Delta PG PLUS-25 User Manual

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa­tion in order to gain warranty coverage.

When receiving the Delta Performance unit, any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.

Leave all documentation received with appliance with owner for future reference.

WARNING

- Input from 100,000 to 199,000 Btu/hr -

NOTICE

2005-7 PG PLUS Manual 1/2005

If the information in this manual is not followed exactly, a fire or explosion may
result causing pro p e r ty damage, personal injury or d e a t h .

FOR YOUR SAFETY

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.

• WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- 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
s u p p l i e r ’s instructions.

- If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the
gas supplier.

PG PLUS-25/30/35/40 & 45

Gas Fired

Combination Heaters

Category IV Vented Appliance

Table of Contents

i

PRODUCT AND SAFETY INFORMATION

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Code Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION I - PRE-INSTALLATION ITEMS

Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Flooring and Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION II - COMBUSTION AIR AND VENTING

Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Outside Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Air Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Methods of Accessing Combustion Air into a Space . . . . . . . . . . . . . . . . . . 8-10

Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 11

SECTION III - UNIT PREPARATION

Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydrostatic Pressure Test

Hydrostatic Test Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydrostatic Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Completion of Hydrostatic Test and Draining . . . . . . . . . . . . . . . . . 13

SECTION IV - DOMESTIC PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Domestic Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Temperature / Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table of Contents

ii

U-Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Domestic Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Storage Tank Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TR/Smart Series Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Domestic Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19

SECTION V - PRIMARY PIPING

General Piping Requirements

Low Water Cut-off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Primary System Piping Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Expansion Tank and Makeup Water

Diaphragm (Bladder) Expansion Tank. . . . . . . . . . . . . . . . . . . . . . . 20

Closed-Type (Standard) Expansion Tank . . . . . . . . . . . . . . . . . . . . . 20

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Closet (Zero Clearance) Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Piping - Radiant Heating with Mixing Valves. . . . . . . . . . . . . . . . . 21-22

System Piping - Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . 22

Primary Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-26

SECTION VI - VENT / COMBUSTION AIR INSTALLATION

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Category IV Vent Termination Guideline. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Category IV Vent Termination Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Multiple Vent Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Location the Combustion Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Venting Option - Non-Direct Vent / Vertical . . . . . . . . . . . . . . . . . . . . . . . . 29

Venting Option - Direct Vent / Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Venting Option - Non-Direct Vent / Horizontal . . . . . . . . . . . . . . . . . . . . . . 30

Venting Option - Direct Vent / Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Horizontal Wall Thimble Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Excessive Horizontal Vent Runs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Vent Appliance Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Vent Condensate Tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Condensate Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Determining Piping Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33

Venting Option Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36

iii

Table of Contents

SECTION VII - GAS PIPING

Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Natural Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . 38

Propane Gas

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 39

SECTION VIII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Internal Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-42

SECTION IX - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Outdoor Temperature Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

External Control Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-46

SECTION X - START-UP PREPARATION

Check System and Domestic Water Chemistry

Water pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Water Hardness Less Than 7 Grains. . . . . . . . . . . . . . . . . . . . . . . . . 47

Chloride Concentration Less Than 80mg/L . . . . . . . . . . . . . . . . . . . 47

Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Flush Primary and Domestic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Use of Antifreeze in the Primary System . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Filling the Inner (Domestic) Tank and System . . . . . . . . . . . . . . . . . . . . . . 48

Filling the Outer (Primary) Tank and System . . . . . . . . . . . . . . . . . . . . . . . 48-49

Check Low Water Cut-off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Verify Correct Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Verify Correct Air Shutter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

iv

Table of Contents

SECTION XI - START-UP PROCEDURES

Final Checks Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

PERFORMANCE PLUS Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

If PERFORMANCE PLUS Does Not Start Correctly . . . . . . . . . . . . . . . . . 51

Check the PERFORMANCE PLUS and System . . . . . . . . . . . . . . . . . . . . . 51

Start-Up / Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-53

SECTION XII - TEMPERATURE LIMITS

Setting Primary Thermostat Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Adjustment of Secondary Thermostat Limit . . . . . . . . . . . . . . . . . . . . . . . . 54

Setting the Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION XIII - CHECK-OUT PROCEDURES

Check-out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SECTION XIV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SECTIONS XV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION XVI - MAINTENANCE PROCEDURES

Maintenance Procedures

Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Check System (Primary and Domestic) Piping . . . . . . . . . . . . . . . . 59

Check Combustion/Ventilation Air Operating . . . . . . . . . . . . . . . . . 60

Inspect Vent System and Combustion Air Piping . . . . . . . . . . . . . . 60

Check Primary System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Domestic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Temperature / Pressure Relief Valve . . . . . . . . . . . . . . . . . . . 61

v

Table of Contents

Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61

Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Thermostat Limit Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 61

Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

SECTION XVII - REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-67

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-69

Product & Safety Information

1

Indicates the presence of a hazardous
situation which, if ignored, will result
in death, serious injury or substantial
property damage.

