HTP MODCON500 FS Installation, Start-Up, Maintenance, Parts, Warranty Download Page 1

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ModCon

Commercial Boilers

Installation

Start-Up

Maintenance

Parts

Warranty

MODCON500 / 700 / 850 Models*

*“LP” Denotes Propane Gas Operation
“HL” Denotes Installed High and Low Gas Pressure Switches
“FS” Denotes Installed Flow Switch
“WL” Denotes Installed High Temperature Water Limit

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.

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.

New Bedford, MA 02745

www.htproducts.com

lp-445-r4 Rev. 006 Rel. 027 Date 7.21.20

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property

damage, severe personal injury, or death.

This Manual For Use With Boilers Manufactured After

August 13, 2013

Heat Exchanger Bears the ASME “H” Stamp

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth

defects, or other reproductive harm.

Summary of Contents for MODCON500 FS

Page 1: ...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 New Bedford MA 02745 www htproducts com lp 445 r4 Rev 006 Rel 027 Date 7 21 20 Improper installation adjustment alteration service or maintenance could void product warr...

Page 2: ...nce Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be provided by a qualified installer service agency or the gas supplier Improper installation adjustment alteration service or maint...

Page 3: ...st be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the boiler and by local codes and utility company requirements In the absence of local codes preference should be given to the National Fuel Gas Code ANSI Z223 1 latest version Installations Must Comply With Local state provincial and national codes laws regulations and ordinances ...

Page 4: ...he control will reduce the maximum fan speed If the temperature difference exceeds 60 F the control will effectively sense there is little or no water flow or heat load and shut the boiler down The controller will restart automatically once the temperature difference has dropped below 55 F and the minimum off time anti cycle time has expired In addition if the control senses that the outlet water ...

Page 5: ...ES 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 qualified 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 ca...

Page 6: ...ranty E Freeze Protection NOTE Consider piping and installation when determining boiler location Remove all sides of the shipping crate of the boiler Components included with the boiler Temperature and Pressure Gauge Outdoor Sensor Three 3 Stainless Steel Screens Installation Manual and Warranty User s Information Manual CSD 1 Form H 3 Data Sheet A What s in the Box B How the Boiler Operates ModCo...

Page 7: ...Compliant Low Water Cut Off Interface Kit with Manual Reset 7350P 601 Alarm System to monitor any failure 7350P 602 PC Connection Kit 7250P 320 Condensate Neutralizer 7350P 611 Caster Kit 7350p 604 Stacking Kit 7350P 603 Flow Switch Kit 7350P 605 COLD WEATHER HANDLING If the boiler has been stored in a very cold location BELOW 0o F before installation handle with care until the components come to ...

Page 8: ... a boiler NOTE When installing in a zero clearance location it may not be possible to read or view some product labeling It is recommended to make note of the boiler model and serial number Use extreme care not to drop the boiler or cause bodily injury while lifting the boiler Gas conversion should be performed BEFORE the boiler is installed Carefully follow the gas conversion instructions when pe...

Page 9: ...all the boiler burner and ignition devices a minimum of 18 above the floor of the garage This will ensure the burner and ignition devices are well off the floor When raising the boiler ensure the entire bottom and fully filled weight of the boiler are fully supported Locate or protect the boiler so it cannot be damaged by a moving vehicle Figure 3 Recommended Service Clearances F Exhaust Vent and ...

Page 10: ...d be provided with two permanent openings one located 6 15 cm below the space ceiling the other 6 15cm above the space floor Each opening should have a free area of one square inch per 1 000 BTU hr 22cm2 kW of the total input of all appliances in the space but not less than 100 square inches 645cm2 If the confined space is within a building of tight construction air for combustion must be obtained...

Page 11: ...thermostat so the appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined return doors windows exhaust fans fireplace dampers ...

Page 12: ...5 Boiler Dimensions NOTE All Dimensions Are Approximate VWH in Model Number Denotes Volume Water Heater Model scale build up throughout the system Water below 5 grains gallon 85 mg L may be over softened Consult local water treatment companies for unusually hard water areas above the required amounts or for other treatment solutions if water is being over softened below 5 grains gallon 85 mg L Chl...

Page 13: ...park Ignition Flame Rectification Burner System Premixed Fuel Modulation Stainless Steel Metal Fiber Burner Gas Valve System Air Ratio Valve Dimensions in Inches W 20 5 H 36 D 46 68 5 Boiler Water Content Gallons 4 2 5 8 Minimum Flow Rate 30oF T GPM 33 54 Boiler Setpoint Temperature Range 50 190oF 32 190oF with Outdoor Reset Curve DHW Indirect Setpoint Temperature Range 70 185oF Water Pressure PSI...

