HTP PHE130, PHE199 Installation Manual
Installation
Start-Up
Maintenance
Parts
Warranty
Versa Hydro
Combined Appliances
PHE130 / PHE199 Models*
* “LP” Denotes Propane Gas Operation
“S” Denotes Solar Models
“SNHX” Denotes Solar Models without Heat Exchanger
This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe
personal injury, or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause
property damage, severe personal injury, or death.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
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 potable (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.
272 Duchaine Blvd. New Bedford, MA 02745 www.htproducts.com
LP-314 Rev. 2.3.17
2
IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING
PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE
VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS
• 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 supplier’s instructions.
• If you cannot reach your gas supplier, call the re department. Installation and service must be provided by a qualied
installer, service agency, or the gas supplier.
LP-314 Rev. 2.3.17
The following dened 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 serious personal injury or
death.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in personal injury or death.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor personal
injury.
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided, may
result in property damage.
NOTICE is used to address practices not related to personal
injury.
Foreword
This manual is intended to be used in conjunction with other
literature provided with the appliance. This includes all related
control information. It is important that this manual, all other
documents included in this system, and additional publications
including the Code for the Installation of Heat Producing
Appliances and National Fuel Gas Code - ANSI Z223.1 (latest
versions), be reviewed
in their entirety before
beginning any work.
Installation should be
made in accordance
with the regulations
of the Authority
Having Jurisdiction,
local code authorities,
and utility companies
which pertain to this
type of water heating
equipment.
Authority Having
Jurisdiction (AHJ) – The
AHJ may be a federal,
state, local government,
or individual such as a
re chief, re marshal,
chief of a re prevention
bureau, labor
department or health
department, building
ocial or electrical
inspector, or others
3
having statutory authority. In some circumstances, the property
owner or his/her agent assumes the role, and at government
installations, the commanding ocer or departmental ocial
may be the AHJ.
NOTE: HTP, Inc. reserves the right to modify product technical
specications and components without prior notice.
For the Installer
This appliance must be installed by qualied and licensed
personnel. The installer should be guided by the instructions
furnished with the appliance, 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.
The latest version of the National Fuel Gas Code, ANSI Z223.1,
from American Gas Association Laboratories, 8501 East Pleasant
Valley Road, Cleveland, OH 44131.
In Canada - CGA No. B149 (latest version), from Canadian Gas
Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario,
Canada M3B 2R3. Also, Canadian Electrical Code, C 22.1, from
Canadian Standards Association, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5N6.
Code for the Installation of Heat Producing Appliances (latest
version) from American Insurance Association, 85 John Street,
New York, NY 11038.
The latest version of the National Electrical Code, NFPA No. 70.
NOTE: The gas manifold and controls met safe lighting and
other performance criteria when undergoing tests specied in
ANSI Z21.10.3 - latest edition.
LP-314 Rev. 2.3.17
4
Table of Contents
Part 1 - General Safety Information 4
A. Improper Combustion 5
B. Gas 5
C. When Servicing the Appliance 5
D. Appliance Water 5
E. Freeze Protection 5
F. High Elevation Installations 5
G. Water Temperature Adjustment 5
Part 2 - Before You Start 6
A. What’s in the Box 6
B. How the Appliance Operates 6
C. Optional Equipment 6
Part 3 - Prepare the Appliance 7
A. Locating the Appliance 7
B. Leveling 8
C. Clearances for Service Access 8
D. Residential Garage and Closet Installations 8
E. Exhaust Vent and Intake Pipe 8
1. Direct Vent of Exhaust and Intake 9
2. Power Venting, Indoor Combustion Air in Conned or Unconned
Space 9
F. Carbon Monoxide Detectors 9
G. Prevent Combustion Air Contamination 9
H. Removing an Appliance from a Common Vent System 10
I. Water Chemistry Requirements 10
Part 4 - Domestic Hot Water and Hydronic Piping 13
A. Plumbing 13
1. System Domestic Water Piping 13
2. Appliance Domestic Water Piping 13
B. Scalding 13
C. Mixing Valve Installation 14
D. Auxiliary Connections 15
E. Temperature and Pressure Relief Valve for DHW 15
F. Backow Preventer 16
G. Potable Expansion Tank 16
H. Hydronic Heating Module Piping 16
I. Pressure Relief Valve for the Hydronic System 16
J. Hydronic Expansion Tank and Make-Up Water 16
K. Hydronic Heating Module System Piping 16
L. Hydronic Heating Module Output 17
M. Applications 19
N. Filling the Appliance 21
Part 5 - Venting and Condensate Removal 22
A. General 22
B. Approved Materials for Exhaust Vent and Intake Pipe 23
C. Additional Requirements for Installation in Canada 23
D. Exhaust Vent and Intake Pipe Location 24
E. Exhaust Vent and Intake Pipe Sizing 25
F. Longer Vent Runs 25
G. Exhaust Vent and Intake Pipe Installation 25
H. Applications 26
1. Direct Vent Installation of Exhaust and Intake 26
2. Venting Through an Existing System 28
3. Power Venting, Indoor Combustion Air in Conned or Unconned
Space 29
I. Condensate Removal System 31
Part 6 - Wiring 32
A. Field Wiring 32
B. Line Voltage Wiring 32
C. Low Voltage Wiring 32
D. Alarm Connections 32
E. Optional 0-10 Volt Building Control Signal 32
F. Customer Connection Board 33
G. Internal Wiring Diagram 34
Part 7 - Gas Connections 35
A. Gas Piping 36
LP-314 Rev. 2.3.17
B. Gas Table 36
C. Gas Valve 37
Part 8 - Start-Up Preparation 38
A. Fill and Purge DHW 38
B. Fill and Purge Hydronic Heating Loop 38
C. Purge Air from Hydronic Heating Module 38
D. Using the Control to Assist in Purging System Loops 39
E. Programming the Total System Control 39
Part 9 - Start-Up Procedures for the Installer 40
A. Navigation of the Display 40
B. Programming the Control 41
C. Programming the System Setting 42
D. System Setting Program Navigation 42
E. Control Status Menu 43
F. Resetting the Maintenance Schedule 44
G. Test Mode 44
Part 10 - Troubleshooting 45
A. Error and Fault Codes 45
B. Appliance Error 45
C. Appliance Fault 45
D. User Interface Display 46
Part 11 - Maintenance 49
Part 12 - Shutdown 50
A. Shutdown Procedure 50
B. Vacation Procedure 50
C. Failure to Operate 50
D. Important Notice 50
Part 13 - Installation Checklist 54
Part 14 - Maintenance Report 55
Limited Warranty 57
Maintenance Notes 59
Customer Installation Record Form 60
Part 1 - General Safety Information
This appliance is approved for indoor installations only and is
not intended for use as a pool heater. Clearance to combustible
materials: 0” top, bottom, sides, and back. Appliance must
have room for service: 24” front and 12” sides are minimum
recommended service clearances. (A combustible door or
removable panel is acceptable front clearance.) This appliance
has been approved for closet installation and installation on
combustible ooring. Do not install directly on carpeting.
