HTP PHE130, PHE199 Installation Manual

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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 qualied 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

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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 qualied

installer, service agency, or the gas supplier.

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The following dened 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 ocial or electrical inspector, or others

having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding ocer or departmental ocial may be the AHJ.

NOTE: HTP, Inc. reserves the right to modify product technical specications and components without prior notice.

For the Installer

This appliance must be installed by qualied 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 specied in ANSI Z21.10.3 - latest edition.

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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 Conned or Unconned

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. Backow 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 Conned or Unconned

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

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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 qualied heating installer / service technician. Have this appliance serviced / inspected annually by a qualied 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.

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NOTE: If the appliance is exposed to the following, do not operate. Immediately call a qualied 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 qualied 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.

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.

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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 eciency central heating and domestic hot water from one appliance. Total System Control manages system needs, ensuring maximum comfort and ecient 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 Eciency Heat Exchanger

The 90/10 copper nickel heat exchanger provides highly ecient 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 eciency of 98% and thermal eciency 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 eciency 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 eciency.

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)

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• 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 eciency.

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 certied 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 inuenced 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

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• 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 conned and unconned 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.

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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. Dierent 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 Conned or Unconned 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 sucient 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. Unconned 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. Conned 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 conned space, such space should

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 conned 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 qualied 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 certied.

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

Page 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 renishing 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 deciencies 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 aect eciency 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 aect 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 dened

Page 11

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 eect.

*NOTE: To promote appliance service life, it is strongly recommended to follow the maintenance procedures in this manual.

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Figure 3 - Appliance Dimensions - NOTE: All Dimensions Are Approximate

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Page 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. Teon 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 certied 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. Teon 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

specically 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

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Page 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 certied 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 Specications

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 Dierential (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:

Maximum permissible temperature in accordance with ASSE 1070. The limit locking ring may be adjusted for applications not requiring ASSE 1070 valves.

27oF (15oC)

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. Dierential 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, ret 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.

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Page 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 qualied service technician to ensure that the product has not been aected 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

Page 16

F. Backow Preventer

Use a backow preventer specically 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 oset 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 eciency 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 eciency. 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 specically 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 specic 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

Page 17

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.

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

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Page 18

EXAMPLE: At 12 GPM there is approximately 10 ft of head loss.

Figure 7 - Sizing Chart for 199kBTU Model

Figure 8 - Pressure Drop

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Page 19

M. Applications

CAUTION

NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater ow is required.

2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance.

3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator.

4. All circulators shall have an integral ow check.

NOTES FOR AIR HANDLER APPLICATION (APPLIES TO DOMESTIC WATER OUTLET CONNECTIONS ONLY):

1. MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE APPLIANCE TO THE FAN COIL IN THE AIR HANDLER.

2. MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX HOURS FOR 60 SECONDS. THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS.

3. ALL WATER PIPING MUST BE INSULATED.

4. YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR.

NOTE: THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING CONCEPT ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

Figure 9 - Piping with Air Handler Application

Figure 10 - Piping with Zone Valves

DO NOT use the heat pack for high temperature (over 160oF) applications. Failure to comply will result in substantial overworking of the appliance, and possibly lead to early appliance failure. Use of the heat pack for high temperature applications WILL VOID the warranty.

The piping will not support the weight of the appliance circulator pump. Refer to the pump manufacturer’s installation instructions to properly support the circulator pump. Failure to comply with these instructions could result in substantial property damage, severe personal injury, or death.

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Page 20

CAUTION

NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater ow is required.

2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance.

3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator.

4. All circulators shall have an integral ow check.

NOTES FOR AIR HANDLER APPLICATION (APPLIES TO DOMESTIC WATER OUTLET CONNECTIONS ONLY):

1. MASSACHUSETTS STATE PLUMBING CODE REQUIRES A DISTANCE NO GREATER THAN 50 FEET FROM THE APPLIANCE TO THE FAN COIL IN THE AIR HANDLER.

2. MASSACHUSETTS STATE PLUMBING CODE REQUIRES AN ELECTRONICALLY TIMED CIRCULATOR PUMP TO ACTIVATE EVERY SIX HOURS FOR 60 SECONDS. THIS CIRCULATOR IS REQUIRED TO BE BRONZE OR STAINLESS.

3. ALL WATER PIPING MUST BE INSULATED.

4. YOU MUST INSTALL A VACUUM RELIEF VALVE PER 248 CMR.

NOTE: THIS DRAWING IS MEANT TO DEMONSTRATE SYSTEM PIPING CONCEPT ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

Figure 11 - Piping with Zone Circulators

Figure 12 - Piping with Recirculation

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Page 21

N. Filling the Appliance

The appliance must be full of water and the system fully purged BEFORE powering the appliance. When lling the appliance, open a hot water tap to release air in the tank and piping. All air has been purged from the system when water runs freely from the faucets. Applying power to the appliance when it is not full of water will damage the heat exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by appliance warranty.

• Make certain the drain valve is completely closed.

• Open the shut-o valve in the cold water supply line.

• Open the hot water faucets to allow air to vent from the appliance and piping.

• Allow sucient time for the appliance to completely ll with water.

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Page 22

Part 5 - Venting and Condensate Removal

The appliance must be vented as detailed in this section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect nished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as the instructions provided in this manual. Failure to properly install the vent system will result in severe personal injury or death.

A. General

This appliance is certied as a “Category IV” appliance and requires a special venting system. The vent system will operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Follow the venting instructions carefully. Failure to do so will result in substantial property damage, severe personal injury, or death.

1. 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.

2. Install the venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, CAN/CGA B149, and / or applicable provisions of local building codes.

3. This appliance must be vented with materials, components, and systems listed and approved for Category IV appliances.

Exhaust and intake are to be piped separately. This appliance cannot share a common exhaust or intake with multiple appliances. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death.

NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors. NOTE: If exhaust vent pipe system passes through an unheated space such as an alcove or attic, the space must be heated.

Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent pipe is properly beveled and seated before insertion into the ue adapter. Failure to do so could result in property damage, severe personal injury, or death.

Due to the extreme ammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’ responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.

CPVC, Polypropylene, or Stainless Steel pipe material MUST be used for the rst 3 feet of the vent run if the exhaust vent passes through an enclosed space greater than 6”, such as a wall. The balance of the vent run can be installed with standard Schedule 40 PVC pipe. Failure to comply with this warning could result in property damage, severe personal injury, or death. Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust vent must be pitched a minimum of 1/4” per foot back to the appliance to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

LP-314 Rev. 2.3.17

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B. Approved Materials for Exhaust Vent and Intake Pipe

Item Material

PVC Schedule 40/80 ANSI / ASTM D1785

Exhaust Vent or Intake

Pipe and Fittings

Pipe Cement

Pipe Primer PVC / CPVC ASTM F656

• The exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID heater warranty.

• PVC / CPVC pipe and ttings of the same diameter are considered interchangeable.

• Use of cellular core pipe PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenysulfone) in nonmetallic venting

systems is prohibited.

• DO NOT connect PVC / CPVC to Polypropylene without an approved vent connector.

• Any transition to Polypropylene MUST be done in the vertical within ve (5) feet of the appliance.

• When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the heater vent connection, and at the

termination when using a PVC termination kit. DO NOT mix AL29-4C piping from dierent manufacturers unless using adapters specically designed for the purpose by the manufacturer.

• Covering non-metallic vent pipe and ttings with thermal insulation is prohibited.

• A double wall vent may be used when using stainless steel vent material in a freezing climate.

• *PVC-DWV may be used for air intake applications ONLY.

• Contact the venting material manufacturer if there is any question about the applicability of the proposed venting

material.

Failure to follow these directions will result in substantial property damage, severe personal injury, or death.

Table 4 - Approved Materials for Exhaust Vent and Intake Pipe

PVC-DWV* ANSI / ASTM D2665

CPVC Schedule 40/80 ANSI / ASTM F441

Polypropylene UL-1738 or ULC-S636

Stainless Steel AL29-4C Certied for Category IV and Direct Vent Appliance Venting

PVC ANSI / ASTM D2564

CPVC ANSI / ASTM F493

United States Canada

Standards for Installation In:

PVC, CPVC, and PP Venting Must

be ULC-S636 Certied. IPEX is

an approved manufacturer in

Canada.

IPEX System 636 Cements and

Primers

DO NOT mix components from dierent venting systems. The vent system could fail, causing leakage of ue products into the living space. Use only the approved pipe and tting materials, and primer and cement specically designed for the material used, as listed in the above table. Failure to do so could result in property damage, serious injury, or death.