Indicates a potentially hazardous situ­ation which, if ignored, can result in
death, serious injury or s u b s t a n t i a l
property damage.

Indicates a potentially hazardous situ­ation which, if ignored, may result in
minor injury or property damage.

Indicates special instructions on instal­lation, operation or m a i n t e n a n c e ,
which are important to equipment but
not related to personal injury hazards.

Indicates recommendations made by
Triangle Tube for the installers which
will help to ensure optimum operation
and longevity of the equipment

BEST PRACTICES

NOTICE

CAUTION

WARNING

DANGER

The following terms are used throughout this manual to bring attention to the presence of
potential hazards or to important information concerning the product.

Triangle Tube reserves the right to modify the technical specifications and components of
its products without prior notice.

NOTICE

Product & Safety Information

2

Bacteria can develop in the domestic
w a t e r system if certain minimum water
t e m p e r a t u r es are not maintained.

Water temperature over 125ºF can cause
s e v e re burns instantly or death fro m
scalds.

• Children, disabled and elderly are at
highest risk of being scalded.

- Never leave them unattended in or

near shower, bathtub or sink.

- Never allow small children to use a

hot water faucet or draw their own
bath.

• If any one using hot water in the building
fits this description or codes require spe­cific water temperatures at hot water
faucet, we recommend:

a) ensure the factory installed thermosta-

tic mixing valve is working properly.

b)to set the thermostatic mixing valve

for the lowest temperature which sat­isfies your hot water need.

.

Protection must be taken against excessive
temperature and pressure!

TO PROTECT AGAINST EXCESSIVE
TEMPERATURE AND PRESSURE

• Check if the Temperature and
Pressure (T&P) relief valve is in the
location provided. (Domestic Water)

• Check if the 30 psi relief valve sup­plied is in the location provided.
(Primary water)

• To avoid injury, install the relief
devices to comply with local code
requirements.

CAUTION

DANGER

WARNING

3

Product & Safety Information

Do not use this appliance if any part
has been under water. Immediately call
a qualified service technician to inspect
the appliance and to replace any part of
the control system which has been
under water.

WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; do
not use any phone in your b u i l d i n g .

- Immediately call your gas supplier
f r om 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 per­formed by a qualified installer, service
agency or the gas supplier.

Should overheating occur or the gas
supply fails to shut off, turn OFF the
manual gas control valve external to
the appliance.

To prevent damage to inner t a n k ,
installer must:

• Fill inner tank prior to outer tank
during start-up.

• Relieve primary system pressure
below 15 psig prior to draining
inner tank.

CAUTION

WARNING

DANGER

DANGER

Qualified Installer:

Prior to installing this product read all
instructions included in this manual.
Perform all installation steps required in this
manual in the proper order given. Failure to
adhere to the guidelines within this manual
can result in severe personal injury, death or
substantial property damage.

Homeowner:

-This product should be maintained / ser­viced and inspected annually by a qual­ified service technician.

- This manual is intended for use by a
qualified Installer/Service Technician.

Please reference the unit’s model num­ber and the serial number from the rat­ing label when inquiring about service or
troubleshooting.

Triangle Tube accepts no liability for any
damage resulting from incorrect instal­lation or from the use of components or
fittings not specified by Triangle Tube.

NOTICE

NOTICEWARNING

4

Product & Safety Information

OPERATING RESTRICTIONS

• Maximum working pressure for inner
(domestic water) tank is 150 psig.

• Maximum working pressure for outer
(primary water) tank is 45 psig.

• Inner tank has factory installed
Temperature & Pressure Relief Valve
with an AGA rating of 100,000 Btu/hr
for PG-25 and 200,000 Btu/hr for PG­30/35/40/45.

• Outer tank has a factory installed 30
psig relief valve rated at 535,000
Btu/hr

• Electrical rating:120 V, 60 Hz, less
than 12 amperes

• pH & chloride limits for the PER­FORMANCE PLUS are:

- Chloride, less than 80 mg/l.