Install the appliance in a location where temperature and
pressure relief valve discharge or a leak will not result in
damage to the surrounding area. If such a location is not
available, install an auxiliary catch pan. Use only Category IV
vent systems.
Installer - Read all instructions in this manual before installing.
Perform steps in the given order.
User - This manual is for use only by a qualied heating
installer / service technician. Have this appliance serviced /
inspected annually by a qualied service technician.
FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE
CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE,
SEVERE PERSONAL INJURY, OR DEATH.
NOTE: Obey all local codes. Obtain all applicable permits
before installing the appliance.
NOTE: Install all system components and piping in such a
manner that does not reduce the performance of any re
rated assembly.
NOTE: If the appliance is exposed to the following, do not
operate. Immediately call a qualied 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 APPLIANCE IF ANY PART HAS BEEN
SUBMERGED IN WATER. Immediately call a qualied service
technician. The appliance MUST BE replaced if it has been
submerged. Attempting to operate a appliance that has been
submerged could create numerous harmful conditions, such
as a potential gas leakage causing a re and/or explosion, or
the release of mold, bacteria, or other harmful particulates
into the air. Operating a previously submerged appliance
could result in property damage, severe personal injury, or
death.
NOTE: Appliance damage due to ood or submersion is
considered an Act of God, and IS NOT covered under product
warranty.
Altering any HTP, Inc. appliance with parts not manufactured
by HTP, Inc. WILL INSTANTLY VOID the appliance warranty
and could result in property damage, personal injury, or
death.
5
C. When Servicing the Appliance
Be sure to disconnect electrical power before performing
service. Failure to do so could result in electrical shock, property
damage, serious personal injury, or death.
To avoid electric shock, disconnect electrical supply before
performing maintenance.
NOTE: When inquiring about service or troubleshooting,
reference the model and serial numbers from the appliance
rating label.
To avoid severe burns, allow appliance and associated
equipment to cool before servicing.
D. Appliance Water
Do not use petroleum-based cleaning or sealing compounds in
a water heating system. Gaskets and seals in the system may be
damaged. This can result in substantial property damage.
Do not use “homemade cures” or “patent medicines”. Damage
to the appliance, substantial property damage, and/or serious
personal injury may result.
E. Freeze Protection
NOTE: Consider piping and installation when determining
appliance location.
Do not use this appliance for anything other than its intended
purpose (as described in this manual). Doing so could result in
property damage and WILL VOID product warranty.
High heat sources (sources generating heat 100oF / 37oC or
greater, such as stove pipes, space heaters, etc.) may damage
plastic components of the appliance as well as plastic vent
pipe materials. Such damages ARE NOT covered by warranty.
It is recommended to keep a minimum clearance of 8” from
high heat sources. Observe heat source manufacturer
instructions, as well as local, state, provincial, and national
codes, laws, regulations and ordinances when installing this
appliance and related components near high heat sources.
A. Improper Combustion
Do not obstruct the ow of combustion and ventilating air.
Adequate air is necessary for safe operation. Failure to keep
the exhaust vent and combustion air intake clear of ice, snow,
or other debris could result in property damage, serious
personal injury, or death.
B. Gas
Should overheating or gas supply fail to shut o, turn o the
manual gas control valve to the appliance.
Failure of the appliance due to freeze related damage IS NOT
covered by product warranty.
NEVER use any toxic chemical, including automotive, standard
glycol antifreeze, or ethylene glycol made for hydronic (nonpotable) systems. These chemicals can attack gaskets and seals
in water systems, are poisonous if consumed, and can cause
personal injury or death.
UNCRATING THE APPLIANCE - Any claims for damage or
shortage in shipment must be led immediately against the
transportation company by the consignee.
F. High Elevation Installations
Natural gas at high elevation might contain less heating value
than typical 1,000 BTU/cu ft and therefore can cause improper
air / gas mix leading to improper combustion. For natural gas
installations above 3,000 ft, call your gas provider to determine
the heating value of the supplied natural gas.
G. Water Temperature Adjustment
If the appliance is going to have a set temperature above 120oF,
you must use an ASSE 1017 rated mixing valve to avoid severe
burns or death from scalding temperatures.
Households with small children, disabled, or elderly persons
may require a 120oF or lower temperature setting to prevent
severe personal injury or death due to scalding.
LP-314 Rev. 2.3.17
6
Approximate Time / Temperature Relationships in Scalds
120oF More than 5 minutes
125oF 1 1/2 to 2 minutes
130oF About 30 seconds
135oF About 10 seconds
140oF Less than 5 seconds
145oF Less than 3 seconds
150oF About 1 1/2 seconds
155oF About 1 second
Table 1 - Approximate Time / Temperature Relationships in Scalds
Part 2 - Before You Start
Remove all sides of the shipping crate of the appliance.
A. What’s in the Box
Components included with the appliance:
• Intake PVC Tee with Screens
• Exhaust PVC Coupling with Screens
• Temperature and Pressure Relief Valve
• Installation Manual and Warranty
• User’s Information Manual
• Solar Addendum (S Models Only)
• Outdoor Sensor (Part # 7250P-319)
• Mixing Valve (7100P-315)
B. How the Appliance Operates
The Versa Hydro with Total System Control provides high
eciency central heating and domestic hot water from one
appliance. Total System Control manages system needs,
ensuring maximum comfort and ecient operation. Some
features of the appliance are:
Stainless Steel Water Storage Tank
The storage tank is constructed of 316L stainless steel to provide
maximum corrosion resistance. Water blown foam insulation
and a plastic jacket provide superior insulation, allowing no
more than ½ degree heat loss per hour.
High Eciency Heat Exchanger
The 90/10 copper nickel heat exchanger provides highly ecient
energy transfer. Hot gases from the primary circuit heat the
combustion walls. The walls transfer heat directly into the
domestic water. The secondary circuit then transfers the last
bit of energy to the bottom of the tank, where hot gases are
converted to water vapor, giving the appliance a combustion
eciency of 98% and thermal eciency of up to 96%.
Modulating Combustion System
The modulating combustion system regulates ring rate based
on heat demand. Total System Control monitors tank operation,
system parameters, and controls the ring rate of the burner,
providing only the energy required to satisfy both domestic hot
water and central heating needs.