High heat sources (generating heat 100oF / 37oC or greater, such as boiler ue pipes, space haters, 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.

NOTE: The use of double-wall vent or insulated material for the combustion air intake pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application will result in serious injury or death.

C. Additional Requirements for Installation in Canada

1. Installations must be made with a vent pipe system certied to ULC-S636. IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. Additionally, you may use AL29-4C stainless steel venting to comply with Canadian requirements.

2. The rst three (3) feet of vent pipe from the appliance ue outlet must be readily accessible for visual inspection.

3. The components of the certied vent system must not be interchanged with other vent systems or unlisted pipe / ttings.

LP-314 Rev. 2.3.17

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Area Where Terminal Is Not Permitted

Intake Pipe Terminal

Exhaust Vent Terminal

D. Exhaust Vent and Intake Pipe Location

Figure 13 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – NOTES: INSTALLATIONS IN THE UNITED STATES A. Provide a minimum of 1 foot clearance from the bottom of the

exhaust vent and intake pipe above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. B. Provide a minimum of 1 foot distance from exhaust vent termination to any door, operable window, or gravity intake into any building. C. Provide a minimum of 1 foot distance from exhaust vent termination to any permanently closed door or window. D. Provide a minimum of 4 feet vertical clearance from the exhaust vent to all roof overhangs. E. Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather, and could result in blockage of the exhaust vent. To prevent icicles from forming, maintain 4 feet vertical clearance from the exhaust vent to all roof overhangs. F. Provide 4 feet clearance from the outside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs. G. Provide 6 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs. H. Provide 4 feet clearance from center line within a height of 15 feet above electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. I. Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained. J. This appliance vent system shall terminate at least 3 feet (0.9 m) above any forced air intake located within 10 ft (3 m). NOTE: This does not apply to the combustion air intake of a directvent appliance. K. When venting with a two pipe system, maximum distance between exhaust vent and intake pipe is 6 feet (1.8 m). Minimum distance between exhaust vent and intake pipe on single direct vented appliance is 10” (0.255 m) center-to-center. Minimum distance between exhaust vents and intake pipes on multiple appliances is 10” (0.255 m) center-to-center. L. When adjacent to a public walkway, locate exit terminal at least 7 feet above grade. In addition:

• Total length of vent piping shall not exceed the limits specied in this manual.

• The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.

• The ue products coming from the exhaust vent will create a large plume when the appliance is in operation. Avoid venting in areas that will aect neighboring buildings or be considered objectionable.

• DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.

• DO NOT locate the exhaust vent or intake pipe terminals under a porch, balcony, or veranda.

• Avoid terminating exhaust vents near shrubs, air conditioners, or other objects that will obstruct the exhaust stream.

• DO NOT vent over a public walkway. Condensate could drip or freeze and create a nuisance or hazard.

• DO NOT vent near sot vents, crawl space vents, or other areas where condensate or vapor could create a nuisance or hazard or cause property damage.

• DO NOT vent where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valve, or other equipment.

• DO NOT vent the appliance in a chimney ue serving a separate appliance designed to burn solid fuel. The appliance may only be vented in vacant chimneys.

• NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider

venting installation and location to save time and cost.

INSTALLATIONS IN CANADA NOTE: Canadian installation must comply with the CAN/CSA B149.1

code and applicable local codes and supersede the restrictions for the United States outlined in this section.

The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routing maintenance. Failure to keep the vent piping terminations clear and properly maintain the appliance could result in property damage, severe personal injury, or death. For each oor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the appliance. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with these requirements could result in product damage, severe personal injury, or death.

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E. Exhaust Vent and Intake Pipe Sizing

1. The exhaust vent and intake pipe size is 2” for 130kBTU models and 3” for 199kBTU models.

2. The maximum total equivalent length of 2” exhaust vent and intake pipe should not exceed 85 feet. The maximum total equivalent length of 3” exhaust vent and intake pipe should not exceed 200 feet.

a. The equivalent length of elbows, tees, and other ttings are listed in the Friction Loss Table.

Friction Loss Equivalent in Piping and Fittings

Fittings or Piping

90 Degree Elbow* 5’ 5’ 3’

45 Degree Elbow 3’ 3’ 1’

Coupling 0’ 0’ 0’

Air Inlet Tee 0’ 0’ 0’

Straight Pipe 1’ 1’ 1’

Concentric Kit 3’ 3’ N/A

V500 2” Kit 1’ N/A N/A

V1000 3” Kit N/A 1’ 1’

V2000 4” Kit N/A 1’ 1’

Table 5 - *Friction loss for long radius elbow is 1 foot less. NOTE: Consult Polypropylene venting instructions for friction loss and pressure drop equivalents.

2” 3” 4”

b. For example: If the exhaust vent has two 90o elbows and 10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet. Further, if the intake pipe has two 90o elbows, one 45o elbow, and 10 feet of PVC pipe, the following calculation applies: Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. Finally, if a concentric kit is used we nd: Total Equivalent Length = 20 + 23 + 3 = 46 feet. The total equivalent length is 46 feet, well below the maximum of 85 feet for 2” pipe. c. Eort should be made to keep a minimum dierence in equivalent length between the exhaust vent and intake pipe.

3. The minimum total equivalent length is 16 feet.

Equivalent Feet

pipe to prevent the condensate from pooling in the vent pipe.

Standard

Vent Connection and

Maximum Total

Equivalent Length

2” (85’) 3” x 2” 3” (125’)

3” (200’) 4”x 3” 4” (200’)

Table 6 - Vent Run Transition

Reducing

Coupling

Increased Vent Size and Maximum Total

Equivalent Length

c. If transition occurs at a distance greater than 15 equivalent feet from the appliance, the maximum equivalent length will be reduced.

Total maximum equivalent length of increased diameter exhaust vent and intake pipe must not exceed the lengths dened in this manual. 125 maximum total equivalent feet for 2” increased to 3” vent pipe; 200 maximum total equivalent feet for any increase to 3” vent pipe diameter. Failure to keep the total equivalent length below the maximum lengths determined in this manual will result in faulty appliance operation, substantial property damage, serious personal injury, or death.

Transition

Point (Ft. from

Appliance)

15 95 125

20 77 1/2 117 1/2

25 60 1/2 110 1/2

30 43 103

35 26 96

40 8 1/2 88 1/2

NONE 0 85

Table 7 - TEL = Total Equivalent Length *Oversized vent pipe diameter is 1” or greater than factory supplied connection.

TEL of Oversized

Vent Pipe (Ft.)*

Maximum TEL of all Vent Pipe (Ft.)

G. Exhaust Vent and Intake Pipe Installation

Do not exceed the maximum lengths for vent pipes. Excessive length could result in appliance shutdown and property damage.

Failure to provide a minimum total vent length of 16 equivalent feet could result in property damage and improper product operation.

F. Longer Vent Runs

The maximum total equivalent length can be extended by increasing the diameter of both the exhaust vent and intake pipes equally. However, the transitions should begin a minimum of 15 equivalent feet from the appliance.

a. The maximum total equivalent length for increased diameter vent pipes is 125 feet for 2” transitioning to 3” pipe (this length includes the minimum 15 total equivalent feet necessary for transition). NOTE: 3” vent pipe can be increased in diameter, but total equivalent length cannot be increased beyond 200 feet. b. Transitions should always be made in vertical sections of

All joints of positive pressure vent systems must be sealed completely to prevent leakage of ue products into the living space. Failure to do so could result in property damage, serious injury, or death.

1. Use only solid PVC, CPVC, or stainless steel pipe or a Polypropylene vent system approved for use with Category IV appliances. FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS. Foam core piping may be used on air inlet piping only.

2. Remove all burrs and debris from joints and ttings.

3. When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe. NOTE: DO NOT CEMENT POLYPROPYLENE PIPE.

4. Ensure the vent is located where it will not be exposed to prevailing winds.

LP-314 Rev. 2.3.17

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5. In all roof venting applications, exhaust discharge must point away from the pitch of the roof.

6. If the exhaust vent is to be terminated in a walled o area (such as a roof with a parapet wall), ensure the exhaust vent terminates a minimum of 10’ from nearest wall and extends level with or above the top of the wall. This will ensure ue gas does does not get trapped and possibly recirculated into the intake air pipe, which could contaminate the combustion air.

7. To prevent water leakage, install adequate roof ashing where the pipe enters the roof.

8. Do not locate vent over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.

9. Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully consider venting installation and location.