- pH, 6.0 - 8.0.

Any water conditioning system must be
installed and maintained in accordance
with manufacturer’s specifications.

• 180º Maximum operating temperature

- primary side.

• 120º Maximum outlet/mixed tempera­ture - domestic side.

CODE RESTRICTIONS

Single wall heat exchanger in the PERFOR­MANCE PLUS complies with National
Standard Plumbing Code, provided that:

- Outer tank water (including additives)
is practically non-toxic, having toxici­ty rating or Class of 1, as listed in
Clinical Toxicology of Commercial
Products,

- Outer tank pressure is limited to max­imum 30 psig by approved relief
valve.

Single wall heat exchangers are permitted
under the Uniform Plumbing code - Paragraph
L3.2. if they satisfy all of the following
r e q u i r e m e n t s .

1 . The heat transfer medium is potable

water or contains only substances
which are recognized as safe by the
U.S. Food and Drug A d m i n i s t r a t i o n .

2 . The pressure of the heat transfer medium

is maintained less than the normal mini­mum operating pressure of the potable
water system

3 . The equipment is permanently labeled

to indicate that only additives recog­nized as safe by the FDA shall be used
in the heat transfer medium.

O r , per Uniform Plumbing Code paragraph
L3.3 as follows:

Other heat exchanger designs may be permitted
where approved by the Administrative A u t h o r i t y.

NOTICE

Pre-Installation Items

5

SECTION I - Pre-Installation Items

Code Compliance

This product must be installed in accor­dance to the following:

• All applicable local, state, national and
provincial codes, ordinances, regula­tions and laws.

• The National Fuel Gas Code NFPA54/
ANSI Z332.1 - Latest edition.

• National Electric Code ANSI/NFPA 70.

• For installations in Canada -“Installation
Code for Gas Burning Equipment”
C G A / B 1 4 9 .

Determining Product Location

Before locating the PERFORMANCE PLUS
check for convenient locations to:

- Domestic water supply piping

- Heating system piping

- Venting

- Gas supply piping

- Electrical service

Ensure the area chosen for the installation of
the PERFORMANCE PLUS is free of any
combustible materials, gasoline and other
flammable liquids.

Failure to remove or maintain the area
free of combustible materials, gasoline
and other flammable liquids or vapors
can result in severe personal injury,
death or substantial property damage.

Ensure the PERFORMANCE PLUS and its
controls are protected from dripping or spray­ing water during normal operation or service.

The PERFORMANCE PLUS should be
installed in a location so that any water
leaking from the tank or piping connections
or relief valves will not cause damage to
the area surrounding the unit or any lower
floors in the structure.

- When such a location is unavoidable a
suitable drain pan with adequate
drainage should be placed under the
unit. The drain pan must not restrict the
flow of combustion air to the unit.

Boiler Replacement

If the PERFORMANCE PLUS is replacing an
existing boiler / hot water heater system, the
following items should be checked and correct­ed prior to installation:

• Primary and domestic piping leaks and
corrosion.

• Improper location and sizing of the
expansion tank on the primary heating
loop.

• Improper sizing of the thermal expan­sion tank (if used) on the domestic sup­ply line.

• Vent condition and sizing.

Recommended Clearances

The PERFORMANCE PLUS is approved for
zero clearance to combustibles, excluding the
vent hood and vent piping.

Vent hood and vent piping - 2 inches from
combustible materials unless otherwise stated
by the vent pipe manufacturer.

Primary and domestic hot water piping - 1 inch
from combustible material.

WARNING

Pre-Installation Items

To provide serviceability to the unit it is
recommended that the following clear­ances be maintained:

Top and vent hood area - 36 inches.

Front and burner area - 24 inches.

Rear and primary piping areas - 12
inches.

When installing the PERFORMANCE
PLUS in a confined space, sufficient air
must be provided for proper combustion
and venting and to allow under normal
operating condition pro p e r a i r f l o w
around the product to maintain ambient
temperatures within safe limits to com­ply with the National Fuel Gas Code
NFPA 54 - latest edition.

Flooring and Foundation

The PERFORMANCE PLUS is approved for
installation on combustible floors, but never on
carpeting.

Do not install the PERFORMANCE
PLUS on carpeting even with a metal or
wood foundation base. Fire can result
causing severe personal injury, death or
substantial property damage.

