI / ASTM D2665 be ULC-S636 Certified. IPEX is Exhaust Vent or Intake an approved manufacturer in CPVC Schedule 40/80...

  • Page 25: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location Intake Pipe Terminal Area Where Terminal Is Not Permitted Exhaust Vent Terminal Figure 9 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION –...

  • Page 26: Exhaust Vent And Intake Pipe Sizing

    Exhaust Vent Max. Total Equivalent Input De-Rate Model Vent Length (Intake Per 25’ of Vent Intake Diameter Intake Min. Length Vent Diameter Vent Min. Length and Exhaust) MODCON1000 6” 6” 16’ 16’ 150’ MODCON1700 8” 8” Table 8 - Exhaust Vent and Intake Pipe Sizing F.

  • Page 27: Applications

    G. Applications 1. Direct Vent Installation of Exhaust and Intake If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3.
  • Page 28 Figure 12 - Venting with Optional Kits (NOT INCLUDED WITH THE BOILER) NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. All vent pipes must be glued, properly supported, and the Figure 13 - Unbalanced Venting - Roof Exhaust and Sidewall exhaust must be pitched a minimum of ¼”...

  • Page 29: Room And Indoor Combustion Ventilation Requirements

    2. Room and Indoor Combustion Ventilation Requirements should not be less than 3”. When using an indoor combustion air installation, the mechanical room MUST be provided with properly sized openings, and/or be of sufficient volume to assure adequate combustion air and proper ventilation for all gas fired appliances in the mechanical room to assure adequate combustion air and proper ventilation.

  • Page 30: Condensate Removal System

    4.5. To avoid long term damage to the drainage system and to combustion and premature boiler failure. Such failure IS NOT meet local code requirements, HTP recommends neutralizing covered under warranty. condensate with a Condensate Neutralizer Kit (Part # 7350P- EXHAUST FANS: Any fan or appliance which exhausts air from 611).

  • Page 31: Part 6 - Wiring

    2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be It is of extreme importance that this unit be properly grounded. It subject to corrosion or deterioration. is very important that the building system ground is inspected by 3.

  • Page 32: Line Voltage Wiring

    3. Connect the central heating pump motor starter coil to the either a thermostat type aquastat installed in the indirect terminals marked BOILER HOT, BOILER NEUT, and BOILER tank, or an HTP 7250P-325 tank sensor. When a tank sensor GRD in the bottom boiler. is used, the control will 4.

  • Page 33: Optional High Gas Pressure Switch

    Figure 20 - Cascade Master and Follower Wiring 2. Locate the two pigtails hanging from the electrical box inside control signal to the terminals marked 16, 0-10 VOLT + and of the boiler cabinet. Remove and discard the jumper plug from 17, 0-10 VOLT –...

  • Page 34: Optional Flow Switch

    Figure 21 - MODCON Internal Connection Diagram on the inlet side. certain the branch points up on horizontal runs. 2. Locate the two pigtails hanging from the electrical box inside 3. Thread flow switch into tee using pipe dope. Make certain of the boiler cabinet.

  • Page 35: Optional Ul353 Low Water Cut-Off Interface Kit

    UL353 LWCO (available from HTP, Part # 7350P- If you possess the skills you can also construct custom length 601). In this installation, it is recommended to install the flow cables.

  • Page 36: Part 7 - Gas Connections

    Figure 24 - Gas Connection The gas connection on the boiler is 2” for the MODCON1000 and 2 1/2” for the MODCON1700. It is mandatory that this fitting is used for connection to a field fabricated drip leg as shown in the illustration per the National Fuel Gas Code.

  • Page 37: Gas Table

    This gas valve must not be replaced with a conventional gas valve under any circumstances. Model 1 Unit 2 Units 3 Units 4 Units MODCON1000 2” 3” 3” 4” @ 100’ of Pipe DO NOT adjust or attempt to measure gas valve outlet pressure.

  • Page 38: Boiler Gas Valve

    D. Boiler 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 Propane gas...

  • Page 39: Part 8 - Start-Up Preparation

    2. For zoned systems, flush each zone separately through a Part 8 - Start-Up Preparation purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.) 3. Flush system until water runs clean and you are sure piping is Thoroughly clean and flush any system that has used glycol free of sediment.

  • Page 40: Fill And Test Water System

    This may be done by the installer or c. Close zone isolation valves. you may purchase a condensate neutralizer from HTP (7350P- d. Open quick-fill valve on cold water make-up line. 611).

  • Page 41: Condensate Removal

    FLUE on all boilers EXCEPT the Master Boiler. This is the 3. Fill condensate trap with water. default setting on the top boiler in a MODCON1000 or 1700 4. Verify electrical connections are correct and securely unit.

  • Page 42: Part 9 - Start-Up Procedure

    f. Exit the installer menu. described below. NOTE: The temperature set point of the follower must match RESET – The RESET button has two functions. the master boiler set point in order for the system to operate – Resets any lockout error code properly.

  • Page 43: Programming Boiler Settings

    6. If the boilers fail to start, refer to the troubleshooting CLOCK HOUR Allows the user to adjust the hour section in the back of this manual. 08/28/2009 Fr 10:01A setting. D. Programming Boiler Settings CLOCK MINUTE Adjusts the minute setting. Boiler Setting Program Access 08/28/2009 Fr 10:01A...
  • Page 44 Screen Description Function 16 Optional Inputs Function 6 DHW Post Pump Time Allows the user to select optional inputs to control or monitor the The indirect pump has the ability to OPTIONAL INPUT system. Default: RETURN (Range: post purge energy from the boiler RETURN SEN Off / Booster Board / 0-10 Volt / DHW to run the pump after the set point...
  • Page 45 Bottom Boiler Function 30 Extra Boiler Mode Follower (top boiler). Range: ALL Allows for a non HTP boiler to 926 / 2 – 8 BOILERS [on cascade CASCADE MODE be controlled when the cascade master ONLY] / COMMON FLUE [on...