Total System Control
Total System Control automatically manages the central heating
and domestic hot water systems through the use of sensors.
These sensors monitor inputs (such as outdoor temperature,
tank temperature, and heating module outlet temperature)
providing data that allows accurate control of the entire system.
You may choose to use the control’s factory default settings or
reprogram system parameters to provide design exibility.
Hydronic Heating Module
The hydronic heating module connects to the storage tank
through two dip tubes. The rst dip tube draws heated water
from the top of the storage tank and circulates it through a
brazed plate heat exchanger to transfer the water’s stored
energy to the hydronic side of the plate. Once the energy is
transferred, the water returns through the second dip tube
to a lower section of the storage tank to continue circulating.
A stainless steel circulator pump modulates output, varying
ow through the brazed plate heat exchanger to meet
domestic hot water and central heating demand. An outlet
sensor provides feedback to the control to assure accurate
temperature control.
Venting System
This appliance must be exhausted to the outdoors. Use only
the approved venting materials outlined in the Venting section
of this manual. Vent size can vary from 2” to 3” depending on
the appliance input rate. Special attention should be taken
when selecting vent location. Vents can run horizontally
or vertically, depending on system design, and should be
supported as shown in the Venting section of this manual.
Burner
The burner is constructed of high grade stainless steel and
uses pre-mixed air and gas to provide a wide range of ring
rates.
Condensate Drain Connection
This is a condensing high eciency appliance with a
condensate removal system. Condensate is nothing more
than water vapor derived from combustion products, similar
to that of an automobile when it is initially started. It is very
important that the condensate line slopes away from the
appliance and down to a suitable inside drain.
If the appliance condensate outlet is lower than the drain, use
a condensate removal pump (Part # 554200, available from
HTP). In addition, local authorities may require a condensate
neutralizer to neutralize the condensate. Condensate
neutralizers are made up of lime crystals, marble, or phosphate
chips. Neutralizers can be installed in the eld by the installer
and purchased from HTP (7450P-212).
It is also very important not to expose the condensate line to
freezing temperatures or any type of blockage. Plastic tubing
must be the only material used for the condensate line. Steel,
brass, copper, or other materials will be subject to corrosion
or deterioration. A second vent may be necessary to prevent
condensate line vacuum lock on a long horizontal run. Also,
an increase in pipe size may be necessary to allow condensate
to drain properly. Support of the condensate line may be
necessary to avoid blockage of the condensate ow.
Spark Ignition
The burner ame is ignited by applying high voltage to the
system spark electrode. This causes a spark from electrode to
ground.
Outdoor Sensor
Monitors outdoor temperature and adjusts the set point to
provide greater eciency.
C. Optional Equipment
Optional equipment available from HTP (and Part #):
• 3” Stainless Steel Vent Termination Kit (V1000)
• 4” Stainless Steel Vent Termination Kit (V2000)
• 2” PVC Concentric Vent Kit (KGAVT0501CVT)
LP-314 Rev. 2.3.17
7
• 3” PVC Concentric Vent Kit (KGAVT0601CVT)
• 3” Polypro Vent Kit (8400P-001)
• 3” Polypro Pipe
(33’ length # 8400P-002, 49.5’ length # 8400P-003)
• System Sensor (7250P-324)
• Alarm System (7350P-602) to monitor any failure
• Outdoor Sensor (7250P-319)
• PC Connection Kit (7250P-320)
• Condensate Neutralizer (7450P-212)
• Solar Kit (7100P-220) applies to Solar models only
NOTE: When using an optional system sensor, pipe insulation
must be wrapped around it to improve temperature
measurement accuracy and increase overall system eciency.
Part 3 - Prepare the Appliance
Remove all sides of the shipping crate to allow the appliance
to be moved into its installation location.
COLD WEATHER HANDLING - If the appliance has been
stored in a very cold location (BELOW 0oF) before installation,
handle with care until the components come to room
temperature. Failure to do so could result in damage to the
appliance.
Carefully consider installation when determining appliance
location. Please read the entire manual before attempting
installation. Failure to properly take factors such as appliance
venting, piping, condensate removal, and wiring into account
before installation could result in wasted time, money, and
possible property damage and personal injury.
A. Locating the Appliance
This appliance is certied for indoor use only. DO NOT
INSTALL OUTDOORS. Outdoor installations ARE NOT
covered by warranty. Failure to install the appliance indoors
could result in property damage, severe personal injury, or
death.
Incorrect ambient conditions can lead to damage to the
heating system and put safe operation at risk. Ensure that the
installation location adheres to the information included in
this manual. Failure to do so could result in property damage,
serious personal injury, or death. Failure of an appliance or
components due to incorrect operating conditions IS NOT
covered by product warranty.
This appliance must be installed upright in the vertical
position as described in this manual. DO NOT attempt to
install this appliance in any other orientation. Doing so will
result in improper appliance operation and property damage,
and could result in serious personal injury or death.
1. Installation Area (Mechanical Room) Operating Conditions
• Ensure ambient temperatures are higher than 32oF /
0oC and lower than 104oF / 40oC
• Prevent the air from becoming contaminated by the
products, places, and conditions listed in this manual
• Avoid continuously high levels of humidity
• Never close existing ventilation openings
• Ensure a minimum 1” clearance around hot water and
exhaust vent pipes
• NOTE: To prevent condensing in the fan, it is
recommended to avoid prolonged exposure to
temperatures below 45oF
This appliance has a condensate disposal system that may
freeze if exposed to sustained temperatures below 32oF.
Precautions should be taken to protect the condensate trap and
drain lines from sustained freezing conditions. Failure to take
precautions could result in property damage, severe personal
injury, or death.
2. Check for nearby connections to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
• Condensate drain
3. Check area around appliance. Remove any combustible
materials, gasoline, and other ammable liquids.
Failure to keep the appliance area clear and free of combustible
materials, liquids, and vapors can result in substantial property
damage, severe personal injury, or death.
The service life of the appliance’s exposed metallic surfaces,
such as the casing, as well as internal surfaces, such as the heat
exchanger, are directly inuenced by proximity to damp and
salty marine environments. In such areas higher concentration
levels of chlorides from sea spray coupled with relative humidity
can lead to degradation of appliance components. In these
environments, appliances must not be installed using direct
vent systems which draw outdoor air for combustion. Such
appliances must be installed using room air for combustion.
Indoor air will have a much lower relative humidity, and hence
potential corrosion will be minimized.