10. Horizontal lengths of exhaust vent must slope back towards the appliance not less than ¼” per foot to allow condensate to drain from the vent pipe.

11. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.

12. In vacant chimney applications, install and seal a rain cap over existing chimney openings.

13. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

14. Do not use the appliance to support any piping.

15. A screened straight coupling is provided with the appliance for use as an outside exhaust termination.

16. A screened inlet air tee is provided with the appliance to be used as an outside intake termination.

17. Maximum Snow Level Determination: These installation instructions reference snow levels in establishing a minimum height for the installation of exhaust vent or air intake terminations. Snow levels shall be determined as follows:

a. The installation location may, by ordinance, designate how snow levels are calculated in that location; or b. In the absence of specic ordinances, snow levels shall be calculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service’s 10 year statistics for the installation location/geographical area.

In the Commonwealth of Massachusetts and as Required by State and Local Codes:

• The vented gas fueled appliance shall not be installed so its combustion, ventilation, or dilution air is obtained from a bedroom or bathroom.

• Signage: Whenever any through-the-wall (horizontal or sidewall) vent is installed less than seven feet above the nished grade, a metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height of eight feet above grade directly in line with the exhaust vent terminal. The sign shall read, in print no less than 0.5 inches in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

• Marking of Exhaust Vent and Intake Pipe: Piping used for ventilation, make-up, or combustion air intake shall be labeled as follows: a. Throughout the entire developed length:

i. Labels must be placed every ten feet for exposed/visible

piping; or ii. Labels must be placed every three feet for concealed

piping. b. At all changes of direction; c. On each side of a penetration through a partition, wall or ceiling; and d. The labels shall be black lettering that:

i. Indicates that the piping is used for ventilation, make-

up, or combustion air intake, and

ii. The letters shall be sized equal to a minimum of the

pipe diameter. However, for piping with a diameter

exceeding two inches, said lettering does not need to

be larger than two inches.

The following table lists optional exhaust/intake terminations available from HTP:

Description Stock Code

2” PVC Concentric Termination Kit KGAVT0501CVT

3” PVC Concentric Termination Kit KGAVT0601CVT

2” Stainless Steel Termination Kit V500

3” Stainless Steel Termination Kit V1000

4” Stainless Steel Termination Kit V2000

3” Polypro Vent Kit 8400P-001

Table 8 - Optional Vent Kits

H. Applications

1. Direct Vent Installation 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 outside. 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 pipe can be routed through the building and properly terminated. Dierent 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 pipe lengths, routing and termination methods must all comply with the methods and limits given in the Venting section of this manual. When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. NOTE: To prevent combustion air contamination, see Table 2.

LP-314 Rev. 2.3.17

Page 27

Take extra precaution to adequately support the weight of

6/23/15

TWO PIPE SIDEWALL VENTING WITH TEE (INTAKE)

AND COUPLING (EXHAUST)

Sidewall Venting with Kit

Sidewall Venting with Concentric Vent Kit

Roof Venting with Concentric Vent Kit

vent pipes terminating through the roof. Failure to properly support roof terminated piping could result in property damage, serious injury, or death.

Figure 14 - Two Pipe Roof and Sidewall Venting with Included Equipment (Tee and Coupling)

NOTE: These drawings are meant to demonstrate system

venting only. The installer is responsible for all equipment and detailing required by local codes.

All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4” per foot back to the appliance to allow drainage of condensate. When placing support brackets on vent piping, the rst bracket must be within 1 foot of the appliance and the balance of 4 foot intervals on the vent pipe. Venting must be readily accessible for visual inspection from the rst three feet from the appliance.

Figure 15 - Venting with Optional Kits (NOT INCLUDED WITH THE APPLIANCE)

LP-314 Rev. 2.3.17

Page 28

UNBALANCED VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST)

SIDE VIEW

FRONT VIEW

Intake

Exhaust

FRONT VIEW

SIDE VIEW

LP-325-PP 03/03/11

Figure 16 - Horizontal (Snorkel) Venting NOTES:

A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D. Minimum 12” between vents when installing multiple vents.

E. 12” minimum beyond air intake.

LP-314 Rev. 2.3.17

Figure 17 - Unbalanced Venting - Roof Exhaust and Sidewall Intake

NOTE: These drawings are meant to demonstrate system

venting only. The installer is responsible for all equipment and detailing required by local codes.

2. Venting Through an Existing System

This appliance may be vented through an existing unused vent system. The inner diameter of the existing vent system is utilized for the combustion air source. Two methods have been approved for such venting: Concentric Venting Through an Existing System and Venting as a Chase.

Vent / Air Inlet Size Minimum Existing Vent / Chase Size

2” 4”

3” 5”

4” 7”

Table 9 - Minimum Existing Vent / Chase Sizing

Do not install the appliance into a common existing vent with any other appliance. This will cause ue gas spillage or appliance malfunction, resulting in substantial property damage, serious personal injury, or death.

Page 29

Contractors must check state and local codes before installing

AIR INTAKE W/ SCREEN

Exhaust

Intake

Concentric Venting Through an Existing System 1

Exhaust

Intake

Concentric Venting Through an Existing System 2

Exhaust

Intake

AIR INTAKE W/ SCREEN

EXISTING VENT

INTAKE

Chase Venting Through an Existing System 3

Intake

Exhaust

through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions. Failure to check state and local codes before installing through an existing opening could result in property damage and add signicantly to installation costs.

If an existing venting system is converted for use with this appliance, the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the appliance. Failure to do so could result in property damage and appliance failure. Such failure IS NOT covered under warranty.

Concentric Venting Through an Existing System

NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits. Concentric venting through an existing system must run vertically through the roof. See Table 9 for proper minimum vent sizing. Use only the approved venting materials specied in Table 4 for piping the system. All instructions listed in this Venting section apply. See Figures 18-1 and 18-2 for venting demonstrations.

The upper and lower vent terminations as well as all joints in the venting system must be properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system. Failure to properly seal the venting system will result in property damage, serious personal injury, or death.

Chase Venting Through an Existing System

When venting as a chase, follow all instructions included in this Venting section, including those in the previous Concentric

Venting Through an Existing System section. See Figure 18-3 for chase venting demonstration.

3. Power Venting, Indoor Combustion Air in Conned or Unconned 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 sucient 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 Figure 19) 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. Unconned space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (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. Conned space is space with volume less than 50 cubic feet per 1,000 Btu/hour (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 conned space, such space should 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 conned 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. See Figure 20.

Figure 18 - 1, 2 - Concentric Venting Through an Existing System, 3, Chase Venting Through an Existing System NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by

local codes.

LP-314 Rev. 2.3.17

Page 30

LP-325-X

DO NOT PLACE DRYER NEAR WATER HEATER OR BOILER

BOILER OR

HEATER

INDOOR COMBUSTION AIR (SINGLE PIPE)

OUTDOOR COMBUSTION AIR (SINGLE PIPE)

BOILER

HEATER

Figure 19 - Do Not Place Appliance Near Dryer

LP-314 Rev. 2.3.17

Figure 20 - Indoor and Outdoor Combustion Air - Single Pipe

Page 31

I. Condensate Removal System

7450P-212

NOTE: Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of Massachusetts, condensate must be neutralized before entering a drain. This condensing high eciency appliance has a condensate removal system. Condensate is water vapor derived from combustion products, similar to that produced by an automobile when it is initially started. It is very important that the condensate line is sloped down away from the appliance and to a suitable drain. If the appliance condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP). If required by local authorities, a condensate lter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate. This can be installed in the eld and purchased from HTP (p/n 7450P-212).

The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the appliance tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for use with condensing appliances and furnaces. The condensate pump should have an overow switch to prevent property damage from spillage. Condensate from the appliance will be slightly acidic (pH from 3.2 to 4.5). Install a neutralizing lter if required by local codes.

Power to the optional condensate pump is continuous. When the appliance is powered o the condensate pump will remain on. It is important to remember to turn o the condensate pump when powering down the appliance. Failure to do so could result in property damage, severe personal injury, or death.

Figure 21 - Condensate Piping NOTES:

1. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length of condensate hose is used, increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line.

2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be subject to corrosion or deterioration.

3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate line from freezing temperatures or any type of blockage. In installations that may encounter sustained freezing conditions, the use of heat tape is recommended to avoid freezing of the condensate line. It is also recommended to bush up the condensate line size to 1” and terminate condensate discharge as close to the unit as possible. Longer condensate runs are more prone to freezing. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.

