User Manual
Mod Con
USER’S INFORMATION
MANUAL
Mod Con Models
500 / 850 / 1000 / 1700
Mod Con VWH Models*
500 / 850 / 1000 / 1700
Heat Exchanger Bears the ASME “H” Stamp
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
*The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe
Drinking Water Act, Section 1417.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
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 BOILER.
WHAT TO DO IF YOU SMELL GAS
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Do not try to light any boiler.
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.
120 Braley Rd. P.O. Box 429
East Freetown, MA 02717-0429
www.htproducts.com
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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.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
NOTICE
NOTICE is used to address practices not related to personal injury.
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TABLE OF CONTENTS
PART 1 – PRODUCT AND SAFETY INFORMATION ............................................................................................................................... 4
A. BOILER OPERATION ........................................................................................................................................................................ 4
B. PRIMARY WATER ............................................................................................................................................................................. 4
C. FREEZE PROTECTION FLUIDS....................................................................................................................................................... 4
PART 2 – COMBUSTION AIR – CONTAMINATION PREVENTION ........................................................................................................ 5
PART 3 – MAINTENANCE SCHEDULE.................................................................................................................................................... 5
A. SERVICE TECHNICIAN .................................................................................................................................................................... 5
B. OWNER MAINTENANCE .................................................................................................................................................................. 6
PART 4 – MAINTENANCE PROCEDURES .............................................................................................................................................. 6
A. DAILY MAINTENANCE ...................................................................................................................................................................... 6
B. MONTHLY MAINTENANCE .............................................................................................................................................................. 7
C. 6 MONTH MAINTENANCE ................................................................................................................................................................ 7
MAINTENANCE NOTES .................................................................................................................................................................... 8
PART 1 – PRODUCT AND SAFETY INFORMATION
USER – Have this boiler serviced/inspected by a qualified service technician annually.
FAILURE TO ADHERE TO THE GUIDELINES IN THIS MANUAL CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE
PERSONAL INJURY, OR DEATH.
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).” DO NOT, UNDER ANY
CIRCUMSTANCES, OPEN THE COMBUSTION CHAMBER OF THIS BOILER! The combustion chamber of this boiler may be opened
by a qualified service technician ONLY. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SUBSTANTIAL
PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
A. BOILER OPERATION
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Do not block flow of the boiler exhaust vent or intake pipe.
Should overheating occur, or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead,
shut off the gas supply at a location external to the boiler following the instructions on page 2.
Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and
replace any part of the control system or gas control that has been under water.
B. PRIMARY WATER
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Do not attempt to clean the heating system. Call a qualified service technician for service.
If you notice any leaks, immediately call a qualified service technician. Leaks in boiler or piping must be repaired at once.
C. FREEZE PROTECTION FLUIDS (DOES NOT APPLY TO VWH MODELS)
Hydronic systems that use glycol as heat transfer fluid must be serviced periodically. Glycol can break down over time, become acidic,
and attack gaskets and seals in boilers. This can result in property damage, severe personal injury, or death.
Each glycol manufacturer has different recommendations for testing and replacement. Do not test glycol quality yourself. Have your
qualified service technician check glycol quality during annual servicing. If you are unsure when your glycol was last tested, call a
qualified service technician to test and replace glycol, if necessary.
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PART 2 – COMBUSTION AIR – CONTAMINATION PREVENTION
Do not operate the boiler if its combustion air intake is located in or near one of the areas or in the vicinity of products listed in Table 1.
These areas will always contain hazardous contaminates that can form strong acids while passing through the burner and vent system.
These acids will corrode the boiler’s heat exchanger, burner components and vent system, resulting in flue gas spillage and/or water
leakage, possible substantial property damage, severe personal injury, or death. If the boiler combustion air intake is located in any
area likely to cause or contain contamination, or if products which would contaminate the air cannot be removed, the intake must be repiped and terminated to another location.
DO NOT re-pipe ventilation system on your own. Call a qualified service provider for assistance.
PRODUCTS TO AVOID
Spray cans containing fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric or Muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, laundry detergents, and cleaning solvents
Adhesives used to fasten building products
Table 1
AREAS LIKELY TO HAVE CONTAMINANTS
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages and workshops
PART 3 – MAINTENANCE SCHEDULE
A. SERVICE TECHNICIAN
The following maintenance should be performed by a qualified service
technician annually:
General
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Attend to any reported problems.
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Inspect the interior of the boiler jacket area; clean and
vacuum if necessary.
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Clean the condensate trap and fill with fresh water.
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If applicable, check the condensate neutralizer and ensure it
is full of condensate neutralizing marble chips.
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Check for leaks: Water, gas, flue and condensate.
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Verify exhaust vent and intake piping are in good condition
and sealed tight.
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Check exhaust vent and intake pipe bracing. Ensure bracing
is undamaged and in good condition.
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Check boiler water pressure, piping and expansion tank.
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Check control settings.
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Check ignition electrode. Sand off any white oxide. Clean and reposition.
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Check ignition and ground wiring.
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Check all control wiring and connections.
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Check burner flame pattern (stable and uniform).
Additional Items if Combustion or Performance is Poor
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Clean heat exchanger and flue ways.
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Remove burner assembly and clean burner head using compressed air only.
Once the maintenance items are completed, the service technician should review service with the owner.
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B. OWNER MAINTENANCE
Periodically
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Check area around the boiler.
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Check and remove any blockage from the outdoor exhaust vent and intake pipe terminations. DO NOT perform this
maintenance if exhaust vent and intake pipe terminations are in difficult to reach locations.