Installer should provide a solid brick or con­crete foundation pad, at least 2 inches above
the floor level if:

- There is a potential for the floor to
become flooded. The height of the
foundation should be such to sufficient­ly elevate the unit.

- The floor is dirt, sand, gravel or other
loose material.

- The flooring is severely uneven or
sloped.

The minimum foundation size required is 24
inches x 23 inches.

Residential Garage Installations

When installing the PERFORMANCE PLUS in
a residential garage the following special pre­cautions per N F PA 54/ANSI Z223.1 must be
t a k e n :

- Mount the unit with a minimum 18
inches above the floor level of the
garage. Ensure the burner and ignition
devices / controls are no less than 18
inches above the floor level.

- Locate or protect the unit in a matter
so it cannot be damaged by a moving
v e h i c l e .

WARNING

WARNING

BEST PRACTICES

6

Combustion Air and Venting

7

SECTION II - Combustion Air and
Venting

Combustion Air Contamination

If the PERFORMANCE PLUS combus­tion air inlet is located in any area likely
to cause or contain contamination, or if
products, which would contaminate the
air cannot be removed, the combustion
air must be repiped and terminated to an
outside location. Contaminated combus­tion air will damage the unit and its
b u r n e r system, resulting in possible
severe personal injury, death or substan­tial property damage.

Do not operate a PERFORMANCE
PLUS if its combustion air inlet is taken
inside in a laundry room or pool facility.
These areas will always contain haz­ardous contaminants.

Pool chemicals, laundry products, com­mon household cleaners and hobby
products often contain fluorine or chlo­rine compounds. When these chemicals
pass through the burner and vent sys­tem, they can form strong acids. These
acids can create corrosion of the outer
tank, burner components and vent sys­tem, causing serious damage and pre­senting a possible threat of flue gas
spillage or water leakage into the sur­rounding area.

Please read the information listed below.
If contaminating chemicals are located
near the location of the combustion air
inlet, the installer should pipe the com­bustion air inlet to an outside area per
SECTION VI of this installation manual.

Potential contaminating products

- Spray cans containing chloro/fluorocar­bons

- Permanent Wave Solutions

- Chlorinated wax

- Chlorine - based swimming pool chem­icals / cleaners

- Calcium Chloride used for thawing ice

- Sodium Chloride used for water soften­ing

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid / muriatic acid

- Cements and glues

- Antistatic fabric softeners used in
clothes dryers

- Chlorine-type bleaches, detergents, and
cleaning solvents found in household
laundry rooms

- Adhesives used to fasten building prod­ucts and other similar products

Areas likely to contain these products

- Dry cleaning / laundry areas and estab­lishments

- Beauty salons

- Metal fabrication shops

- Swimming pools and health spas

- Refrigeration Repair shops

- Photo processing plants

- Auto body shops

- Plastic manufacturing plants

- Furniture refinishing areas and estab­lishments

- New building construction

- Remodeling areas

- Garages with workshops

WARNING

WARNING

8

Combustion Air and Venting

Combustion Air Requirements

The PERFORMANCE PLUS can use inside
air if no contaminants are present in the area of
installation. If contaminants are likely to be
present in the area of installation, outside air
must be piped directly to the unit as referenced
in Section VI Venting and Combustion Air
Piping.

In order to avoid the potential of indoor
contaminates when venting the appli­ance, it is recommended to pipe combus­tion air directly from the outdoors to the
unit as referenced in Section VI Venting
and Combustion Air Piping.

Outside Combustion Air

Combustion air can be ducted directly from the
outside to the air inlet fitting of the PERFOR­MANCE PLUS using the following materials:

- PVC

- Galvanized metal vent

- Flexible metal vent

All seams and joints must be sealed with
sealant or mechanical fasteners. Do not use
tape as it is not considered a sealing material.

Air Openings

Air openings to the PERFORMANCE PLUS
are always required even if the combustion air is
obtained indoors or outdoors. These air open­ings provide ventilation to prevent overheating
of the PERFORMANCE PLUS and its control
as well as providing combustion air.

The air openings must be sized to handle
the re q u i r ements of all appliances and air
movers (exhaust fans, etc.) contained in
the same space using the same air s u p p l y.