Page 14: ...f and call a plumber immediately Connect discharge piping to a safe disposal location by following these guidelines RE INSPECTION OF T P RELIEF VALVES T P valves should be inspected AT LEAST ONCE EVERY THREE YEARS and replaced if necessary by a licensed plumbing contractor or qualified service technician to ensure that the product has not been affected by corrosive water conditions and to ensure t...

Page 15: ...pressure and outlet temperature from the boiler It is important to note that the boiler has a minimal amount of pressure drop that must be calculated when sizing the circulators Each boiler installation must have an air elimination device that will remove air from the system Install the boiler so the gas ignition system components are protected fromwater dripping spraying etc Allowclearanceforbasi...

Page 16: ...30 Δt Model Friction Ft Flow Rate GPM Friction Ft Flow Rate GPM Friction Ft Flow Rate GPM 500 19 50 11 40 8 33 700 850 35 85 26 65 18 54 Table 6 Temperature Rise Friction Feet and Flow Rate 500 Model 700 850 Models In addition the boiler heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator Minimum boiler flow rates are listed in the table below...

Page 17: ...ediment NOTE It is recommended you clean heat exchanger at least once a year to prevent lime scale buildup Follow the maintenance procedure to clean the heat exchanger in the Maintenance Section of this manual Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are ...

Page 18: ...ke up water line 5 Install a pressure reducing valve on the cold feed make up water line 15 PSI nominal on the system return Check temperature and pressure gauge when operating It should read a minimum pressure of 12 PSI 6 Install a circulator as shown in piping details this section Make sure the circulator is properly sized for the system and friction loss 7 Install an expansion tank on the syste...

Page 19: ...and downstream of all closely spaced tees 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 2 8 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 9 Installations must comply with all local codes 10 In Massachusetts a vacuum relief valve must be in...

Page 20: ...rate 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 Piping shown is Primary Secondary 5 The minimum pipe size for connecting a Mod Con boiler is 2 6 System flow Secondary Loop must be greater than the boiler s Primary Loop flow 7 Installati...

Page 21: ...t pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter Failure to do so could result in property damage severe personal injury or death Due to the extreme flammability of most glues cements solvents and primers used to join plastic exhaust vent and intake pipes explosive solvent vap...

Page 22: ...ce must be used for near appliance piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID appliance warranty PVC CPVC pipe and fittings of the same diameter are considered interchangeable The use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in non metallic venting systems is prohibited Covering ...

Page 23: ...hat may be opened Direct Vent 1 foot 3 feet 91 cm Power Vent 4 ft below or to side of opening 1 ft above opening C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Cl...

Page 24: ...pe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is located where it will not be exposed to prevailing winds 5 In all roof venting applications exhaust discharge must point away from the pitch of the roof 6 If the exhaust vent is to be terminated in a walled off area such as a roof with a parapet wall ensure t...

Page 25: ...ches in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS Marking of Exhaust Vent and Intake Pipe Piping used for ventilation make up or combustion air intake shall be labeled as follows a Throughout the entire developed length i Labels must be placed every ten feet for exposed visible piping or ii Labels must be placed every three feet for concealed piping b At all changes of direction ...

Page 26: ...ckets on vent piping the first bracket must be within 1 foot of the boiler and the balance of 4 foot intervals on the vent pipe Venting must be readily accessible for visual inspection from the first three feet from the boiler NOTES A For every 1 of overhang the exhaust vent must be located 1 vertical below overhang overhang means top of building structure and not two adjacent walls corner of buil...

Page 27: ...ting only The installer is responsible for all equipment and detailing required by local codes Ensure the terminations are screened to prevent blockage caused by debris or birds Figure 15 Unbalanced Venting Roof Exhaust and Sidewall Intake An unbalanced vent system can be installed ONLY when the exhaust is in the vertical position Failure to do so could result in serious personal injury or death F...

Page 28: ...mbustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room each of the two openings should be sized based on a minimum free area of one square inch per 2000 BTU hr input See Figure 18 3 If air is taken from another interior space combined with the mechanical room a Two spaces on same story Each of the two openings specified should have a net free...

Page 29: ...y air from the unit Failure to follow these instructions could result in property damage or personal injury Combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the boiler See Table 1 for a list of combustion air contaminants These chemicals when burned form acids which quickly attack the stainless steel heat exchanger he...

Page 30: ... boiler Wiring errors can cause improper and dangerous operation Failure to follow these instructions may result in property damage or personal injury It is of extreme importance that this unit be properly grounded It is very important that the building system ground is inspected by a qualified electrician prior to making this connection Electrical power must only be turned on when the boiler is c...

Page 31: ... preferably on the north side in an area that will not be affected by direct sunlight and will be exposed to varying weather conditions I Indirect Sensor NOTE There is no connection required if an indirect water heater is not used in this installation 1 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 t...

