HTP Mod Con 300 HL Installation & Maintenance Manual
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HTP Mod Con 300 HL Installation & Maintenance Manual

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This manual must only be used by a qualified heating installer/service technician. Read all
instructions in this manual before installing. Perform steps in the order given. Failure to comply
could result in substantial property damage, severe personal injury, or death.
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.
120 Braley Rd. P.O. Box 429
East Freetown, MA 02717-0429
Mod Con
INSTALLATION
START-UP
MAINTENANCE
PARTS
Mod Con Models
300 / 500 / 850
LP / HL / LPHL
www.htproducts.com
LP- 205 REV. 3.18.11

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Summary of Contents for HTP Mod Con 300 HL

  • Page 1 Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: 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.

  • Page 3: For The Installer

    The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 4: Table Of Contents

    The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131. In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.
  • Page 5 C. BACKFLOW PREVENTER ......................... 18 D. SYSTEM WATER PIPING METHODS ....................18 E. CIRCULATORS ..........................19 F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS ....19 G. BOILER PIPING DETAILS ......................... 21 H. CIRCULATOR SIZING ........................25 I. FILL AND PURGE HEATING SYSTEM ....................26 J.
  • Page 6 F. THERMOSTAT ............................ 48 G. OUTDOOR SENSOR ......................... 49 H. INDIRECT SENSOR ........................... 49 I. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL ..............49 J. OPTIONAL HIGH GAS PRESSURE SWITCH ..................49 K. OPTIONAL LOW GAS PRESSURE SWITCH ..................50 L. OPTIONAL FLOW SWITCH ........................ 50 M.

  • Page 7: Part 1 - General Safety Information

    Due to low water content of the boiler, improperly sizing the boiler in regard to heating system load will result in excessive boiler cycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler...

  • Page 8: Improper Combustion

    B. IMPROPER COMBUSTION Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. C. GAS WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch. •...

  • Page 9: Part 2 - Before You Start

    Consider piping and installation when determining boiler location. PART 2 – BEFORE YOU START A. WHAT’S IN THE BOX Also included with the boiler: • Pressure and Temperature Gauge • Outdoor Sensor • Intake PVC Tee with Screens • Exhaust PVC Coupling with Screens •...

  • Page 10: Optional Equipment

    Indirect Tank Sensor (optional) – Monitors storage tank temperature. C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP. These additional options may be purchased through your HTP distributor. •...

  • Page 11: Part 3 - Prepare Boiler Location

    PART 3 – PREPARE BOILER LOCATION Before considering location, there are many factors to be addressed. Piping, Venting, and Condensation Removal are just a few of the important issues covered in detail in this manual. Please read the entire manual before attempting installation. Doing so could save time and money. Consider piping and installation when determining boiler location.

  • Page 12: Leveling And Dimensions

    B. LEVELING AND DIMENSIONS Figure 1 In order for the condensate to properly flow out of the collection system, the area where you locate the boiler must be level. The boiler comes equipped with leveling feet. Should you find the floor beneath the boiler is uneven, adjust the leveling feet with a wrench.
  • Page 13 Figure 2...

  • Page 14: Clearances For Service Access

    C. CLEARANCES FOR SERVICE ACCESS See Figure 3 for recommended service clearances. If you do not provide the minimum clearances shown, it might not be possible to service the boiler without removing it from the space. Figure 3 Space must be provided with combustion/ventilation air openings correctly sized for all appliances located in the same space as the boiler.

  • Page 15: Prevent Combustion Air Contamination

    You must also install air intake piping from outdoors to the boiler flue adaptor. The resultant installation is categorized as direct vent (sealed combustion). NOTE: To prevent combustion air contamination, see Table 1 in this section when considering exhaust vent and intake air vent termination. Intake and exhaust vents must terminate near each other and may be vented vertically through the roof or out a side wall.

  • Page 16: Uncrating And Moving Boiler

    When removing an existing boiler, the following steps must be followed. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.

  • Page 17: Part 4 - Boiler Piping

    Remove all sides of the shipping crate in order to allow the boiler to be lifted into its installation location. Pick the boiler up by the lift rings to avoid damage to the boiler enclosure. Use either a solid ¾” diameter black iron pipe or lifting straps to lift the boiler off of its shipping crate.

  • Page 18: Backflow Preventer

    All piping methods shown in this manual use primary/secondary connection to the boiler loop. This is to avoid the possibility of inadequate flow through the boiler. For other piping methods, consult your local HTP representative, or refer to Boiler Piping Details in this manual, Part 4, Section G. D. SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE-UP WATER 1.