4. Support of the condensate line may be necessary to avoid blockage of the condensate ow.

LP-314 Rev. 2.3.17

Page 32

Part 6 - Wiring

To avoid electrical shock, turn o all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains o while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death. Such product failure IS NOT covered by warranty. Jumping out control circuits or components WILL VOID product warranty and can result in property damage, personal injury, or death.

NOTE: Wiring must be N.E.C. Class 1. If original wiring as supplied with appliance must be replaced, use only TEW 105

C wire or equivalent. Appliance must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

A. Field Wiring

All the wiring connections made to the appliance in the eld are done on the eld connection board located on the right side of the cabinet. The cabinet has multiple knockouts available to route eld wiring into and out of the eld connection board. The control provides a pump output thermostat and outdoor sensor inputs to operate the central heating system.

B. Line Voltage Wiring

1. Connect the normal incoming power to the terminals marked as shown in Figure 22. A line voltage fused disconnect switch may be required to be externally mounted and connected according to local codes and standards.

2. Connect the central heating pump as shown in the terminals marked CH/DHW PUMP (see Figure 22). The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If the pump requires more current or voltage than the 120 volts supplied, an external motor starter will be required.

3. Connect the NHX pump (if applicable) as shown in the terminals marked NHX PUMP (see Figure 22). The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If the pump requires more current or voltage than the 120 volts supplied, an external motor starter will be required.

C. Low Voltage Wiring

1. Make all low voltage connections to the terminal strip located on the eld connection board (shown in Figure 22) as outlined below.

2. The room thermostat should be connected to the terminals marked T STAT (shown in Figure 22). Alternately, any dry contact closure across these terminals will cause the unit to operate the hydronic heating module. NOTE: Caution must be used to ensure neither of the terminals becomes connected to ground. Mount the thermostat on an inside wall as central as possible to the area being heated, away from drafts or heat producing devices such as a television, which could inuence the ability of the thermostat to measure room temperature accurately. NOTE: If the thermostat is equipped with a directly connected anticipator, the anticipator should be set at .1 amps. If the thermostat is connected to other devices, the anticipator should be set to match the power requirements of those connected devices. Refer to the instruction manuals of the connected

devices for further information.

3. The outdoor sensor must be connected for the unit to operate at optimum eciency. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs up to 150 feet. Instructions are included with the outdoor sensor to correctly mount the sensor on the exterior surface of the building. It is preferable to mount the sensor on the north side in an area that will not be aected by direct sunlight but will be exposed to varying weather conditions. Connect the outdoor sensor to terminals marked “Outdoor” in Figure 22.

It is of extreme importance that this unit be properly grounded. It is very important that the building system ground is inspected by a qualied electrician prior to making this connection. Electrical power must only be turned on when the appliance is completely lled with cold water. Failure to follow these instructions could result in component or product failure, serious injury, or death. An ASSE 1017 thermostatic mixing valve MUST be installed when using 0-10V or outdoor reset. Failure to do so could result in substantial property damage, serious injury, or death.

Label all wires prior to disconnecting them when servicing the appliance. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions may result in property damage or personal injury.

D. Alarm Connections

The control includes an alarm output. This circuit is rated at 3 amps at 120 volts. This contact can be used to activate an alarm light or bell or notify a building management system if the appliance goes into a lockout condition.

E. Optional 0-10 Volt Building Control Signal

A signal from a building management system may be connected to the appliance to enable remote control. This signal should be a 0-10 volt positive-going DC signal. When this input is enabled using the installer menu, a building control system can be used to control the set point temperature of the appliance. The control interprets the 0-10 volt signal as follows; when the signal is between 0 and 1.5 volts, the appliance will be in stand-by mode, not ring. When the signal rises above 1.5 volts, the appliance will ignite. As the signal continues to rise towards its maximum of 10 volts, the appliance will increase in set point temperature. See Part 10 for details on the setting of function 16. NOTE: During 0-10V operation, the minimum tank temperature set point (default 95oF) will be at the activation input of 1.5 volts. The maximum temperature set point value will be at the input voltage of 10 volts. The maximum temperature set point can be changed by increasing or decreasing the DU setting (Range: 77oF – 160oF / Default 119oF). Once programmed, the 0-10V feature will change the set point temperature automatically.

1. Connect a building management system or other auxiliary control signal to the terminals marked 0-10 VOLT + and 0-10 VOLT – in the electronics assembly (shown in Figure 22). Caution should be used to ensure that the 0-10 VOLT + connection does not become connected to ground.

2. Conguring the appliance for 0-10 volt operation (change only the functions in the descriptions below):

a. Press and hold S3 and S4 together for 5 seconds

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b. Use S1 and S2 to adjust ashing 000 to code 975. Press S3 until you enter the menu. c. Use S3 to scroll to Function 16 to enable/disable 0-10 volt operation. Use S1 and S2 to adjust display to desired setting (Range: 0 = O, 2 = On / Default O). d. Press and hold S4 to exit the menu.

F. Customer Connection Board

Figure 22 - Customer Connection Board

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G. Internal Wiring Diagram

Figure 23 - Internal Wiring Diagram

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Figure 24 - Control Board Wiring

Part 7 - Gas Connections

Failure to follow all precautions could result in re, explosion, severe injury, or death.

Ensure the gas on which the appliance will operate is the same type specied on the rating plate. Failure to do so could result in appliance malfunction, property damage, personal injury, or death.

The gas supply shall have a maximum inlet pressure of less than 14” water column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 3.5” water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5” WC as stated in the National Fuel Gas Code. This information is listed on the rating plate. It is very important that you are connected to the type of gas as noted on the rating plate: “LP” for liqueed petroleum, propane gas, or “Nat” for natural or city gas. All gas connections must be approved by the local gas supplier or utility, in addition to the

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governing authority, prior to turning the gas supply on. Do not remove the adaptor in Figure 25! It is mandatory that this tting is used for connection to a eld fabricated drip leg per the National Fuel Gas Code. You must ensure that the entire gas line to the connection at the appliance is no smaller than 3/4”. Once all inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum gas inlet pressure, you must isolate the appliance from the gas line to continue leak testing. To do this, you must turn o the factory and eld-installed gas cocks. This will minimize the possibility of damaging the gas valve. Failure to do so may damage the gas valve. In the event the gas valve is exposed to a pressure greater than ½ PSI, 14” water column, the gas valve must be replaced. Never use an open ame (match, lighter, etc.) to check gas connections.

Figure 25 - Gas Connection

UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications where there is a potential for an explosive mixture of fuel gas to accumulate. The installation of these detectors should be made in accordance with the detector manufacturer’s recommendations, and/or local laws. Failure to install fuel gas detectors in these applications could result in re, explosion, property damage, severe personal injury, or death.

A. Gas Piping

Run the gas supply line in accordance with all applicable codes. Locate and install manual shuto valves in accordance with local and state requirements.

Support gas supply piping with hangers, not by the appliance or its accessories. The appliance gas valve and blower will not support the weight of the piping. Make sure the gas piping is protected from physical damage and freezing, where required. Failure to follow these instructions could result in gas leakage, and result in re, explosion, property damage, severe personal injury, or death.

Do not use Teon tape on gas line pipe thread. Use a pipe compound rated for use with natural and propane gases. Apply sparingly on male pipe ends, leaving the two end threads bare. Failure to follow these instructions could result in gas leakage, and result in re, explosion, property damage, severe personal injury, or death.

B. Gas Table

Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit. Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of .5 psi or less and a pressure drop of .3 inch water column. It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. The gas piping must be sized for proper ow and length of pipe to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1” WC, the meter, regulator or gas line is undersized or in need of service. You can attach a manometer to the incoming gas drip leg by removing the cap. The gas pressure must remain between 3.5” WC and 14” WC during stand-by (static) mode and while in operating (dynamic) mode at full output. If an in-line regulator is used, it must be a minimum of 10 feet from the appliance. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines or improper line sizing will result in ignition failure. This problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts o service to an area to provide maintenance to their lines. The gas valve must not be replaced with a conventional gas valve under any circumstances. As an additional safety feature, the gas valve in this appliance has a anged connection to the swirl plate and blower.

Nominal Iron Pipe Size (in.)