High heat sources (generating heat 100oF / 37oC or greater,
such as boiler ue pipes, space heaters, etc.) may damage
plastic components of the appliance as well as plastic vent pipe
materials. Such damages ARE NOT covered by warranty. It is
recommended to keep a minimum clearance of 8” from high
heat sources. Observe heat source manufacturer instructions,
as well as local, state, provincial, and national codes, laws,
regulations, and ordinances when installing this appliance and
related components near high heat sources.
Locate the appliance where any leakage from the relief valve,
related piping, tank, or connections will not result in damage to
surrounding areas or lower oors of the building. The appliance
should be located near a oor drain or installed in a drain pan.
Leakage damages ARE NOT covered by warranty.
Failure of the appliance or components due to incorrect
operating conditions IS NOT covered by product warranty.
4. Gas control system components must be protected from
dripping water during operation and service.
5. If the appliance is to replace an existing appliance, check for
and correct any existing system problems, such as:
• System leaks
LP-314 Rev. 2.3.17
8
• Location that could cause the system and appliance to
freeze and leak
• Incorrectly sized expansion tank
6. Clean and ush system when reinstalling a appliance.
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 appliance model and serial
number.
B. Leveling
In order for the condensate to properly ow out of the collection
system, the area where you locate the appliance must be
level. Location must also fully support the weight of the lled
appliance.
C. Clearances for Service Access
All appliances eventually leak. It is recommended to install
a catch pan beneath the appliance. This catch pan should be
sized with a maximum depth of 2”, and a minimum diameter
2” greater than the diameter of the appliance. The catch pan
should empty into an open drain line. This drain line should be
3/4” ID minimum, piped to an open drain. Failure to follow these
instructions could result in property damage. Such damages
ARE NOT covered by product warranty.
NOTE: A combustible door or removable panel is acceptable
front clearance.
The space must be provided with combustion / ventilation
air openings correctly sized for all other appliances located in
the same space as the appliance. The appliance cover must
be securely fastened to prevent the appliance from drawing
air from the appliance room. This is particularly important if
the appliance is in a room with other appliances. Failure to
comply with the above warnings could result in substantial
property damage, severe personal injury, or death.
D. Residential Garage and Closet Installations
Check with your local Authority Having Jurisdiction for
requirements when installing the appliance in a garage or
closet. Please read the entire manual before attempting
installation. Failure to properly take factors such as venting,
piping, condensate removal, and wiring into account before
installation could result in wasted time, money, and possible
property damage and personal injury.
Precautions
If the heater is located in a residential garage, per ANSI Z223.1:
• Install the appliance burner and ignition devices a
minimum of 18” above the oor of the garage. This will
ensure the burner and ignition devices are well o the
oor.
• When raising the appliance ensure the entire bottom
and fully lled weight of the appliance are fully
supported.
• Locate or protect the appliance so it cannot be
damaged by a moving vehicle.
Figure 1 - Catch Pan Dimensions and Recommended Service
Clearances
NOTE: If you do not provide the minimum clearances shown in
Figure 1 it might not be possible to service the appliance without
removing it from the space.
The space must be provided with correctly sized combustion/
ventilation air openings for all other appliances located in
the space with the appliance. For power venting installations
using room air for combustion, refer to the venting section,
this manual, for descriptions of conned and unconned
spaces. Do not install the appliance in an attic. Failure to
comply with these warnings could result in substantial
property damage, severe personal injury, or death.
E. Exhaust Vent and Intake Pipe
The appliance is rated ANSI Z21.10.3 Category IV (pressurized
vent, likely to form condensate in the vent) and requires a
special vent system designed for pressurized venting.
NOTE: The venting options described here (and further
detailed in the Venting section, this manual) are the lone
venting options approved for this appliance. Failure to
vent the appliance in accordance with the provided venting
instructions will void the warranty.
Failure to vent the appliance properly will result in serious
personal injury or death.
LP-314 Rev. 2.3.17
Do not attempt to vent this appliance by any means other
than those described in this manual. Doing so will void the
warranty and may result in severe personal injury or death.
Vents must be properly supported. Appliance exhaust and
intake connections are not designed to carry heavy weight.
Vent support brackets must be within 1’ of the appliance
and the balance at 4’ intervals. Appliance must be readily
accessible for visual inspection for rst 3’ from the appliance.
Failure to properly support vents could result in property
damage, severe personal injury, or death.
The exhaust discharged by this appliance may be very hot.
Avoid touching or other direct contact with the exhaust gases
of the vent termination assembly. Doing so could result in
severe personal injury or death.
1. Direct Vent of Exhaust and Intake
If installing a direct vent option, combustion air must be drawn
from the outdoors directly into the appliance intake and
exhaust must terminate outdoors. There are three basic direct
vent options detailed in this manual: 1. Side Wall Venting, 2.
Roof Venting, and 3. Unbalanced Venting.
Be sure to locate the appliance such that the exhaust vent and
intake piping can be routed through the building and properly
terminated. Dierent vent terminals can be used to simplify
and eliminate multiple penetrations in the building structure
(see Optional Equipment in Venting Section). The exhaust
vent and intake piping lengths, routing, and termination
methods must all comply with the methods and limits given
in the Venting Section, this manual.
When installing a combustion air intake from outdoors, care
must be taken to utilize uncontaminated combustion air. To
prevent combustion air contamination, see Table 2.
2. Power Venting, Indoor Combustion Air in Conned or
Unconned Space
This appliance requires fresh, uncontaminated air for safe
operation and must be installed in a mechanical room where
there is adequate combustion and ventilating air. NOTE: To
prevent combustion air contamination, see Table 2.
Combustion air from the indoor space can be used if the space
has adequate area or when air is provided through a duct
or louver to supply sucient combustion air based on the
appliance input. Never obstruct the supply of combustion air
to the appliance. If the appliance is installed in areas where
indoor air is contaminated (see Table 2) it is imperative that
the appliance be installed as direct vent so that all combustion
air is taken directly from the outdoors into the appliance
intake connection.
Unconned space is space with volume greater than 50
cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the
total input rating of all fuel-burning appliances installed in
that space. Rooms connected directly to this space through
openings not furnished with doors are considered part of the
space. See Venting Section for details.
Conned space is space with volume less than 50 cubic feet
per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input
rating of all fuel-burning appliances installed in that space.
Rooms connected directly to this space through openings not
furnished with doors are considered part of the space.
When drawing combustion air from inside a conventionally
constructed building to a conned space, such space should
9
be provided with two permanent openings: one located 6” (15
cm) below the space ceiling, the other 6” (15cm) above the space
oor. 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 conned space is within a building of tight construction, air
for combustion must be obtained from the outdoors as outlined
in the Venting section of this manual.