  • Page 19: Circulators

    Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual boiler failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY. 2. The expansion tank must be located as shown in Part 4, Boiler Piping Details, or following recognized design methods.
  • Page 20 the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle. Chilled water medium must be piped in parallel with the boiler. Freeze protection for new or existing systems must use glycol specifically formulated for this purpose.

  • Page 21: Boiler Piping Details

    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 1 ½” for the 300 and 2” for the 500 and 850.
  • Page 22 Figure 8 – Cascade Multiple Boilers – Indirect Priority on One FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119 3.
  • Page 23 Figure 9 – Single Boiler Space Heating FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. Installations must comply with all local codes. 3. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4.
  • Page 24 Figure 10 – Cascaded Boilers – Space Heating FIGURE NOTES: 1. This drawing is meant to demonstrate system piping concept only. 2. Installations must comply with all local codes. 3. Install a minimum of 12 diameters of straight pipe upstream of all circulators. 4.

  • Page 25: Circulator Sizing

    3. Install purge and balance valve or shut off valve and drain on system return to purge air out of each zone. 4. Install a back flow preventer on the cold feed make-up water line. 5. Install a pressure reducing valve on the cold feed make-up water line (15 PSI nominal on the system return).

  • Page 26: Fill And Purge Heating System

    The chart below represents the various system design temperature rise through the boiler, along with respective flows and friction loss which will aid in circulator selection. Table 3 – Temperature Rise Chart 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 27: Freeze Protection Fluids

    • Open first zone balance and purge or drain valve to let water flow out the hose. If zone valves are used, open the valves one at a time manually. (NOTE: You should check the valve manufacturer’s instructions prior to opening valves manually, so as not to damage the valves.) •...

  • Page 28: Zoning With Circulators

    2. Connect DHW (domestic hot water) piping to indirect storage water heater. L. ZONING WITH CIRCULATORS 1. Connect the boiler to the system when using circulator zoning as shown in Boiler Piping Details. NOTE: The boiler circulator cannot be used for a zone. It must only supply the boiler loop. 2.

  • Page 29: General

    B. GENERAL 1. Install the boiler venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes. 2. This boiler is a direct vent appliance and is listed as a Category IV appliance with Underwriters Laboratories, Inc.
  • Page 30 GALVANIZED U.L. LISTED U.L. LISTED Table 9 – Approved Metallic Venting Material APPROVED STAINLESS STEEL VENT ADAPTERS AND TERMINATIONS Mod Con 300 & 500 HTP PART NUMBER Boiler Adapter 4” 7250P-732 Horizontal Vent Terminal 4” 7350P-607 Vertical Rain Cap 4”...
  • Page 31 Figure 13...

  • Page 32: Exhaust Vent And Intake Air Vent Pipe Location

    E. EXHAUST VENT AND INTAKE AIR VENT PIPE LOCATION You must insert the provided intake and exhaust screen at your vent termination to prevent blockage caused by debris or birds. NOTE: SEE ADDITIONAL REQUIREMENTS FOR MASSACHUSETTS IN THE BACK OF THIS MANUAL.
  • Page 33 Condensate from the boiler is slightly acidic with a pH of 3.2 - 4.5. To avoid long term damage to the drainage system and to meet local code requirements, HTP recommends neutralizing the condensate with a Condensate Neutralizer Kit (Part # 7350P-611). The neutralizer kit connects to the drain system and contains marble chips that neutralize the pH level of the water vapor.

  • Page 34: Exhaust Vent And Intake Air Vent Sizing

    The condensate line must remain unobstructed, allowing free flow of condensate. If condensate freezes in the line, or if line is obstructed in any other manner, condensate can exit from boiler tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage.

  • Page 35: Exhaust Vent And Intake Air Pipe Installation

    The maximum equivalent length for increased diameter vent pipes is 275 feet, which includes the combined 32 feet from the boiler, 16 ft. (inlet) + 16 ft. (exhaust) = 32 ft. combined with transition total of 245 ft. upsize piping for longer vent runs. VENT TRANSITION FITTING SIZE REDUCING COUPLING...
  • Page 36 NOTE: For Canadian Installations, it is required that Non Metallic Vent Installations conform to ULC S636. Where plastic venting is not allowed, HTP recommends AL294C Stainless Steel Venting be used for Exhaust venting installations and “B” vent for intake air.

  • Page 37: Sidewall Venting Diagrams

    J. SIDEWALL VENTING DIAGRAMS Figure 16 – Sidewall Venting with Tee and Coupling...
  • Page 38 Figure 17 – Sidewall Venting Diagrams...