3/4 .824 278 190 152 130 115 105 96 90 84 79 72 64 59 55

1 1.049 520 650 285 245 215 195 180 170 160 150 130 120 110 100

1 1/4 1.38 1050 730 590 500 440 400 370 350 320 305 275 250 225 210

1 1/2 1.61 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

Table 10 - Source - ANSI Z223.1

Internal

Dia. (in.)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

Length of Pipe (Feet)

LP-314 Rev. 2.3.17

BTU’s

Per Hour

x 1,000

Page 37

C. Gas Valve

Do not do a gas conversion on this appliance without an ocially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the appliance to re on Natural or Propane gas will result in extremely dangerous burner operation, leading to re, explosion, severe personal injury, or death.

Strain on the gas valve and ttings may result in vibration, premature component failure and gas leakage, and result in re, explosion, property damage, severe personal injury, or death. Adjustments to the throttle screw or oset may only be made by a qualied gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in re, explosion, property damage, severe personal injury, or death.

Figure 26 - Gas Valve

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Part 8 - Start-Up Preparation

FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

2. BEFORE OPERATING: Smell all around the appliance area for gas. Be sure to smell next to the oor because some gas is heavier than air and will settle on the oor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch, do not use any phone in

your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas suppliers’ instructions.

• If you cannot reach your gas supplier, call the re department.

• Turn o the gas shuto valve (located outside the appliance) so that the handle is crosswise to the gas pipe. If the handle will not turn by hand, don’t try to force or repair it, call a qualied service technician. Force or attempted repair may result in a re or explosion.

4. Do not use this appliance if any part has been under water. Immediately call a qualied service technician to inspect the appliance and to replace any part of the control system and any gas control that has been damaged.

5. The appliance shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.)

Failure to follow these instructions could result in property

damage, serious personal injury, or death.

A. Fill and Purge DHW

The power must remain o until the potable water side of the appliance is fully purged of air. To purge the tank, turn on the cold water feed and open a faucet at the highest point of the system. Observe lling of the tank and inspect for any leaks in the system which may occur and need to be repaired. Shut o faucet once all evidence of air is purged from the water stream.

Ensure the appliance is full of water before ring the burner. Failure to do so will damage the appliance. Such damage IS NOT covered by warranty, and could result in property damage, serious personal injury, or death.

B. Fill and Purge Hydronic Heating Loop

Never use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems. Use only freeze-prevention uids certied by uid manufacturer as specied for use with stainless steel hydronic heating module heat exchanger and veried in uid manufacturer’s literature. Thoroughly clean and ush any system that has used glycol before connecting to the stainless steel hydronic heating module heat exchanger. Provide MSDS material data safety sheet on uid used to owner.

1. Local codes may require back ow preventer or actual disconnect from city water supply.

2. The power must remain o until the hydronic heating loop is fully purged of air.

3. Determine freeze protection uid quantity using total system water content of 1/2 gallon. Remember to include expansion tank water content and follow uid manufacturer’s instructions.

4. When using freeze protection uid with automatic ll, install a water meter to monitor water make-up. Freeze protection uid may leak before the water begins to leak, causing concentration to drop, reducing the freeze protection level.

5. Manually close any automatic air vents and any drain valves in the hydronic system loop.

6. Fill the system to correct pressure after ensuring the water quality meets the water quality standards outlined within this manual. The correct pressure will vary with each application. a. Typical system pressure is 15 PSI. b. Pressure will rise when the hydronic module starts to heat with the heated water from the domestic side of the system. Operating pressure must never exceed the relief valve pressure setting of 30 psi. c. At initial ll and during start-up and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

Eliminate all system leaks. Continual fresh make-up water will reduce the hydronic heating module heat exchanger ability to eectively transfer heat and reduce performance.

7. The system may have residual substances that could aect water chemistry. After the system has been lled and leak tested, verify that water pH and chloride concentrations are acceptable by sample testing.

It is important that you purge the system of air to avoid damage to the modulating pump.

C. Purge Air from Hydronic Heating Module

1. Connect to a purge and drain valve location (shown in piping details) and route hose to an area where water can drain and be seen.

2. Close the ball valves below the purge and drain valve.

3. Close zone isolation valves.

4. Open quick-ll valve on make-up water line.

5. Open purge valve.

6. Open the isolation valves one zone at a time. Allow water to run through the zone and push out air. Run until no noticeable air ow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

7. Close the quick-ll valve and purge valve and remove the hose. Open all isolation valves. Watch the system pressure rise to correct cold-ll pressure. It is recommended that you put the pumps into manual operation to assist in purging the circuits.

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D. Using the Control to Assist in Purging System Loops

Before powering up the control assure the thermostat connection is disconnected on the eld connection board. Apply power to the appliance (Note: The appliance will re the burner and heat the water inside the storage tank to the domestic hot water temperature set point). Press >. The display can show the temperature set point of the appliance. Press the v and ENTER keys simultaneously and hold for 1 second. The display will read:

SERVICE PUMP CH PUMP ON TIME

The central heating pump will come on. Run pump until all the air has been purged through each circuit. If you press the ^ v keys simultaneously, the central heating pump will shut o. The display will read:

READY PUMP OFF 12:42

Once the system has been purged of air, the installer can now proceed to program the control and system design parameters.

E. Programming the Total System Control

Before programming the Total System Control to the specic needs of the system, verify that the system is ready for operation. Be certain that:

• The Domestic Hot Water system is lled with water that meets the qualications and all air is purged.

• The mixing valve supplied is properly installed.

• The Hydronic Heating System is lled with water and

meets all qualications and all air is purged.

• The outdoor reset sensor is installed in a proper location.

• The electrical power supply is installed by a licensed professional.

• Turn down thermostats, making sure that they are set so there is no call for heat while programming.

This following discusses how to program a few of the major sections of the control parameters for optimum system performance. See Start-Up Procedures for the Installer for more detailed information on the operation of the display and other parameters.

1. Turn on the main power switch on the top right of the burner cabinet. NOTE: At rst startup, the water in the tank is cold and the burner will ignite. This is normal operation. You can continue to adjust settings while the burner is running.

2. Press and hold ENTER for 4 seconds until you see the screen to enter the log in access code shown below.

ENTER MENU CODE 000

3. Use the < key to move the blinking zero to the left most zero. Next, use ^ and v to log in 600, the access code. Press ENTER conrm the code and access Appliance Setting Program Navigation menu.

4. Once the code is conrmed, you can begin to set the Appliance Settings. Use the arrow keys to navigate. To change a setting, press ENTER. Appliance settings can be increased by pressing ^ and decreased by pressing v on the display. Once a new value has been selected, press ENTER to store the new value.

5. The rst screen is the “Central Heating” value. Enter the value for your designed hydronic heating supply temperature. The factory default is 140oF. NOTE: Values are determined based on program settings.

CENTRAL HEATING 140oF

6. After you have entered and stored the “Central Heating” value, press > once. The second screen adjusts the heating system “Heating Delta T” value. The factory default is 20oF.

HEATING DELTA T 20oF

7. After you have entered and stored the “Heating Delta T” value, press > once. The third screen adjusts the “DHW Set Point”. Adjust the value to the desired Domestic Hot Water temperature. The factory default is 119oF. IMPORTANT NOTE: This value sets the tank temperature when the appliance is in warm weather shutdown. A mixing valve must be properly installed and adjusted to a proper outlet value for safe operation.

DHW SETPOINT 119oF

8. After you have entered and stored the “DHW Set Point” value, press RESET to return to the home screen on the display. This completes the essential programming in Appliance Setting Programs. If other values need to be changed in this section, such as the display time, refer to Control Overview, this manual.

9. A proper outdoor reset curve should be set to further optimize system performance and eciency. The following chart shows how each function will aect system performance. The values in the chart show the system default.

10. Press and hold ENTER for 4 seconds until you see the Enter Menu Code screen.

11. Use the < and > arrow keys to move the blinking zero to the left and right. Next, use the ^ and v arrow keys on to log in the access code of 925. Press ENTER to access the System Setting Program Navigation menu. Once the code is conrmed, you can set the System Settings. Use < and > to navigate through the System Setting Program.

12. Press > 3 times to scroll to Function 4 - “WARM WEATHER OFF”. This is the warm weather shutdown. This function determines the outdoor temperature that will turn o the hydronic heating module and operate the appliance only as an appliance for the warmer weather. To adjust this value, press

ENTER and the factory default of 68°F starts to blink. Use ^ and v to adjust this value to your system needs. To store the new

value press ENTER.

13. Next, press > once to scroll to Function 5 - “MIN OUTDOOR TEMP”. This function is the rst step to setting the outdoor reset curve. Enter your system’s minimum outdoor temperature value. To adjust the value, press ENTER and the factory default of 5°F starts to blink. Use ^ and v to adjust to your designed temperature. To store the new value press ENTER.