Page 32: ...and place the jumper plug into the mating connector coming from the LWCO control box 6 Connect the pigtail to the remaining plug coming from the LWCO control box Installation is complete 7 If the pigtail located in step 5 is connected to a gas pressure switch disconnect it from the gas pressure switch and connect the pigtail to the mating connector coming from the LWCO control box Connect the gas ...

Page 33: ...ed Master Q 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 If you are using an indirect fired water tank connected directly to the follower boiler connect the pump for it to the DHW HOT DHW NEUT and DHW GND terminals If desired an alarm bell or light can be connec...

Page 34: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 34 Figure 26 Cascade Master and Follower Wiring ...

Page 35: ... GAS VALVE WIRING APPLICATION Figure 27 Internal Connection Diagram Part 8 Gas Connections Failure to follow all precautions could result in fire explosion severe injury or death It is very important that you are connected to the type of gas noted on the rating plate LP for liquefied petroleum propane gas or NG for natural or city gas Do not do a gas conversion without an approved gas conversion k...

Page 36: ...e you must isolate the boiler from the gas line In order to do this shut the gas off using factory and field installed gas cocks This will prevent high pressure Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure greater than PSI 14 w c 3 5 kPa the gas valve must be replaced Never use an open flame match lighter etc to check gas connections Never use an op...

Page 37: ...by static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the boiler It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition failure This problem is especially DO NOT adjust or attempt to measure gas valve outlet pressure...

Page 38: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 38 Figure 29 500 Model Gas Valve D Boiler Gas Valve Figure 30 700 850 Model Gas Valve ...

Page 39: ...ons B Check for Gas Leaks Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove boiler front door and smell interior of boiler enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leaks at once PROPANE BOILERS ONLY The propane supplier mixes an odorant with the propane to ma...

Page 40: ... DHW pump will shut off The display will read The system pump will come on Use the and v keys to toggle between running each pump in the system as required to help bleed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and pump operation becoming very quiet Pressing and v together at any time will return the boiler to normal operati...

Page 41: ...e system has its individual safety controls intact and operational even if the firing of the boiler is under control of the master boiler In the event that the system sensor fails all boilers in the system will ignite simultaneously when there is a demand and each boiler will L Cascade System Programming 1 If the boiler is used alone skip this section 2 Programming the Master Boiler a Make sure th...

Page 42: ... digit to the correct value Use the arrow keys to select the next digit to change and again use the v keys to change the value Repeat until the correct code is entered Press the ENTER key to accept the code entered If the code is correct the readout will change to the appropriate screen If the programming code is not accepted the readout will continue to display as shown above ENTER is also used t...

Page 43: ...l clock does not adjust for daylight savings time and requires manual adjustment E Programming the System Setting System Setting Program Access Note Programming the boiler control is not possible when the boiler is firing Make sure any input which can create a demand on the boiler such as the tank thermostat is turned off so the boiler will remain idle to allow programming Screen Description ENTER...

Page 44: ...on which regulates burner output in six steps at one minute intervals Step modulation will start at the last modulation rate of the boiler and work up one minute at a time Default OFF Selection OFF or ON Function 19 Boiler DHW Temp BOILER SUPPLY DHW 180 oF 19 Allows the user to program the boiler supply water temperature to the indirect heat exchanger during a demand cycle Default 180oF Range 119o...

Page 45: ...aintenance schedule Factory Default OFF Range Date or Run Hours NOTE Without setting thisfunction Functions33 34 35 36 will not display Function 37 Modbus Mode MODBUS MODE OFF 37 Enables Modbus Mode on the appliance Factory Default OFF Range OFF ON AUTO NOTE Turning Modbus Mode ON will open a number of additional parameters to customize Modbus installation See Modbus Instructions lp 372 for detail...

Page 46: ...after pressing and shows the actual temperatures measured by the supply and return sensors NOTE If the boiler is configured to use a 0 10 volt input the return sensor is disabled and the second line of the display will be blank Press v once CH SET 180oF SUPPLY SEN 122oF The screen displays the current central heating temperature set point on the top line NOTE This temperature set point may vary fr...

Page 47: ...ternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display the date and time that the fault occurred Press v once FAULT HISTORY 3 08 28 2009 Fr 5 19A This screen displays the third oldest boiler control lockout fault The top line will alternate between the words FAULT HISTORY and the actual fault encountered The bottom line will display the date and time ...

Page 48: ...cascade status The TT in the center of the top line shows that cascade demand is coming from TT contact being closed You may also see DHW if the demand is from a DHW sensor or 0 10 if the demand is from a 0 10 volt input The following numbers show which boiler addresses are currently communicating to the master If a boiler address is not used or communicating the number will not display In the exa...