  • Page 39: Vertical Venting Diagrams

    K. VERTICAL VENTING DIAGRAMS Figure 18 – Two Pipe Roof Venting with Tee and Coupling...
  • Page 40 Figure 19 – Roof and Sidewall Venting with Stainless Steel...

  • Page 41: Part 6 - Gas Piping

    PART 6 – GAS PIPING FAILURE TO FOLLOW ALL PRECAUTIONS IN THIS SECTION COULD RESULT IN FIRE, EXPLOSION, OR DEATH! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" w.c. (3.5 kPa), and a minimum of 3.5"...

  • Page 42: Gas Table

    4. It is important to support gas piping as the unit is not designed to structurally support a large amount of weight. 5. Purge all gas lines thoroughly to avoid start up issues with air in the lines. 6. Sealing compound must be approved for gas connections. Care must be taken when applying compound to prevent blockage or obstruction of gas flow which may affect the operation of the unit.
  • Page 43 2. Loosen the pressure tap with a small screwdriver. Refer to Figs. 20 and 21 for locations. 3. Each unit is equipped with a needle valve that will accept a 5/16 ID hose to connect to a digital manometer or liquid gauge to measure incoming pressure from 0-35” w.c. 4.

  • Page 44: Gas Valve

    E. GAS VALVE Figure 21...
  • Page 45 Figure 22...

  • Page 46: Part 7 - Field Wiring

    PART 7 – FIELD WIRING ELECTRICAL SHOCK HAZARD - For your safety, turn off electrical power supply at service entrance panel before making any electrical connections. Failure to do so can result in severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring supplied with the boiler must be replaced, use only TEW 105 C wire or equivalent.

  • Page 47: Alarm Connections

    4. If using DHW, connect the domestic hot water pump to the terminals marked DHW HOT, DHW NEUT, DHW GND. The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If a pump requires more current or voltage than the 120 volts supplied, an external motor starter or contactor will be required.

  • Page 48: Thermostat

    Figure 24 – Mod Con VWH Control F. THERMOSTAT 1. Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box (shown in Figure 24). Alternately, any dry contact closure across these terminals will cause the boiler to run.

  • Page 49: Outdoor Sensor

    2. The boiler will operate an indirect fired water heater with either a thermostat type aquastat installed in the indirect tank, or an HTP 7250P-325 tank sensor. When a tank sensor is used, the control will automatically detect its presence and a demand for heat from the indirect water heater will be generated when the tank temperature falls below the user selected set point by more than the user selected offset.

  • Page 50: Optional Low Gas Pressure Switch

    UL353 LWCO (available from HTP, Part # 7450P-225). In this installation, it is recommended to install the flow switch kit first. M. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT 1.

  • Page 51: Wiring Of The Cascade System Communication Bus

    Do not run unprotected cables across the floor or where they will become wet or damaged. Avoid running communication cables parallel and close to or against high voltage (120 volt or greater) wiring. HTP recommends that the maximum length of communication bus cables not exceed 200 feet.

  • Page 52: Cascade Master Pump And Sensor Wiring

    Figure 25 O. CASCADE MASTER PUMP AND SENSOR WIRING 1. Place the cascade master overlay sticker onto the field connection board on the boiler designated as the cascade master. 2. Connect the system pump hot wire to the terminal marked SYS PUMP. 3.

  • Page 53: Cascade Follower Pump And Sensor Wiring

    Figure 26 – Mod Con Cascade Master P. CASCADE FOLLOWER PUMP AND SENSOR WIRING 1. If it is desired to have the boiler control the boiler pump, connect the boiler pump to the BOILER HOT, BOILER NEUT, and BOILER GND terminals. 2.
  • Page 54 To connect a device that should be powered off during a boiler lockout condition, follow the same instructions as above and use the ALARM NC terminal rather than the ALARM NO terminal. NOTE: In a cascade system, the alarm output of the boiler addressed as #1 will also be active if the master boiler has a lockout condition.
  • Page 55 Figure 28 – Mod Con Internal Connection Diagram...

  • Page 56: Part 8 - Start-Up Preparation

    PART 8 – START-UP PREPARATION A. CHECK / CONTROL WATER CHEMISTRY It is recommended that you test your water quality prior to installation. Listed below are some guidelines. Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage.

  • Page 57: Fill And Test Water System

    1. Determine freeze protection fluid quantity using total system water content following fluid manufacturer’s instructions. Remember to include expansion tank water content. 2. Local codes may require back flow preventer or actual disconnect from the city water supply. 3. When using freeze protection fluid with automatic fill, install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

  • Page 58: Check For Gas Leaks

    begin alternating between SEP and CH and the central heating pump will come on. If you then press {S2}, the central heating pump will shut off, the display will begin alternating between SEP and DH, and the DHW pump will come on. If the boiler is set up as the cascade master and you press the {S2} key again, the DHW pump will shut off, the display will begin alternating between...