When drawing combustion air from the outside into the
mechanical room, care must be taken to provide adequate
freeze protection.
Failure to provide an adequate supply of fresh combustion air can
cause poisonous ue gases to enter the living space, resulting
in severe personal injury or death. To prevent combustion air
contamination, see Table 2.
F. Carbon Monoxide Detectors
In the Commonwealth of Massachusetts and As Required by
State and Local Codes:
Installation of Carbon Monoxide Detectors: At the time of
installation or replacement of the vented gas fueled appliance,
the installing plumber or gas tter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is
installed on the oor level where the gas appliance is installed,
unless the appliance is located in a detached, uninhabitable
structure separate from the dwelling, building, or structure used
in whole or in part for residential purposes.
In addition, the installing plumber or gas tter shall observe
that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on each additional level of
the dwelling, building, or structure served by the vented gas
appliance. It shall be the responsibility of the property owner
to secure the service of qualied licensed professionals for the
installation of hard wired carbon monoxide detectors.
a. In the event that the vented gas fueled appliance is installed
in a crawl space or attic, the hard wired carbon monoxide
detector with alarm and battery back-up shall be installed on
the next adjacent oor level.
b. In the event that these requirements cannot be met at the
time of completion of installation, the owner shall have a period
of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm
shall be installed.
Do not attempt to vent this appliance by any means other than
those described in this manual. Doing so will void the warranty
and may result in severe personal injury or death.
Approved Carbon Monoxide Detectors: Each carbon monoxide
detector as required in accordance with the above provisions
shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS
certied.
G. Prevent Combustion Air Contamination
Install intake air piping for the appliance as described in the
Venting Section, this manual. Do not terminate exhaust in
locations that can allow contamination of intake air.
LP-314 Rev. 2.3.17
10
Ensure that the intake air will not contain any of the
contaminants in Table 2. Contaminated air will damage the
appliance, resulting in possible substantial property damage,
severe personal injury, or death. For example, do not pipe
intake air near a swimming pool or laundry facilities. These
areas always contain contaminants.
Products to Avoid
Spray cans containing
uorocarbons
Permanent wave solutions Swimming pools
Chlorinated waxes / cleaners Metal fabrication plants
Chlorine-based swimming pool
chemicals
Calcium chloride used for thawing Refrigeration repair shops
Sodium chloride used for water
softening
Refrigerant leaks Auto body shops
Paint or varnish removers Plastic manufacturing plants
Hydrochloric or Muriatic acid
Cements and glues New building construction
Antistatic fabric softeners used in
clothes dryers
Chlorine-type bleaches, laundry
detergents, and cleaning solvents
Adhesives used to fasten building
products
Table 2 - Products and Areas Likely to Have Contaminants
Areas Likely to Have
Contaminants
Dry cleaning / laundry areas and
establishments
Beauty shops
Photo processing plants
Furniture renishing areas and
establishments
Remodeling areas
Garages and workshops
NOTE: DAMAGE TO THE APPLIANCE CAUSED BY
EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY
WARRANTY. (Refer to the limited warranty for complete terms
and conditions.)
H. Removing an Appliance from a Common Vent
System
common venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, at maximum speed.
Do not operate a summer exhaust fan. Close all replace
dampers.
4. Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust the 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 ame 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,
replace dampers, and any other gas burning appliances to
their previous condition of use.
7. Any improper operation of the common venting system
should be corrected to conform to the National Fuel Gas
Code, ANSI Z223.1. When resizing any portion of the common
venting system, the system should approach the minimum
size as determined using the appropriate tables in Appendix
G of ANSI Z223.1.
Do not install the appliance into a common vent with any
other appliance. This will cause ue gas spillage or appliance
malfunction, resulting in possible substantial property damage,
severe personal injury, or death.
Failure to follow all instructions can result in ue gas spillage
and carbon monoxide emissions, causing severe personal injury
or death.
When removing an existing appliance, follow the steps below.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch to determine if there is blockage, leakage,
corrosion, or other deciencies that could cause an unsafe
condition.
3. If practical, close all building doors, windows, and doors
between the space in which the appliance remains connected
to the common venting system and other spaces in the building.
Turn on clothes dryers and any appliances not connected to the
LP-314 Rev. 2.3.17
Figure 2 - CO Warning Label
I. Water Chemistry Requirements
Chemical imbalance of the water supply may aect eciency
and cause severe damage to the appliance and associated
equipment. Water quality must be professionally analyzed to
determine whether it is necessary to treat the water. Various
solutions are available to adjust water quality. Adverse water
quality will aect the reliability of the system. In addition,
operating temperatures above 135oF will accelerate the buildup of lime scale and possibly shorten appliance service life.
Failure of an appliance due to lime scale build-up, low pH, or
other chemical imbalance IS NOT covered by the warranty.
The water must be potable, free of corrosive chemicals, sand,
dirt, and other contaminates. It is up to the installer to ensure
the water does not contain corrosive chemicals or elements
that can damage the heat exchanger. Potable water is dened
as drinkable water supplied from utility or well water in
compliance with EPA secondary maximum contaminant levels
(40 CFR Part 143.3). If the water contains contaminants higher
than outlined by the EPA, water treatment is recommended
and additional, more frequent maintenance may be required.
If you suspect that your water is contaminated in any way,
discontinue use of the appliance and contact an authorized
technician or licensed professional.
• Water pH between 6.5 and 8.5
• pH levels below 6.5 can cause an increase in the rate
of corrosion. pH of 8.5 or higher can potentially cause
lime scale build-up
• Maintain water pH between 6.5 and 8.5. Check with
litmus paper or have it chemically analyzed by a local
water treatment company.
• If the pH is not between 6.5 and 8.5, consult a local
water treatment company for solutions.
• Hardness less than 12 grains (200 mg/L) (Residential
Use - water temperatures below 140oF)
• Hardness less than 7 grains (120 mg/L) (Commercial
Use - water temperatures of 140oF and greater)
• Hardness levels above the required amounts can
lead to lime 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]).
• Chloride concentration less than 100 ppm (mg/L)
• Do not ll appliance or operate with water containing
chlorides in excess of 100 ppm (mg/L).
• Using chlorinated fresh water should be acceptable
as levels are typically less than 5 ppm (mg/L).
• Do not connect the appliance to directly heat
swimming pool or spa water.
• Total Dissolved Solids (TDS) less than 500 ppm
(mg/L)
• Total dissolved solids are minerals, salts, metals, and
charged particles that are dissolved in water.
• The greater the amounts of TDS present, the higher
the corrosion potential due to increased conductivity
in the water.