  • Page 46: Resetting The Maintenance Schedule

    NOTE: For the following functions, you must have your maintenance function turned on. To change these functions, press ENTER. The left most digit will begin to blink. Use the ^ or v arrows to change the digit. Use the < > arrow keys to switch between digits. When you’ve made your selection, press ENTER again.
  • Page 47 Press v once. The actual temperature measured This screen displays how many hours by the tank or return sensor (HTP SYS CH ON the boiler has run to meet central 7250P-325) is displayed on the SYS DHW ON heat and DHW demand.

  • Page 48: Cascade Menu

    Press v once. B. Cascade Menu This menu is accessed by pressing < at the default menu or > at This screen displays the fourth the status menu of the Master Boiler. oldest boiler control lockout fault. The top line will alternate between FAULT HISTORY Screen Description...

  • Page 49: Boiler Test Mode

    Press v once. Combustion Settings on All Models This screen displays overall cascade Natural Gas (NG) Propane (LP) Fan Speed power output. The range of this Low Ignition High Low Ignition High value is the number of boilers Carbon communicating with the Master x CASCADE PWR 100% Monoxide...

  • Page 50: User Interface Display

    When servicing or replacing components that are in direct DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN contact with boiler water, be certain that: SUBMERGED IN WATER. Immediately call a qualified service • There is no pressure in the boiler. (Pull the release on technician.
  • Page 51 1. Check line voltage. It must be between 100 and 128 volts. 2. If available, connect a PC and use HTP service software to 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 no greater than 250.
  • Page 52 F02 indicates the supply temperature sensor 1. Check the electrical connection to the thermistor on the outlet of the boiler has failed. The boiler will not manifold. Verify 5 VDC by checking the Molex connector. If restart until a technician replaces the sensor there is no 5 VDC, check the harness.
  • Page 53 1. Watch the igniter through the observation window. 2. If there is no spark, check the spark electrode for the proper .196” (5.0 mm ± 1mm) gap. See below. 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.
  • Page 54 1. Check flue system for obstructions. 2. Check proper communication between boilers. FLAP CLOSED Flapper valve physically stuck closed. 3. Check operation of flapper valve. 4. Check wiring between valve and controller. 5. Replace valve-flapper. 1. Check flue system for obstructions. 2.

  • Page 55: Part 12 - Maintenance

    E19 indicates the line voltage frequency is Inspect power wiring to the boiler and repair as necessary. out of range. This could happen if the boiler If connected to line voltage, notify the power company. If LINE VOLTAGE is being powered from a small gasoline connected to an alternate power source such as a generator or PUMP OFF powered generator that is overloaded or not...

  • Page 56: C. Cleaning Water Side Of Heat Exchanger

    4. Spray the coils again with clear tap water. Confine the spray FDA approved for use in a potable water system. to the area being cleaned. Flush the combustion chamber with 3. Thoroughly flush the heat exchanger before commissioning fresh water until it runs clear from the condensate reservoir. At the unit back in service.
  • Page 57 MODCON1000 Figure 28 - MODCON1000 External Replacement Parts MODCON1700 Figure 29 - MODCON1700 External Replacement Parts LP-428 Rev. 6.6.16...
  • Page 58 MODCON1000 Figure 30 - MODCON1000 Combustion System Replacement Parts LP-428 Rev. 6.6.16...
  • Page 59 MODCON1700 Figure 31 - MODCON1700 Combustion System Replacement Parts LP-428 Rev. 6.6.16...
  • Page 60 Figure 32 - Water Side Replacement Parts - All Models LP-428 Rev. 6.6.16...
  • Page 61 Figure 33 - Cabinet Replacement Parts - All Models LP-428 Rev. 6.6.16...

  • Page 62: Part 13 - Installation Checklist

    Locate the stickers in the appropriate locations on the boiler. 9. Convert the Boiler Verify combustion settings after gas (MODCON1000 ONLY) %CO2 High Fire %CO2 Low Fire conversion - Carbon Dioxide. Verify combustion settings after gas ppm CO High Fire ppm CO Low Fire conversion - Carbon Monoxide.
  • Page 63 Inspection Activities Date Last Completed Piping 1st Year 2nd Year 3rd Year 4th Year* Check boiler and system piping for any sign of leakage; make sure Near boiler piping pipes are properly supported. Check condition of all vent pipes and joints. Ensure the vent piping Vent terminations are free of obstructions and blockages.
  • Page 64 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 65 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.

  • Page 66: Limited Warranty

    COVERAGE boiler and keep it running at optimum efficiency. A. During the first year after the date of installation, HTP warrants Maintain all related heating components in good operating that it will repair or replace, at its option, any defective or condition.
  • Page 67 NOTE: Any parts or heaters returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied. If all warranty conditions are satisfied, HTP will provide replacement parts to the retailer.

  • Page 68: Maintenance Notes

    Maintenance Notes LP-428 Rev. 6.6.16...

  • Page 69: Customer Installation Record Form

    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. Customer’s Name Date of Installation Installation Address...

This manual is also suitable for:

Modcon1700

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