Methods of Accessing Combustion A i r Into A
S p a c e

Indoor Combustion Air

The methods listed in this section for
accessing Indoor Combustion A i r
assume that the infiltration rate is ade­quate and not less than .40 ACH. For
infiltration rates less than .40 ACH, ref­erence the NFPA 54 National Fuel Gas
Code for additional guidance.

Opening Size and Location

Openings used to connect indoor spaces shall
be sized and located in accordance with the
following, see Fig.1:

NOTICE

NOTICE

BEST PRACTICE

Equipment Located in Confined
Spaces; All Air from inside the
building.

Fig. 1:

9

Combustion Air and Venting

- Combining spaces on the same story.
Each opening shall have a minimum
free area of 1 sq. in./1000 Btu/hr of the
total input rating of all gas utilization
equipment in the space, but not less than
100 sq. inches. One opening shall com­mence within 12 inches of the top, and
one opening shall commence within 12
inches of the bottom of the enclosure.

- Combining spaces in different stories.
The volumes of spaces in different sto­ries shall be considered as communicat­ing spaces where such spaces are con­nected by one or more openings in
doors or floors having a total minimum
free area of 2 sq. in./1000 Btu/hr of
total input rating of all gas utilization
equipment.

Outdoor Combustion Air

Isolating the combustion appliance room
from the rest of the building and bring­ing in uncontaminated outside air for
combustion and ventilation is always
preferred.

Openings used to supply combustion and ven­tilation air shall be sized and located in accor­dance with the following:

One Permanent Opening Method.

One permanent opening, commencing within 12
in. of the top of the enclosure, shall be provided.
The equipment shall have clearances of at least 1
inch from the sides and back and 6 in. from the
front of the appliance. The opening shall direct­ly communicate with the outdoors or shall com­municate through a vertical or horizontal duct to
the outdoors or spaces that freely communicate
with the outdoors and shall have a minimum free
area of the following:

- 1sq. in./3000 Btu/hr of the total input
rating of all equipment located in the
enclosures, and

- Not less than the sum of the areas of all
vent connectors in the space. See Fig. 2.

Two Permanent Openings Method.

Two permanent openings, one commencing
within 12 in. of the top and one commencing
within 12 in. of the bottom of the enclosure,
shall be provided. The openings shall commu­nicate directly, or by ducts, with the outdoors
or spaces that freely communicate with the out­doors, as follows:

- Where directly communicating with the
outdoors or where communication to the
outdoors is through vertical ducts, each
opening shall have a minimum free area
of 1 sq. in./4000 Btu/hr of total input rat­ing of all equipment in the enclosure.
See Fig. 3 page 10.

- Where communicating with the out­doors is through horizontal ducts, each
opening shall have a minimum free area
of not less than 1 sq.in./2000 Btu/hr of
total input rating of all equipment in the
enclosure. See Fig.4 page 10.

BEST PRACTICE

Equipment Located in Confined
Spaces; One Permanent Air Inlet

Fig. 2:

10

Combustion Air and Venting

Combination of Indoor and Outdoor
Combustion Air

Indoor Openings: Where used, openings con­necting the interior spaces shall comply with
the Indoor Combustion Air section on page 8.

Outdoor Opening(s) Location. Outdoor open­ing(s) shall be located in accordance with the
Outdoor Combustion Air section.

Outdoor Opening(s) Size. Outdoor opening(s)
shall be calculated in accordance with the fol­l o w i n g :

- The ratio of the interior spaces shall be
the available volume of all communi­cating spaces divided by the required
volume.

- The outdoor size reduction factor shall
be 1 minus the ratio of interior spaces.

- The minimum size of outdoor open­ing(s) calculated in accordance with the
above outdoor air section multiplied by
the reduction factor. The minimum
dimension of air openings shall not be
less than 3 in.

Vent System

The PERFORMANCE PLUS is designed
to vent as a Category IV appliance, which
requires a special vent system.

Category IV Venting is described as a vent
system that has a positive static pressure
and a flue temperature that may cause
excessive condensate within the vent.

Do not install the PERFORMANCE
PLUS into a common vent with other g a s
appliances.. This may cause flue gas
spillage or appliance malfunction, re s u l t ­ing in possible severe personal injury,
death or substantial pro p e r ty damage.