• If using softened water to ll the appliance, it is
still possible to have high TDS. This water can be
corrosive. Consult local water treatment companies
for other treatment solutions to reduce this eect.
*NOTE: To promote appliance service life, it is strongly
recommended to follow the maintenance procedures in
this manual.
11
LP-314 Rev. 2.3.17
12
Figure 3 - Appliance Dimensions - NOTE: All Dimensions Are Approximate
LP-314 Rev. 2.3.17
13
Part 4 - Domestic Hot Water and Hydronic Piping
Failure to follow the instructions in this section WILL VOID the
warranty and may result in property damage, severe personal
injury, or death.
Dielectric unions or galvanized steel ttings must not be used in
a system with this appliance. Doing so WILL VOID the warranty.
Use only copper, brass, or stainless steel ttings. Teon thread
sealant must be used on all connections.
DO NOT pipe this appliance with black iron, galvanized steel,
steel, or lead pipe. Doing so will result in premature product
failure and property damage, and WILL VOID the warranty.
A. Plumbing
Use two wrenches when tightening water piping at appliance.
Use one wrench to prevent the appliance return or supply
line from turning. Failure to prevent piping connections from
turning could cause damage to appliance components.
1. System Domestic Water Piping
Domestic water connections must be installed in accordance
with all local and national plumbing codes or any applicable
prevailing standards. The appliance is supplied with a rated
mixing valve certied to ASSE 1017. You must completely follow
the instructions included with the mixing valve for proper
installation. This mixing valve must be installed on the domestic
outlet to assure that hot water temperature does not vary more
than +/– 5°F, as the unit adjusts its stored water automatic set
point to meet the requirements of the hydronic heating module.
The valve MUST NOT be allowed to freeze. If the mixing valve
is installed in a potentially freezing situation, suitable insulation
must be tted to prevent damage. DO NOT use excess thread
sealant (in liquid, tape or other form) as this may cause the
mixing valve to fail. Toxic chemicals shall not be introduced into
the mixing valve system.
NOTE: Recommend to the user that the mixing valve be checked
annually to ensure its continued function.
2. Appliance Domestic Water Piping
The domestic inlet and outlet ports on the appliance are 1” NPT
connections. We recommend the installation of shut-o valves
and unions on both the inlet and outlet ports to isolate the
appliance for future service.
It is important that the connections on the inlet and outlet are
brass or copper. Never use dielectric unions or galvanized steel
ttings. Teon thread sealant must be used to seal all tank
connections. An approved ASSE 1017 mixing valve is provided
with every appliance and must be installed on the outlet to
protect the user from scalding temperatures. This valve reduces
the point of discharge temperature by mixing the hot and cold
water from the discharge outlet or mixed outlet port. This device
alone will not protect the user from scalding temperature. To
install and set up the mixing valve, follow the pre-installation
steps in this manual and also follow the enclosed instructions
included with the mixing valve.
B. Scalding
This appliance can
deliver scalding water.
Be careful whenever
using hot water to
avoid scalding injury.
Certain appliances
such as dishwashers
and automatic clothes
washers may require
increased water
temperatures. By
setting the thermostat
on this appliance to
obtain the increased
water temperature
required by these
appliances you may
create the potential
for scald injury.
To protect against injury, install the mixing valve included with
this appliance. This valve will reduce point of use discharge
temperatures by mixing cold and hot water in the branch
supply lines.
Table 3 details the relationship of water temperature and
time with regard to scald injury and may be used as a guide
in determining the safest water temperature for your
applications.
ASSE 1017 or ASSE 1070 temperature limiting or mixing
valves do not eliminate the risk of scalding.
To avoid scalding:
• Set the appliance set point temperature as low as
possible.
• Feel water before bathing or showering.
• If thermostatic valves are required, use devices
specically designed for such purpose. Install these
devices in accordance with instructions provided by
the manufacturer.
Failure to install a temperature limiting or mixing valve and
follow these instructions could result in property damage,
severe personal injury, or death due to scalds.
Approximate Time / Temperature Relationships in Scalds
120oF More than 5 minutes
125oF 1 1/2 to 2 minutes
130oF About 30 seconds
135oF About 10 seconds
140oF Less than 5 seconds
145oF Less than 3 seconds
150oF About 1 1/2 seconds
155oF About 1 second
Table 3 - Approximate Time / Temperature Relationships in Scalds
LP-314 Rev. 2.3.17
14
C. Mixing Valve Installation
This appliance can deliver scalding temperature water at any
faucet in the system. Be careful whenever using hot water
to avoid scalding injury. By setting the thermostat on this
appliance to obtain increased water temperature, you may
create a higher potential for scald injury. To protect against
injury, you should install the ASSE approved thermostatic
mixing valve (a device to limit the temperature of water to
protect against scald injury by mixing hot and cold water
supply) shipped with appliance in the system. This valve will
reduce point of discharge temperature in branch supply lines.
Install this valve according to the directions in the mixing
device packaging. DO NOT OPERATE THIS APPLIANCE
WITHOUT AN ASSE APPROVED THERMOSTATIC
MIXING DEVICE. If this appliance was shipped without an
ASSE approved thermostatic mixing valve, contact the
manufacturer. Failure to install the mixing valve could result
in substantial property damage, severe personal injury, or
death.
1. All installations must be carried out by licensed professionals.
2. The installer must ensure compatibility of all installations.
Example: Temperature of hot water – marked “H”, cold water
inlet – marked “C”, and mixed outlet – marked with directional
arrow.
3. The mixing valve may be installed in any position.
4. Local codes shall take priority over any inconsistency in
these instructions.
5. During startup, you must ensure that the valve is set to the
desired temperature (the mixing valve preset is 120oF). If the
valve temperature needs to be adjusted, please refer to the
mixing valve instructions and/or the following settings.
The mixing valve is certied to ASSE 1017. It is not to be used
to provide anti-scald service resulting from system pressure
uctuations, and should not be used where more sophisticated
compensating temperature controls are required.
Mixing Valve Specications
Min. – Max. Hot Water Inlet Temperature 120-180oF (49 - 82oC)
Min. – Max. Cold Water Inlet Temperature 39 - 80oF (4 - 27oC)
Max. Working Pressure 200 PSI
Min. Flow Rate 1 GPM
Outlet Water Temperature Range 85–130oF (29–54oC)
Min. Temperature Dierential
(Between Hot Supply and Outlet)
Factory Set Locking Ring 120oF Max.