14. Press > once to scroll to Function 6 - “MAX SUPPLY TEMP”. This function is the second step to setting your outdoor reset curve. Enter your system’s hydronic heating module maximum supply temperature value. To adjust the value, press ENTER and the factory default of 140°F will start to blink. Use ^ and v to adjust to your designed temperature. To store the new value press ENTER. NOTE: This should be the same value entered in step 5.

15. Press > once to scroll to Function 7 - “MAX OUTDOOR

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Page 40

TEMP”. This function is the third step to setting your outdoor reset curve. Enter your system’s maximum outdoor temperature value. To adjust the value, press ENTER and the factory default of 68°F will start to blink. Use ^ and v to adjust to your designed temperature. To store the new value press ENTER.

16. Press > once to scroll to Function 8 - “MIN SUPPLY TEMP”. This function is the nal step to setting your outdoor reset curve. Enter your system’s hydronic heating module minimum supply temperature value. To adjust the value, press ENTER and the factory default of 120°F will start to blink. Use ^ and v to adjust to your designed temperature. To store the new value press ENTER.

17. The major Total System Control values are now programmed. Press RESET to return to the main screen. To adjust other system values, refer to Control Overview, this manual.

18. Ensure that there is no air lock or blockage in the tank side loop of the hydronic heating module. To do this, press and hold v and ENTER. This will bring you into the pump service mode. Press ^ 3 times until “SERVICE PUMP RS 5” is on the screen. This puts the hydronic heating module pump at 5 volts (50%). Press > until the value is increased to 10, putting the pump at full speed. Once ow is conrmed, press ^ and v at the same time to return you to the main screen.

19. Allow the temperature in the tank to reach its value. Once the tank is up to temperature the burner will shut o.

20. Once the temperature in the tank is up to its set point, the DHW mixing valve must be set correctly. Turn on the hot water

faucet at a nearby source. Use a temperature measuring device to measure the water temperature. DO NOT USE YOUR HANDS! Any skin contact at this point could cause serious injury. Adjust mixing valve to desired hot water outlet following Mixing Valve Instructions in this manual.

21. Once a safe DHW outlet temperature is set with the supplied mixing valve, the system is ready to run. Adjust thermostats to the desired value. Total System Control will now modulate and control the system.

Part 9 - Start-Up Procedures for the Installer

The control monitors the safety sensors of the appliance to assure safe and ecient operation. It has many features to address congurations associated with hydronic design. This section addresses the programming features of the control. It is important to fully understand its capabilities. This section addresses the adjustment of Appliance Settings / System Settings / Maintenance Settings and System Diagnostics to help customize your control. However, the control is programmed with factory defaults that may already t your hydronic design and may not require any adjustment at all.

A. Navigation of the Display

The display includes a two-line backlit LCD readout that provides informative messages about appliance operation. Many operating parameters can be viewed and adjusted by using the six buttons on the display. The function of each

Figure 27 - Outdoor Reset

LP-314 Rev. 2.3.17

Page 41

button is described below. RESET – The RESET button has two functions:

• Reset any lockout error code.

• Return the user to the default display screen.

ENTER – The ENTER key is used to enter the parameter programming mode. To enter this mode, hold down the ENTER key for more than 4 seconds. The readout will change to:

ENTER MENU CODE 000

One of the zeroes will be blinking. Use the ^ and v arrow keys to change the blinking digit to the correct value. Use the < and > arrow keys to select the next digit to change and again use the ^ and v keys to change the value. Repeat until the correct code is entered. Press the ENTER key to accept the code. If the code is correct, the readout will change to the appropriate screen. If the programming code is not accepted the readout will continue to display as shown above. The ENTER key is also used to enable a parameter for editing. After navigating to the desired parameter, hold down the ENTER key for one second. When the ENTER key is released, the parameter value will begin to blink. The parameter can now be changed using the ^ and v keys. After the new value is selected, presses the ENTER key for 1 second to lock in the new parameter value. The value will then stop blinking. Left < and Right > ARROW Keys – The right and left arrow keys (< and >) are used to navigate between the default Display and Status Display. The < and > keys are also used in programming modes to change between programmable parameters. It is recommended you use the Menu Maps in the back of this manual and the detailed menu instructions printed in this section to help in menu navigation.

Up ^ and Down v ARROW Keys – The up and down (^ and v) arrow keys are used to navigate between the various

parameters displayed in the menu. After the parameter is enabled for editing by pushing the ENTER key, the ^ and v keys are used to adjust the parameter upward or downward to the desired value.

B. Programming the Control

Program Access

Note: Programming the control is not possible when the appliance is ring. Make sure any input which can create a demand on the appliance, such as the thermostat, is turned o, so the appliance will remain idle to allow programming.

Screen Description

ENTER MENU CODE 000

ENTER MENU CODE 600

Table 11 - Program Setting Access

Appliance Setting Program Navigation

Once the code is conrmed, the user can start to set the Appliance Settings. Use the arrow keys on the display to navigate through the Appliance Settings. A blinking setting indicates the setting can be changed. To change a setting,

To access the setting program, press and hold ENTER for 4 seconds until the display shows the screen at left.

Use the arrow keys to log in the Access Code - 600. Press ENTER to conrm the code and access the Program navigation menu.

press ENTER. Appliance settings can be increased by pressing

^ and decreased by pressing v on the display. When done, press ENTER. The setting will stop blinking and the user can move on

to next setting by pressing the < or > arrow keys. Press RESET to exit programming and store settings. Listed below are the settings that can be programmed into the control.

Screen Description

CENTRAL HEAT 140 oF

HEATING DELTA T 20 oF

DHW SETPOINT 119 oF

BURNER RUN OFFSET 5 oF

TEMP DISPLAY C OR F

Table 12 - Appliance Setting Program Navigation

Allows the user to adjust the central heating set point from 50F to 170oF (Factory Default 140oF).

Adjusts the central heating delta T set point from 5oF to 30oF (Factory Default 20oF).

Adjusts the DHW set point from 95 to 180oF (Factory default 119oF). NOTE: The appliance is supplied with a thermostatic mixing valve that must be installed on to the domestic hot water system. Any changes in this set point will also require adjustment to the mixing valve. Please refer to the mixing valve section in Domestic Water Piping, this manual, for further setup and operation details.

Adjusts the oset from the current target tank temperature where the control will begin heating water. Range: 1 to 18oF (Factory default 5oF).

Adjusts the temperature measurement in F = Fahrenheit to C = Celsius (Default is Fahrenheit).

Clock Settings

(NOTE: The clock will reset if the appliance is powered o for more than a week.)

Screen Description

Changes the clock from 12 hour mode (8:45 PM) to 24 hour mode (20:45). To

CLOCK MODE (12/24) 08/28/2009 Fr 9:42A

CLOCK HOUR 08/28/2009 Fr 10:01A

CLOCK MINUTE 08/28/2009 Fr 10:01A

CLOCK DAY OF WEEK 08/28/2009 Fr 10:01A

CLOCK DATE MODE 08/28/2009 Fr 10:01A

CLOCK YEAR 08/28/2009 Fr 10:01A

CLOCK MONTH 08/28/2009 Fr 10:01A

CLOCK DATE 08/28/2009 Fr 10:01A

Table 13 - Clock Setting Screens

change to 24 hour mode, press ENTER. The letter (A or P) after the time will blink. Press the up or down arrow key once and the letter will disappear. Press ENTER to save the new setting.

Allows the user to adjust the hour setting.

Adjusts the minute setting.

Adjusts the day of the week.

Allows the user to switch to European date format (2009/08/28) from US format (08/28/2009).

Adjusts the year setting.

Adjusts the month setting.

The clock is set.

NOTE: The internal clock does not adjust for daylight savings time and requires manual adjustment.

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C. Programming the System Setting

System Setting Program Access

Screen Description

ENTER MENU CODE 000

ENTER MENU CODE 925

Table 14 - System Setting Access

To access the system setting program, press and hold ENTER for 4 seconds until the display shows the screen at left.

Use the arrow keys to log in the System Menu Access Code - 925. Press ENTER to conrm the code and access the System Setting Program navigation menu.

D. System Setting Program Navigation

Once the System Menu Access Code is conrmed, the user can begin to set the system settings. Use the < > keys on the display to navigate through the System Settings. To change a setting, press ENTER. System settings can be increased by pressing ^

and decreased by pressing v on the display. When done, press ENTER. The setting will stop blinking and you can move on

to next setting. Press RESET to exit programming and store settings. Listed below are the appliance settings that can be programmed into the control.