DANGER

Equipment Located in Confined
Spaces; All Air from Outdoors
Through Ventilated Attic

Fig. 3:

Equipment Located in Confined
Spaces; All Air from Outdoors

Fig. 4:

11

Combustion Air and Venting

Removal of an Existing Boiler f rom a
Common Vent System

F o r installations in which the PERFOR­MANCE PLUS is replacing an existing
b o i l e r / hot water h e a t e r system, which
was connected to a common vent system
with other appliances, the following steps
shall be conducted with each re m a i n i n g
appliance connected to the common vent­ing system:

1. Any unused openings in the common
venting system must be sealed.

2. A visual inspection of the venting sys­tem must be conducted for proper siz­ing and horizontal pitch. The inspec­tion should ensure no blockage or
restriction is within the vent system,
and there is no leakage, corrosion or
other items, which could cause an
unsafe condition.

3. To adequately test the venting system,
close all exterior doors and windows
and all doors between the area contain­ing the remaining appliances connected
to the common vent system and other
areas of the building. Turn on any
clothes dryers and any other gas appli­ance not connected to the common vent
system. Turn on all exhaust fans, i.e.
range hoods and bathroom exhaust
fans, preferably at maximum speed.
Close any fireplace dampers.

4. Place in operation the first appliance
being inspected that is connected to the
common vent system. The remaining
appliances should not be in operation.
Follow the appliance’s lighting instruc­tions and adjust the thermostat to allow
the appliance to operate continuously.

5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Spillage can be detected
using the flame of a match or candle or
with smoke from a cigarette.

6. Once it has been determined that each
remaining appliance connected to the
common vent system is properly vent­ed, return doors, windows, exhaust
fans, fireplace dampers and any operat­ing gas appliance to their previous con­dition.

Should any improper operation of the common
venting system be detected in the outline test,
the condition should be corrected so the vent
system conforms with the National Fuel Gas
Code, NFPA 54/ ANSI Z223.1 - latest edition.
Canadian installations must conform with
B149.1 or 149.2 Installation Code.

BEST PRACTICES

12

Unit Preparation

SECTION III - Unit Preparation

Handling Instructions

The PERFORMANCE PLUS is generally eas­ier to handle and maneuver once removed from
the shipping carton and pallet.

To remove the shipping carton and pallet:

a. Remove the shipping straps and open

the top of the shipping carton to remove
the wood shipment insert.

b. Lift the shipping carton over the unit to

remove. If ceiling height is limited the
carton maybe cut open using care not to
damage the exterior jacket of the unit.

c. Remove the front burner hood to pre-

vent damage prior to lifting the unit
from the shipping pallet.

When lifting or moving the unit do not
use the burner or its components as a
means of a handle. Hand-truck the unit
from the rear only.

d. Discard all packing materials.

Hydrostatic Pressure Test

Prior to permanently connecting water,
gas supply or electrical supply, perform
a pressure hydrostatic test of the outer
tank to ensure all piping connections
were not damaged during shipment.

Hydrostatic Test Preparation

1. Mount the circulator on the supply pipe as
shown in Figure 11 page 23.

2. Temporarily plug the primary return con­nections as shown in Figure 11 using a 1”
NPT pipe plug. Use pipe dope sparingly to
allow removal of the plugs upon comple­tion of the test.

3. On the outlet flange of the circulator pipe
install a 1” NPT nipple and shut-off valve.
Use pipe dope sparingly to allow removal
of the fittings upon completion of the test.

To avoid getting water onto the unit
and/or surrounding area additional pip­ing from the shut-off to a catch bucket or
drain may be required.

4. Connect a hose to the primary circuit drain
valve located per Figure 45 page 68, Item 2
and connect the other end to a fresh water
supply. Ensure the hose can be used as a
drain hose upon completion of the test.

Hydrostatic Test Procedures

1. Open the shut-off valve installed on the
outlet flange of the circulator.

2. Open the fresh water supply valve and then
open slowly the primary circuit drain valve
to fill the outer tank with water.

3. When the water within the outer tank
reaches the shut-off on the primary supply,
close the primary circuit drain valve.

4. Close the shut-off valve, on the top of the
c i r c u l a t o r .

5. Slowly reopen the primary circuit drain
valve until the test pressure on the temper­ature / pressure gauge reaches 10 psig
maximum. Close the primary circuit drain
valve.

To prevent damage to the inner tank the
test pressure must not exceed 10 psig.

6. Allow the test pressure to remain for 10
minutes.

CAUTION

NOTICE

BEST PRACTICES

WARNING

Unit Preparation

13

Do not leave the unit unattended while
p r essurized. A cold water fill could
expand and cause excessive pre s s u re ,
resulting in severe personal injury, death
or substantial property damage.