Allowable Supply Pressure Variation +/- 20%
Accuracy of Outlet Temperature +/-3oF (3.4oC)
Performance –
CV 1.8
Max Flow – 1” 14 gpm
Notes:
1
Maximum permissible temperature in accordance with ASSE 1070.
The limit locking ring may be adjusted for applications not requiring
ASSE 1070 valves.
27oF (15oC)
1
2
2
Maximum allowable variation in either supply pressure in order to
control the outlet temperature to within +/- 3oF. Warning: Pressure
variations outside of this range may cause changes in the outlet
temperature.
NOTE: At low ow operation, the outlet temperature may vary
slightly more.
Dierential pressure at the valve inlet should be within a 2 to 1
ratio under normal ow conditions.
Inline ttings, pipe work, layout and sizing must be taken into
consideration. In installations where the valve is supplied with
unbalanced hot cold pressures greater than a 2 to 1 ratio, please
call the HTP Technical Support Department.
Installation of the Mixing Valve
1. Flush all pipe work thoroughly (with water only) before
installing the mixing valve.
2. The mixing valve comes complete with union type connections
for ease of installation and service.
3. The mixing valve must be removed from the pipe work prior
to soldering the end connections. It is recommended to use a
spacer piece while soldering.
Do not solder unions while attached to the valve body. Solder
connections prior to connecting unions to the valve body to
avoid damaging the valve and its function. Failure to follow this
instruction could result in property damage, serious personal
injury, or death.
Setting the Mixing Valve Outlet Temperature
1. Turn both the hot and cold water supplies on. Open an
outlet, preferably a sink or basin faucet rather than a shower.
To calibrate, let water run for 2 minutes and measure the outlet
temperature with a thermometer. Adjust the green cap counter
clockwise to increase and clockwise to decrease temperature,
as shown below.
Figure 4 - Adjusting the Mixing Valve
2. Once the desired outlet temperature has been achieved, ret
the green top so that it snaps onto the body of the mixing valve.
NOTE: See the instruction sheet included with the mixing valve
to adjust the maximum temperature of the mixing valve greater
than 120oF.
LP-314 Rev. 2.3.17
15
Hotter water increases the risk of scald injury. Scalding may
occur within 5 seconds at a setting of 140oF (60oC). Water
temperature over 125oF can instantly cause severe burns, or
death, from scalds. Children, disabled, and elderly are at the
highest risk of being scalded. See instruction manual before
setting temperature at appliance. Feel water before bathing or
showering!
Mixing Valve Maintenance and Service
• It is recommended to check the mixing valve annually to
ensure proper system capabilities. More frequent checks
are recommended in adverse water conditions.
• When checking the mixed water supply temperature,
use the same faucet used in the initial installation
temperature adjustment.
• There may be some variation in the water temperature
from the mixing valve due to seasonal temperature
variations in the cold water supply.
If the water supply is of poor quality, the internal components
may jam, requiring an additional lter or strainer to be
tted to the system. Contact a plumbing professional for
appropriate materials and installation.
D. Auxiliary Connections
The auxiliary connections are additional connections for a
recirculation connection, air handlers, plate exchangers, or
other devices that supply hot water. These connections must
be installed in accordance with all local and national codes or
any applicable standard that prevails. Auxiliary connections are
1” on all models. Never use dielectric unions or galvanized steel
ttings. Use only copper or brass ttings. Sealant must be used
on all connections. The top port is the outlet and the bottom
port is the inlet.
Never connect auxiliary connections to any system that uses
glycol or other solutions formulated for hydronic systems.
These auxiliary connections are to be used only in a potable
water system. Failure to follow this warning could result in
serious injury or death.
E. Temperature and Pressure Relief Valve for DHW
Install a temperature and pressure relief valve into the marked
port (upper right). We recommend a WATTS 40XL5 valve or
equivalent for 130,000 BTU models or above input. The valve
must meet the ANSI Z21.22B requirements for relief valves
for hot water heaters as per a nationally recognized lab that
maintains a periodic inspection of production of such listed
safety device. The pressure rating of the valve must not exceed
the listed working pressure of this appliance, and must be rated
to the proper BTU/hr capacity of the appliance.
Overheated water and high pressures can cause water tank
explosion. A properly sized temperature and pressure relief
valve must be installed in the opening provided on the
appliance. Failure to install a properly sized temperature and
pressure relief valve could result in explosion and property
damage, serious injury, or death.
To avoid water damage or scalding due to relief valve
operation:
• Discharge line must be connected to relief valve outlet
and run to a safe place of disposal. Terminate the
discharge line in a manner that will prevent possibility
of severe burns or property damage should the relief
valve discharge.
• Discharge line must be as short as possible and
the same size as the valve discharge connection
throughout its entire length.
• Discharge line must pitch downward from the valve
and terminate at least 6” above the oor drain, making
discharge clearly visible.
• The discharge line shall terminate plain, not threaded,
with a material serviceable for temperatures of 375oF
or greater.
• Do not pipe discharge to any location where freezing
could occur.
• No valve may be installed between the relief valve and
appliance or in the discharge line. Do not plug or place
any obstruction in the discharge line.
• Test the operation of the relief valve after lling and
pressurizing the system by lifting the lever. Make sure
the valve discharges freely. If the valve fails to operate
correctly, immediately replace with a new properly
rated relief valve.
• Test T&P valve at least once annually to ensure the
waterway is clear. If valve does not operate, turn the
appliance “o” and call a plumber immediately.
• Take care whenever operating relief valve to avoid
scalding injury or property damage.
FAILURE TO COMPLY WITH THE ABOVE GUIDELINES
COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION,
RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY
DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
Do not thread a cap or plug into the relief valve or relief
valve line under any circumstances! Explosion and property
damage, serious injury, or death may result.
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 qualied service technician to ensure that the
product has not been aected by corrosive water conditions
and to ensure that the valve and discharge line have not been
altered or tampered with illegally. Certain naturally occuring
conditions may corrode the valve and its components over
time, rendering the valve inoperative. Such conditions can
only be detected if the valve and its components are physically
removed and inspected. Do not attempt to conduct an
inspection on your own. Contact your plumbing contractor
for a re-inspection to assure continued safety.
FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED
COULD RESULT IN UNSAFE TEMPERATURE AND/OR
PRESSURE BUILD-UP WHICH CAN RESULT IN PROPERTY
DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.
LP-314 Rev. 2.3.17
16
F. Backow Preventer
Use a backow preventer specically designed for water
heater installations. This valve should be installed on the cold
water ll supply line per local codes.
G. Potable Expansion Tank
A potable hot water expansion tank is required to oset
heated water expansion. In most city plumbing systems, the
water meter has a no return or back ow device built into
the system to prevent back owing of water into city mains.