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Check the temperature/pressure gauge.
Monthly
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Check exhaust vent and intake piping.
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Check exhaust vent and intake pipe bracing. Ensure bracing is undamaged and in good condition.
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Check the pressure relief valve.
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Check the condensate drain system.
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If applicable, check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips.
Every 6 Months
Check boiler piping and gas supply piping for corrosion or signs of potential leakage.
PART 4 – MAINTENANCE PROCEDURES
The boiler must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In
addition, the maintenance and care of the boiler as outlined in this manual must be performed by the user/owner to assure maximum
efficiency and reliability. Follow the maintenance procedures given throughout this manual. Failure to perform the service and
maintenance or follow the directions in this manual could damage the boiler or system components, resulting in substantial property
damage, severe personal injury, or death.
A. DAILY MAINTENANCE
Check the Surrounding Area
To prevent the potential of substantial property damage, severe personal injury, or death, eliminate all the materials listed in Table 1
from the area surrounding the boiler and the vicinity of the combustion air intake. If contaminates are found:
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Remove products immediately from area.
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If contaminates have been there for an extended period, call a qualified service technician to inspect the boiler for possible
damage from acid corrosion.
If products cannot be removed, immediately call a qualified service technician to re-pipe the combustion air intake piping away from the
contaminated areas.
Combustible/Flammable Materials
Do not store combustible materials, gasoline, or other flammable vapors or liquids near the boiler. If found, remove these materials
immediately.
Air Contaminates
If allowed to contaminate combustion air, products containing chlorine or fluorine will produce acidic condensate that will cause
significant damage to the boiler. Read the list of potential contaminates and areas likely to have these contaminates in Table 1, Part 2.
If any of these contaminates are in the room where the boiler is located, or combustion air is taken from one of the areas listed, the
contaminates must be removed immediately or the intake pipe must be relocated to another area.
Check Exhaust Vent and Intake Pipe Terminations
Verify that the boiler exhaust vent and intake pipe terminations are clean and free of obstructions. Remove any debris from the exhaust
vent and intake pipe openings. If removing the debris does not allow the boiler to operate correctly, contact your qualified service
technician to inspect the boiler and the vent system.
Check Temperature Display and Pressure Gauge
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Ensure the pressure reading on the gauge does not exceed 25 psig. Higher pressure readings may indicate a problem with the
expansion tank.
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Ensure the temperature on the LED display panel does not exceed 180 F. Higher temperature readings may indicate a
problem with the thermostat operating controls.
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Contact a qualified service technician if problem persists.
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B. MONTHLY MAINTENANCE
Check Exhaust Vent and Intake Piping
Visually inspect the exhaust vent for any signs of blockage, leakage, or deterioration of the piping. Inspect the exhaust vent bracing.
Ensure bracing is undamaged and in good condition. Notify a qualified service technician immediately if any problems are found.
Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure, causing
severe personal injury or death.
Visually inspect the intake piping for any signs of blockage. Inspect the entire length of the intake pipe to ensure piping is intact and all
joints are properly sealed. Inspect the intake pipe bracing. Ensure bracing is undamaged and in good condition. Notify a qualified
service technician if any problems are found.
Check Pressure Relief Valve
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Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage.
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If the pressure relief valve often weeps, the expansion tank may not be operating properly. Immediately contact a qualified
service technician to inspect the boiler and system.
Check Exhaust Vent Condensate Drain System
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While the boiler is running, check the discharge end of the condensate drain tubing. Ensure no flue gas is leaking from the
condensate drain tubing by holding your fingers near the opening.
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If you notice flue gas leaking from the opening, this indicates a dry condensate drain trap. If problem persists, contact a
qualified service technician to inspect the boiler and condensate line and refill the condensate trap.
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If applicable, check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips.
C. 6 MONTH MAINTENANCE
Check Primary and Gas Piping
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Remove the boiler cover and perform a gas leak inspection following Operating Instructions, page 2, this manual. If gas odor
or leak is detected, follow procedures on page 2. Call a qualified service technician.
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Visually inspect for leaks around the internal boiler water connections and around the heat exchanger. Visually inspect the
external system piping, circulators, and system components and fittings. Immediately call a qualified service technician to
repair any leaks.
Have leaks fixed at once by a qualified service technician. Failure to comply could result in substantial property damage, severe
personal injury, or death.
Operate Pressure Relief Valve
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Before proceeding, verify that the relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of
scalding from hot water.
To avoid water damage or scalding due to relief valve operation, a discharge line must be connected to the valve outlet and directed to
a safe place of disposal. This discharge line must be installed by a qualified service technician or heating/plumbing installer in
accordance with the boiler installation manual. The discharge line must be terminated so as to eliminate possibility of severe burns or
property damage should the valve discharge.
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Read the temperature and pressure gauge to ensure the system is pressurized. Minimum is 10 psi. Maximum is 25 psi. Lift the
relief valve top lever slightly, allowing water to relieve through the valve and discharge piping.
If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure
that the valve does not weep after the line has had time to drain. If the valve weeps, lift the lever again to attempt to clean the
valve seat. If the valve does not properly seat and continues to weep, contact a qualified service technician to inspect the
valve and system.
If water does not flow from the valve when you completely lift the lever, the valve or discharge line may be blocked.
Immediately shut the boiler down per instructions on page 2 and call a qualified service technician to inspect the valve and
system.
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MAINTENANCE NOTES
LP-447 REV. 9.4.14
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