7. Ensure constant gauge pressure has been
maintained throughout the 10 minute test.
Check for leaks at all fitting joints. Repair
if found.

Leaks must be re p a i red immediately
when detected. Failure to repair leaks
can damage the unit, resulting in sub­stantial property damage.

8. Check continuity using a voltmeter across
the terminals of the LWCO device. The
contacts on the LWCO should be closed.
See item 6 in Figure 40 page 64 for loca­tion of the LWCO.

Completion of Hydrostatic Test and Draining

1. Disconnect the fill hose from the fresh
water source and direct the hose to a suit­able place of drainage.

2. Open the primary drain valve and complete­ly drain the unit. To aid in draining open the
s h u t - o f f valve on the primary supply.

3. Remove the hose from the primary drain
valve when draining is complete.

4. Remove the plugs, nipple, shut-off valve
and any other piping unless they will
remain for use in the system piping.

WARNING

WARNING

Domestic Piping

SECTION IV - Domestic Piping

General Piping Requirements

• All plumbing must meet or exceed all
local, state and national plumbing codes.

• Use pipe dope or tape suitable for
potable water.

• Use isolation valves to isolate system
components.

• Install unions for easy removal of the
PERFORMANCE PLUS from the sys­tem piping.

Domestic Supply Pressure

For applications in which the domestic sup­ply pressure exceeds 70 psig it is recom­mended to install a pressure reducing valve
on the cold water supply.

Maintaining the cold water supply at or
below 70 psig will prevent normal thermal
expansion from repeatedly forcing the T&P
relief valve open.

Thermal Expansion

If the cold water supply contains a backflow
p r e v e n t e r , check valve and / or a pressure
reducing valve, the installer must install a
domestic thermal expansion tank on the cold
water supply. (See Fig. 6 page 17)

Installing a thermal expansion tank will
prevent normal thermal expansion from
repeatedly forcing the T&P relief valve
open.

When installing a thermal expansion tank
ensure the charge pressure of the tank is
equal to the cold water supply pressure at
the point of installation. Consult the ther­mal expansion tank manufacturer’s instruc­tions for further information on installation
and sizing.

The Temperature / Pressure relief valve
is not intended for constant duty, such as
relief of pressure due to normal thermal
expansion.

Water Hammer

Water hammer is the effect of sudden pres­sure changes occurring in the domestic pip­ing. These pressure changes are typically
the result of “fast acting” positive shut-off
valves closing. These types of valves can
be typically found on dishwashers and
clothes washers.

The effects of water hammering can cause
damage to system components and tank
welds on the unit.

Installation of hammer arresters is recom­mended at these types of appliances, which
incorporate “fast-acting” positive shut-off
valves. Consult the manufacturer of water
hammer arresters for recommendation on
sizing and installation requirements.

Temperature / Pressure Relief Valve

The PERFORMANCE PLUS has a factory
installed Temperature / Pressure Relief
valve. Ensure the rating of the T&P relief
valve is correctly sized as follows per
AGA:

CAUTION

14

Model AGA Rating

PG PLUS-25 100,000 Btu/hr

PG PLUS-30 200,000 Btu/hr

PG PLUS-35 200,000 Btu/hr

PG PLUS-40 200,000 Btu/hr

PG PLUS-45 200,000 Btu/hr

Domestic Piping

The installer must install discharge piping
onto the T&P relief valve. The discharge
piping must be:

• Made of material serviceable for tem­peratures of 250ºF or greater.

• Directed so that any hot water dis­charge flows away from all persons.

• Directed to a suitable place of drainage.

• Installed as to allow complete draining
of the T&P relief valve and the dis­charge piping.

• Terminated with a plain end, not with
threads.

Failure to properly direct the discharge
piping of the T&P relief valve may result
in flooding of the area adjacent to the
unit and or lower floors in the structure
causing substantial property damage.

The installer must not install the T&P
relief valve discharge piping in a manner
that is:

• Excessively long: Using more than 2
elbows and/or 15 feet of discharge pip­ing can reduce the discharge capacity.

• Terminated directly into a drain: The
discharge piping must terminate within
6 inches of the drain. Check with local
plumbing codes for termination guide­lines.

• The discharge piping is plugged, reduced
in size or restricted in any manner.

• The discharge piping is subject to
f r e e z i n g .