Some local codes require back ow preventers on all incoming
water supplies. The hot water expansion tank must be listed
for potable water use. The expansion tank should be located
on the cold inlet piping close to the appliance.
Expansion Tank and Make-Up Water
1. Ensure that the expansion tank is sized to correctly handle
appliance and system water volume and temperature.
Undersized expansion tanks cause system water to be lost
from the relief valve, causing make-up water to be added.
Eventual appliance failure can result due to excessive makeup water addition. SUCH FAILURE IS NOT COVERED BY
WARRANTY.
The expansion tank must be suitable for hot potable water
systems.
2. The expansion tank must be located as shown in
Applications, this manual, or following recognized design
methods. See expansion tank manufacturer’s instructions for
details.
Failure to follow the instructions in this section WILL VOID
the warranty and may result in property damage, serious
personal injury, or death.
H. Hydronic Heating Module Piping
The hydronic heating module comes pre-plumbed and
connected directly to the storage tank. The heated water
inside the tank will be circulated through one side of the
brazed plate heat exchanger while the heating system water
ows through the other side. The heating system piping is
connected to the return and supply pipes located on the top
of the hydronic heating module (see Figure 5). Piping of the
module to the system is not complex and does not require
any of the primary or secondary piping normally used on high
eciency low mass boilers.
NOTE: Do not connect hydronic heating module to air
handler units. This module may not be applied to air handler
applications.
I. Pressure Relief Valve for the Hydronic System
The pressure relief valve supplied with the appliance is
designed to relieve pressure greater than 30 psi. The hydronic
heating module is designed to withstand pressure up to
150 psi. If you are changing the pressure relief valve for a
higher pressure rating, you must make sure that the system
components are designed for the higher pressure. The relief
valve must be rated for the 135,000 Btu maximum capacity
of the brazed plate heat exchanger. Pipe the discharge line in
copper piping to a drain. Provide 6” clearance from the oor
drain.
LP-314 Rev. 2.3.17
J. Hydronic Expansion Tank and Make-Up Water
Ensure that the expansion tank is sized to the system volume,
brazed plate capacity, and related piping for the hydronic
heating module. The capacity of the module and brazed plate
is ½ gallon. Most chilled water systems are piped using a closed
type expansion tank.
Connect the expansion tank to the air separator only if the
separator is on the suction side of the circulator. The hydronic
heating module has a water line connection of ½” NPT to
connect into the pressure reducing valve and back ow
preventer. Normal system pressure is 15 psi.
K. Hydronic Heating Module System Piping
The hydronic heating module is designed to function in a closed
loop hydronic system. The included temperature and pressure
gauge allows the user to monitor the system pressure and
temperature from the hydronic heating module. The gauge
should be installed on the supply outlet piping from the heating
module. The installation of an air elimination device will remove
air from the system which is necessary to avoid an air lock in the
central heating circulator. It is recommended that all the piping
is insulated to improve on the system’s overall eciency. In the
system piping, heating coils in air handler, ow control valves, or
other devices must be installed to prevent gravity circulation of
heated water from the heating module.
Freeze protection for new or existing systems must be composed
of glycol that is specically formulated to include inhibitors
that will prevent the glycol from attacking the metallic system
components. Make certain that the system uid is checked for
the correct glycol concentration and inhibitor level. The system
should be tested at least once a year or as recommended by
the producer of the glycol solution. Allowance should be made
for the expansion of the glycol solution in the system piping.
Example: 50% by volume glycol solution expands 4.8% in
volume for the temperature increase from 32oF to 180oF, while
water expands 3% with the same temperature rise.
Listed below are the basic steps that will help guide you through
the installation of the hydronic heating module to the system
piping.
1. Connect the system return marked “Return”.
2. Connect the system supply marked “Supply”.
3. Install a balance and purge valve (or shut o drain valve) on
the system return to purge air out of the zone at start-up.
4. Install a back ow preventer on the cold feed make–up water
line.
5. Install a pressure reducing valve on the cold feed make up
water line (15 psi operating pressure). Check temperature
and pressure gauge when operating. It should read minimum
pressure of 15 psi.
6. Install the system circulator as shown in the piping details in
this section. Make sure the circulator is properly sized for the
system and friction loss.
7. Install an expansion tank on the system supply. Consult
the expansion tank manufacturer’s instructions for specic
information related to expansion for the required system
volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of system to blow
out the system if needed. NOTE: The hydronic heating module
cannot be drained completely of water without purging the unit
with an air pressure greater than 15 psi but not exceeding 40
psi. If winterizing the unit it is recommended, use glycol on
the closed loop hydronic side only.
10. The relief valve is installed at the factory. A pipe discharge
line should be installed to release 6” above a drain, so
discharge will be visible when pressure is relieved. The pipe
size must be the same size as the relief valve outlet.
Do not thread a cap or plug into the relief valve or relief
valve line under any circumstances! Explosion and property
damage, serious injury, or death may result.
L. Hydronic Heating Module Output
Hydronic heating module output is based on the burner input
and the ow rate supplied by the selected system circulator
through the closed loop side of the brazed plate exchanger.
Included in this section are graphs that will help you size
the appropriate circulator and output needed to meet your
system design requirements. Below is an example on the
steps needed to determine the correct circulator for the
system.
Example: System design requires 120,000 Btu at 20 Delta
Step 1
Using the graphs, select the input rate of the appliance. In
this example, we would have to select a minimum input of
199K (the 130K max. output is 100,000 Btu, which falls below
our operating point).
Step 2
Next, go to the chart for the 199K burner input and select the
point of operation where the Btu and Delta T line intersect.
Mark the point on the chart and go to bottom of the chart to
determine ow rate needed to achieve the rated output from
the module. This example is 12 GPM.
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Figure 5 - Hydronic Heating Module
Step 3
Select the correct circulator to meet the ow and resistance
requirements for the system design. To calculate this, you must
determine the ow and resistance through the system and
heating module. The heating module requires 12 GPM at 10 feet
of head. The system requires 12 GPM at 5 feet of head. To select
a circulator, add the resistance 10 feet of head (module) + 5 feet
of head (system) at 12 GPM. This system requires a circulator
that operates at a resistance of 15 feet at 12 GPM (See examples
in Figures 6, 7, and 8).
Figure 6 - Sizing Chart for 130kBTU Model
LP-314 Rev. 2.3.17
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EXAMPLE: At 12 GPM there is approximately 10 ft of head loss.
Figure 7 - Sizing Chart for 199kBTU Model
Figure 8 - Pressure Drop
LP-314 Rev. 2.3.17
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