  • Page 59: Final Checks Before Starting Boiler

    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 overflow, which, if not corrected, could cause property damage.

  • Page 60: Part 9 - Start-Up Procedure

    Follower Boilers: READ THE NOTES BELOW BEFORE PROGRAMMING FOLLOWER BOILERS • The boiler addressed as 1 will share its alarm output with the master boiler. • If one of the follower boilers has an indirect fired water heater connected to it, the address of this boiler must be 2 or greater.

  • Page 61: Operating Instructions

    5. The boiler shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.) A. OPERATING INSTRUCTIONS Remove boiler cover. If you smell gas, STOP. Follow listed safety instructions. If you do not smell gas, follow the next steps.

  • Page 62: Status Menu

    C. STATUS MENU Installers are also able to check the current status of the boiler parameters by pressing {S4/Reset} for 3 seconds. Once activated, the display will show alternating value of the actual supply temperature. To change the next function value, the user can press {S1} (alternating down to previous function value) or press...

  • Page 63: Test Mode

    installation. Each boiler firing output percentage is displayed. To toggle between values, press {S1} to go down and {S4} to go up. The first function you will see is: System Pump - (0 = Off, 1 = On) |P0| - Master Boiler - Alternating (0-100 Percentage firing rate) |P1| - Follower Boiler #1 –...

  • Page 64: Program Access

    B. PROGRAM ACCESS To start, press and hold {S3} {S4} simultaneously for three seconds. You will notice the display change to |000|. Then, press and hold {S1} until you see |925|. (If you go past |925|, you can use {S2} decrease the number.) This is the pass code.
  • Page 65 Bus address (Cascade 8 Boiler Max) (0 = master 1 – 7 = follower) NOTE: Never address boiler with number 8. Range: 0 to 8. Allows the installer to connect a 0-10 volt directly from Building Management System. To activate, change value to 2. WARNING: Values 1 and 3 are not to be programmed into the board.
  • Page 66 2. Design supply water temperature at the minimum design outside temperature: Function 9. 3. Maximum outside design temperature: Function 10. 4. Design supply water temperature at the maximum outside temperature: Function 11. NOTE: The user can adjust the heat curve down by adjusting the central heating temperature to a lower setting.

  • Page 67: Part 11 - Troubleshooting

    PART 11 – TROUBLESHOOTING A. ERROR CODE If any of the sensors detect an abnormal condition or an internal component fails during the operation of the boiler, the display may show an error code. This code may be the result of a temporary condition, in which case the display will revert to its normal readout when the condition is corrected, or it may be the result of a condition that the controller has evaluated as not safe to restart the boiler.
  • Page 68 1. Check line voltage. Must be between 100 – 128 volts. 2. If available, connect a PC and, using HTP service software, 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 greater than 250.
  • Page 69 1. If the boiler is equipped with High and/or Low gas pressure switches, examine the yellow LED lights on each switch. If lit, correct the gas supply problem associated with the switch. Then, reset the switch by pressing on the cover of the switch over the red button.

  • Page 70: Part 12 - Maintenance

    Control must be re-programmed. If programming does not solve problem, control must Program parameter error be replaced. Table 19 Figure 30 PART 12 – MAINTENANCE A. MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all equipment is operating safely and efficiently.

  • Page 71: Combustion Chamber Coil Cleaning Instructions For Heater

    The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”...
  • Page 72 2. Using a spray bottle filled with lime remover, spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate system. If the condensate system is blocked, let chemical penetrate for at least 15 minutes, or until condensate drains. 3.
  • Page 73 Figure 32...
  • Page 74 Figure 33...
  • Page 75 Figure 34...
  • Page 76 Figure 35...
  • Page 77 Figure 36...

  • Page 78: Boiler Start-Up Report

    BOILER START-UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED ________________ 1) Fill the Check all piping and gas connections, heating verify all are tight system Pressurize system (12 – 15 PSI) ____ PSI Add water to prime condensate cup Percentage of glycol in system (0-50%) ____% Verify near heater piping is properly supported...

  • Page 79: Maintenance Report

    MAINTENANCE REPORT Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.

  • Page 82: Maintenance Notes

    MAINTENANCE NOTES...

  • Page 83: Htp Customer Installation Record Form

    Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative. Distributor/Dealer: Please insert contact details.

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