Screen Description

Function 1 Factory Program Mode

MODE PHOENIX 1

Function 2 Max Tank Temp

MAX TANK TEMP 180 oF 2

Function 3 DHW Oset Temp

OFFSET 0oF 3

Function 4 Warm Weather Shuto

WARM WEATHER OFF 68oF 4

Function 5 Min Outdoor Temp

MIN OUTDOOR TEMP 5oF 5

Function 6 Max Supply Temp

MAX SUPPLY TEMP 140oF 6

This indicates that the control is congured correctly. Do not change this setting.

Sets the overall tank temperature maximum limit. Factory Default is 180oF. (Range: 95 to 180oF).

Not used.

This setting disables the central heating module so the Total System Control will heat domestic hot water only. Warm Weather Shuto occurs if the programmed outdoor temperature is exceeded by the current outdoor sensor temperature. Factory default 68oF (Range 41 to 122oF).

Sets the minimum outdoor design temperature for the system. Factory default 5oF (Range -49 to 122oF).

Allows the user to set the maximum design supply temperature based on the minimum outdoor design temperature. Factory default 140oF (Range 77 to 170oF).

Function 7 Max Outdoor Temp

MAX OUTDOOR TEMP 68oF 7

Function 8 Min Supply Temp

MIN SUPPLY TEMP 120oF 8

Function 9 Min Tank Temp

MIN TANK TEMP 68oF 9

Function 10 CH Post Pump Time

CH POST PUMP TIME 0 MINUTES 10

Function 11 DHW Priority

DHW PRIORITY 30 MINUTES 11

Function 12 Error Outdoor Sensor

ERROR OUTD SENSOR ON 12

Function 13 Error System Sensor

ERROR SYSTEM SENS ON 13

NOTE: Press ENTER to store system parameters.

Function 14 Service Schedule

SERVICE SCHEDULE OFF 14

Function 15 Year

SERVICE SCHEDULE YEAR 00/00/2000 15

Function 15 Hours

SERVICE SCHEDULE 10000’s 000000 15

Sets the maximum outdoor design temperature for the system. Factory default 68oF (Range 32 to 95oF).

Allows the user to set the minimum design supply temperature based on the maximum outdoor design temperature. Factory default 120oF (Range 32 to 200oF).

Allows the user to set the minimum tank temperature. Factory default 68oF (Range 32 to 200oF).

Allows the user to set the central heating pump post purge time once the thermostat is satised. Factory default 0 minutes (Range 0 to 10 minutes).

Sets DHW priority time: the amount of time to shut down the central heating module when the system control senses a substantial domestic hot water demand. Factory default 30 minutes (Range 0 to 60 minutes).

Sets the control to display an error message if an outdoor sensor is open or shorted. NOTE: This error does not stop the appliance from running. Factory default ON (Range: ON / OFF / PHOEN ON).

Sets the control to display an error message if the system sensor is open or shorted. NOTE: This error does not stop the appliance from running. Factory default ON (Range: ON / OFF).

Programs the appliance maintenance schedule by selecting a service date or time based on the appliance run hours. Factory default OFF (Range: DATE or RUN HOURS). NOTE: Without setting this function Functions 15 - 18 will not display.

Allows the user to set the year of the next service reminder.

Allows the user to set the left two digits of the amount of run hours (tens of thousands of hours) before next service reminder.

LP-314 Rev. 2.3.17

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Function 16 Month

If the date function was selected, this

SERVICE SCHEDULE MONTH 00/00/2000 16

Function 16 Hours

SERVICE SCHEDULE 10000’s 000000 16

Function 17 Day

SERVICE SCHEDULE DAY 00/00/2000 17

Function 17 Hours

SERVICE SCHEDULE 10000’s 000000 17

Function 18 Telephone

TELEPHONE # 000 000 0000 18

Function 37 Modbus Mode

MODBUS MODE OFF 37

Function 52

SOLAR MODE ON 52

Table 15 - System Setting Program Navigation

function programs the month. If you selected the run hour function, you will need to program 10,000 hours, if required.

Allows the user to set the middle two digits of the amount of run hours (thousands of hours) before next service reminder.

Sets the day of next service reminder.

Sets the two right digits of the amount of run hours (tens of hours) for the next service reminder.

Allows the user to input a telephone number that will display when maintenance is required.

Enables Modbus Mode on the appliance. Factory Default: OFF (Range: OFF, ON, AUTO). NOTE: Turning Modbus Mode “ON” will open a number of additional parameters to customize Modbus installation. See Modbus Instructions (lp-372) for details. NOTE: Turning this Mode “ON” without a connected and powered Modbus communication adapter (p/n 7350P-629) will result in improper appliance operation. Service calls associated with this ARE NOT covered by warranty.

Solar Mode (Available on Solar Appliances Only)

When turned ON, this parameter enables solar function of the control. Default: OFF. NOTE: Turning Solar Mode “ON” will open a number of additional parameters to customize the solar installation. See Solar Kit Instructions (lp-420) for details. NOTE: Turning this Mode “ON” without a connected Solar Kit (p/n 7100P-220) will result in improper appliance operation. Service calls associated with this ARE NOT covered by warranty.

E. Control Status Menu

The control also has the ability to review system status. To access the status screens, press >. Once the rst value is displayed, press ^ and v to scroll through additional information. At any point press RESET to exit the status screens.

Screen Description

TOP TANK 160oF BOT TANK 123oF

Press v once.

CH TARG ET 14 0oF CH SUPPLY 122oF

Press v once.

CH DE MAND O FF OUTDOOR 55oF

Press v once.

DH W SE TI NG 119oF TA NK TA RG ET 1 60oF

Press v once.

FLAME 0.0uA FAN SPEED 3497 RPM

Press v once.

POWER ON 0h INPUT 0kBTU

Press v once.

DHW USE 0% CH USE 1%

This screen displays the actual temperatures measured by the top and bottom tank sensors.

The current central heating temperature set point is displayed on the top line. NOTE: This temperature set point may vary from what was set in the appliance settings if an outdoor sensor is used. The actual temperature measured by the hydronic heating module supply sensor is displayed on the bottom line.

The top line displays the current status of the central heating demand. The bottom line displays the temperature measured by the outdoor sensor (when used). If there is no outdoor sensor connected to the appliance, the bottom line will read “OFF”. If the contacts are jumped, this line will display “ON” in place of the temperature. NOTE: To ensure a properly installed outdoor sensor, be sure that this temperature reading is similar to the current outdoor conditions.

The top line displays the current domestic hot water temperature set point entered in the Appliance Settings. The bottom line displays the current tank target temperature. NOTE: This target tank temperature set point will vary due to environmental conditions and Total System Control settings.

This screen displays appliance ame current on the top line. The second line displays appliance fan speed.

The top line indicates the amount of hours the appliance has been powered in its lifetime. The bottom line displays how much energy input (in thousand BTU) from the burner into the storage tank.

The top line of this display indicates the percentage of energy used for domestic hot water heating over the appliance lifetime. The bottom line displays the percentage of energy used for central heating over the appliance lifetime.

LP-314 Rev. 2.3.17

Page 44

Press v once.

GOOD IGNIT 0x CH CYCLE 0x

Press v once.

FAULT HISTORY 1 07/27/2009 Mo 5:19A

Press v once.

FAULT HISTORY 2 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 3 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 4 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 5 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 6 08/28/2009 Fr 5:19A

Press v once.

The top line displays the number of times the burner has been ignited over the appliance lifetime. The bottom line indicates the number of times the heating module has cycled for central heating demand.

This screen displays the most recent control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the fault code encountered. The bottom line displays the date and time the fault occurred.

This screen displays the second oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the third oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the fourth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the fth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the sixth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the seventh oldest control lockout fault. The top

FAULT HISTORY 7 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 8 08/28/2009 Fr 5:19A

Press v once.

FAULT HISTORY 9 08/28/2009 Fr 5:19A

FAU LT HIS TORY 10 08/28/2009 Fr 5:19A

Table 16 - System Setting Program Navigation

line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the eighth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the ninth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

This screen displays the tenth oldest control lockout fault. The top line will alternate between the words ‘FAULT HISTORY’ and the actual fault encountered. The bottom line will display the date and time that the fault occurred.