Page 49: ...rror code and message when an error condition occurs These error codes descriptions and recommended corrective actions are described in Section D C Boiler Fault 1 The controller will illuminate the red FAULT indication light and display a fault code and message when a fault condition occurs The alarm output will also activate Most fault conditions cause the CH pump to run in an attempt to cool the...

Page 50: ...This occurs because the water temperature measured by the supply sensor is higher than the tank temperature ignition diff setting This message will stay present until the water temperature measured by the supply sensor is less than the tank temperature ignition diff setting TEMPER BLOCKING PUMP ON DHW DHW indicates there is a demand for heat on the boiler from the DHW circuit the pump is powered o...

Page 51: ...e wiring is ok and this code is still present and the water is not excessively hot replace the ECO sensor Screen Description Possible Remedy FLUE TEMP WAT LV F01 PUMP ON This code indicates that one of the safety interlock switches present in the unit has tripped There are several interlock switches that could possibly trip and cause this error The following four switches are installed and are sta...

Page 52: ...n the chart should be close to the temperature in the flue If not replace the flue sensor Screen Description Possible Remedy SUPPLY TEMP HIGH F05 PUMP ON F05 indicates the boiler supply temperature is excessive When accompanied by the red FAULT light and LOCKOUT flashing on the display this code indicates the supply sensor temperature has exceeded 230oF and a serious safety issue exists The boiler...

Page 53: ...heck the burner and its sealing gaskets FALSE FLAME SIG F11 PUMP ON There is flame when the control is not telling the boiler to run This is a serious safety issue as indicated by the illuminated red light and the word LOCKOUT flashing on the display The boiler will not restart until a technician determines and repairs the cause and pushes RESET on the display During this lockout fault the pump wi...

Page 54: ...trol is left in a locked out mode Press RESET for at least 1 second to use the control OUTDOOR SENSOR FOU PUMP ON 1 45P There is an issue with the outdoor sensor It is shorted damaged or disconnected from the boiler 1 Check outdoor sensor connections and wiring Ensure the sensor and wiring are intact and that the sensor is connected to the boiler 2 Checktheoutdoorsensorresistancewithanohmmeter See...

Page 55: ...he time this document was written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combust...

Page 56: ...31 Heat Exchanger Detail C Cleaning Water Side of Heat Exchanger 1 Make sure power is turned off to the boiler Run water through the hot water system to ensure it is below room temperature 2 Close isolation valves on the return and supply connections to the boilers as shown in the piping diagrams in this manual Slowly open the ball valves and release pressure into a bucket Once pressure is release...

Page 57: ...onvert the Boiler 500 Model ONLY If necessary convert the boiler to the proper fuel type Locate the stickers in the appropriate locations on the boiler Verify combustion settings after gas conversion Carbon Dioxide CO2 High Fire CO2 Low Fire Verify combustion settings after gas conversion Carbon Monoxide ppm CO High Fire ppm CO Low Fire Mail in conversion registration Notes Table 30 Installation C...

Page 58: ...lean probe with plumbers cloth to remove oxides Combination Ignitor and Flame Probe Check ionization in uA d7 in Status Menu in Start Up Procedures Record high fire and low fire Clean probe with plumbers cloth to remove oxides Condensate 1st Year 2nd Year 3rd Year 4th Year Neutralizer Check condensate neutralizer Replace if necessary Condensate Pipe Disconnect condensate pipe Clean out dirt Fill w...

Page 59: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 59 Figure 32 500 Model Combustion System Replacement Parts Not Shown 500 Models Part 16 Replacement Parts ...

Page 60: ...0 60 Figure 33 700 850 Model Combustion System Replacement Parts 700 and 850 Models Model Control Board Part Numbers Model Control Board Part Numbers MODCON500 7350P 1300 MODCON850 7350P 1302 Table 32 Control Board Replacement Part Numbers ...

Page 61: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 61 Figure 34 Water Side Replacement Parts All Models ...

Page 62: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 62 Figure 35 Cabinet Replacement Parts All Models See Table ...

Page 63: ...boiler shall then be deemed to have commenced thirty 30 days after the date of manufacture of the boiler and NOT the date of installation of the boiler and be covered by the unexpired portion of the warranty detailed above G This warranty extends only to boilers utilized in closed loop heating applications that have been properly installed based upon the manufacturer s installation instructions H ...

Page 64: ... respond within three 3 business days The claim will be automatically closed if requested information is not provided within thirty 30 days Claims will not be reopened without HTP Warranty Supervisor approval During the claims process a product that must be replaced will be given a designation of either a field scrap or b return to HTP If the product must be returned to HTP the returned product mu...

Page 65: ...lp 445 r4 Rev 006 Rel 027 Date 7 21 20 65 Maintenance Notes ...

Page 66: ...stallation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Customer Please only sign after the qualified installer service technician has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the qual...

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