DO NOT install any valves between the
T&P relief valve and the discharge pip­ing. DO NOT plug the T&P relief valve
or the discharge piping. Improper place­ment and piping of the T&P relief valve
can cause severe personal injury, death
or substantial property damage.

Thermostatic Mixing Valve

The PERFORMANCE PLUS contains a facto­ry installed thermostatic mixing valve with
built-in check valve.

The operating range of the thermostatic mixing
is 90ºF to 120ºF.

For applications with a domestic recirculation
loop, the recirculation pump should be con­trolled by an aquastat. The maximum recom­mended setting of the aquastat is 10ºF lower
than the thermostatic mixing valve setting.

For proper operation of the thermostatic
mixing valve and to prevent potential
scalding hazards, the recirculation loop
should be controlled by an aquastat. DO
NOT use continuous recirculation.

U-Tube Assembly

The PERFORMANCE PLUS is supplied
with a U-Tube Assembly that directs cold
water to the thermostatic mixing valve.

To install the U-Tube Assembly the
installer must:

1. Disconnect the cold inlet adapter/union
from the thermostatic mixing valve.

2. Using needle-nose pliers remove the
plastic check valve assembly from the
adapter.

DANGER

WARNING

CAUTION

15

Domestic Piping

3. Solder the U-Tube Assembly onto the
adapter. (See Fig. 5)

4. Once the adapter has suff i c i e n t l y
cooled, re-insert the check valve assem­bly making sure of orientation and
reconnect onto the mixing valve.

If the installation of the PERFORMANCE
PLUS requires domestic hot water for a
commercial dishwasher, the installer may
insert a tee connection between the unit and
the mixing valve to provide 140ºF domes­tic hot water. The installer must reference
local plumbing codes to ensure if this type
of application is permissible.

The thermostatic mixing valve MUST be
installed and utilized on the PERFOR­MANCE PLUS. Removal of the thermo­static mixing valve will result in severe
personal injury or death.

The manual valve on the U-Tube assem­bly must remain in the full open position
for proper operation of the thermostatic
mixing valve.

Domestic Drain Valve

- The installer must install a drain valve
and drain leg as shown in Fig. 6 page
17 or Fig. 7 page 18.

- The drain valve should be positioned
close to the floor to aid in the siphon
action required to drain the inner tank.

Multiple Units Installation

For applications using multiple units the
domestic piping should be piped using a bal­anced manifold arrangement.

The installer should remove the thermostatic
mixing valve from the units and install a single
thermostatic mixing valve at the outlet of the
hot water manifold. The thermostatic mixing
valve should be sized according to the required
flow rate and pressure drop. Refer to the ther­mostat mixing valve manufacturer specifica­tion and installation instructions for more
details.

Reference Fig. 8, page 18 for piping diagram.

Storage Tank Application

For applications requiring large volumes of
domestic hot water in a relative short period the
installer may include a storage type tank (see
Fig. 9 page 19) in the domestic piping. The
installer must:

1. Relocate the thermostatic mixing valve
from the PERFORMANCE PLUS to
the outlet of the storage tank.

2. Provide recirculation from the storage
tank back to the PERFORMANCE
PLUS using a bronze type circulator.
Maximum recommended flow rate is 5
to 10 gpm.

CAUTION

DANGER

16

Fig. 5: Mixing Valve Assembly

17

Domestic Piping

TR/SMART Series Application

For applications requiring large volumes of
domestic hot water over an extended period,
the installer may include a Triangle Tu b e
TR/SMART Indirect Water Heater in conjunc­tion with the PERFORMANCE PLUS. (See
Fig. 10 page 19)

The domestic system recirculation, if used, is
directed to the TR/SMART Series Tank. The
circulator should be controlled by an aquastat.

The primary piping to the TR/SMART Series
tank must comply with the piping methods
details in SECTION V - Primary Piping or with
other recognized piping methods.

Additional information regarding domestic and
primary piping can be found in the TR/SMART
Installation Manual.

Fig. 6: PERFORMANCE PLUS

Without Recirculation

Note: All shut off valves shown in

this figure must be shut when siphon
draining the PERFORMANCE
PLUS.

Domestic Piping Diagrams

1. Mixing valve with check valve

3. Shut off valve

4. Backflow preventer or pressure reducing valve*

6. Thermal expansion tank

8. Domestic drain valve

9. Vacuum breaker*

* Optional devices may be required by local Codes