F. Resetting the Maintenance Schedule

When the system control ashes MAINTENANCE REQUIRED, it is advisable that you call for service. After the service is performed, reset the schedule for the next required service by using the following steps. Press ENTER on the display for 3 seconds. The Menu code will appear as 000. This does not change. Press ENTER again. SERVICE SCHEDULE RESET will be displayed. Using the > key scroll to the selection of year or hours. Press ENTER to reset the selected Service Schedule. To change a setting, press

ENTER. Press the ^ and v keys to make adjustments. Press ENTER when reset is complete.

G. Test Mode

This function is intended to simplify gas adjustment. The following tables include recommended combustion settings by fuel type and appliance fan speeds. Automatic modulation does not take place while the controller is in Test Mode. However, the appliances will modulate down if the program set point is reached while running in Test Mode. It is recommended to enter Test Mode with the largest load possible to create such a heat demand that Test Mode will not be interrupted. To enter Test Mode press ^ and ENTER simultaneously. NOTE: The appliance will automatically exit Test Mode after 20 minutes of operation. To leave Test Mode press ^ and v simultaneously.

SERVICE RUN 3400 RPM PUMP ON 4:49P

LP-314 Rev. 2.3.17

Page 45

Combustion Settings on All Models

Fan Speed

Carbon

Monoxide (CO)

PPM

Carbon Dioxide

(CO2)

Table 17 - Combustion Settings - All Models

BTU Ignition Min Max

130,000

199,000 9100

Table 18 - Fan Speeds

Natural Gas (NG) Propane (LP)

Low Ignition High Low Ignition High

1-10 2-15 2-20 1-10 2-15 2-20

8-10 8 1/2- 10 1/2 9-11

Fan Speeds

3000 2000

7300

Part 10 - Troubleshooting

A. Error and Fault Codes

If any of the sensors detect an abnormal condition, or an internal component fails during the operation of the appliance, the display may show an error message and error code. This message and code may be the result of a temporary condition, in which case the display will revert to its normal readout when the condition is corrected, or it may be a condition that the controller has evaluated as not safe to restart the appliance. In this case, the appliance control will be locked out, the red FAULT light will be lit, and the message “LOCKOUT” will be displayed on the readout in the lower line. The appliance will not start until a qualied technician has repaired the appliance and pressed the RESET button for more than 1 second. If there is an error message displayed on the readout, and the message “LOCKOUT” is not displayed and the FAULT light is not lit, then the message is the result of a temporary condition and will disappear when the problem corrects itself. IMPORTANT NOTE: If you see error messages on your display readout, call a technician immediately, since the message may indicate a more serious problem will occur soon.

When servicing or replacing components that are in direct contact with appliance water, be certain that:

• There is no pressure in the appliance. (Pull the release on the relief valve. Do not depend on the pressure gauge reading.

• The appliance water is not hot.

• The electrical power is disconnected.

• The gas is shut o.

Failure to make these checks could result in substantial property damage, serious personal injury, or death.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied service

technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an 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. If overheating occurs or the gas supply fails to shut o, do not turn o electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of appliance damage. Instead, shut o the gas supply to the appliance at the gas service valve. Failure to do so may result in property damage, personal injury, or death.

NOTE: If system return temperatures are maintained below the dew point, condensation will form on the inside of the appliance cabinet and cause some internal sheet metal components to rust.

B. Appliance Error

The controller will display an error code and message when an error condition occurs. These error codes, descriptions, and recommended corrective actions are described in Section D.

C. Appliance Fault

1. The controller will illuminate the red “FAULT” indication light and display a fault code and message when a fault condition occurs. The alarm output will also activate. Most fault conditions cause the CH pump to run in an attempt to cool the appliance.

2. Note the displayed fault code and refer to Section D for an explanation of the message along with several suggestions for corrective actions.

3. Press RESET to clear the fault and resume operation. Be sure to observe the operation of the unit for a period of time to assure correct operation and no reoccurrence of fault message.

LP-314 Rev. 2.3.17

Page 46

D. User Interface Display

Fault Codes

Screen Description Possible Remedy

This indicates that the outdoor sensor is defective, shorted or open, or outdoor temperature is below –40oF.

NOTE: The installer must choose YES in OUTDOOR SENSOR PUMP ON FOU

CH SENSOR FAIL PUMP ON E07

ECS NOT CONNECTED PUMP OFF

TEMPER BLOCKING PUMP ON 12:31P

LINE VOLTAGE PUMP OFF E19

HIGH FLUE PRESS FLU PUMP ON

WARNING: Do not use jumper to remedy an FLU error. Faulty switch MUST be replaced. Failure to follow this instruction could result in serious personal injury or death.

LOW WATER LEVEL PUMP OFF LEO

Function 12 to enable this feature. The unit

will continue to operate when this error

is displayed but the control will ignore

the outdoor reset feature and run at the

programmed temperature. The bottom line

indicates the status of the pump.

This indicates that one or both of the clip-

on temperature sensors in the hydronic

heating module has been disconnected.

This error allows the tank portion of the unit

to operate, but will not allow the hydronic

heating module to operate until the error is

cleared. The error will clear if proper sensor

connection is restored. The bottom line

indicates the status of the pump.

This indicates the main control board and

the smaller ECS control board are not

communicating properly. This error allows

the tank portion of the unit to still operate,

but will not allow the hydronic heating

module to operate until the error is cleared.

The second line indicates the status of the

pump.

This display indicates a temporary hold

on the burner. There is a demand on the

appliance for heat, the pump is powered

on, but the but the top tank sensor is above

the set point and the bottom is substantially

cooler than the top. This is a temporary hold

on the burner only and all other functions will

remain functioning properly.

The line voltage frequency is out of range.

This could happen if the unit is being

powered from a small gasoline powered

generator that is not functioning correctly or

overloaded.

FLU indicates excessive ue pressure. This

code resets automatically after the high

pressure condition is resolved. The second

line indicates pump status.

LEO indicates low water level in the main

tank. This code will not allow the unit to

run until correct water level is restored. The

second line indicates the status of the pump.

NOTE: While the water level is low, the pump

will be o.

Inspect wiring from outside sensor for damage or shorted connections and repair as necessary. Measure resistance of the outdoor sensor and compare to resistance chart. If not within range on chart, shorted or open, replace sensor.

1. Go to the STATUS menu screen that displays “CH Supply” on the bottom line. This will help to determine which sensor has the error. If the temperature displayed is reasonable, the error will be in the return temperature sensor (Horizontal Pipe). If the temperature displayed is not reasonable, the error will be in the supply sensor (Vertical Pipe).

2. Check the electrical connection to the thermistor on the outlet manifold. Check the wiring harness. If both are connected properly, replace the control. NOTE: Verify the thermistor values by referencing the Resistance Tables in this manual.

3. Replace thermistor if necessary.

1. Ensure both ends of the ribbon cable are connected properly and securely in place.

2. Next, check the ribbon cable for damage or wear. If any problems are found, replace the ribbon cable.

3. If problem still occurs with the new ribbon cable, replace the ECS board.

This error will clear itself when either the top tank temperature drops below the set point or the bottom temperature rises.

Inspect power wiring to unit and repair as necessary. If connected to line voltage, notify electric utility company. If connected to an alternate power source such as generator or inverter, make sure the line voltage frequency supplied by the device is 60 Hz.

1. Ensure the ue is not blocked.

2. Check the switch wiring by applying a jumper in place of the switch. If the code clears with the jumper in place, REPLACE the ue switch and connect the wires to the new switch BEFORE running appliance.

1. Ensure there is adequate pressure and ow through the cold water inlet by slightly opening the drain valve near the tank.

2. Ensure the DHW system has all air removed through a high point hot water source, i.e. sink faucet.

3. Check wiring and probes. Replace if necessary.

LP-314 Rev. 2.3.17

Page 47

1. Ensure line voltage is between 100-128 volts.

2. Disconnect TT wiring. If error clears, there is an issue in the thermostat wiring. Review external wiring.

3. If available, connect a PC and use HTP service software to check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be at least 250. Use this as a troubleshooting guide as you follow the steps below.

LOU indicates the 24 volt power supply on the control is damaged or overloaded. This

24 VOLT LOW PUMP ON LOU

The following blocking codes will block operation until the control determines the situation safe for appliance operation.

WATER HIGH TEMP PUMP ON F00

FLUE TEMP PUMP ON F01

TOP TEMP SENSOR PUMP ON F02

BOT TEMP SENSOR PUMP ON F03

code will reset automatically if it is the result of an overload and that overload condition is removed. The second line indicates the status of the pump. NOTE: While 24 volt power is low, the pump output will be on.

F00 indicates the water in the tank has overheated. This is a serious safety issue, as indicated by the red fault light and the ashing word LOCKOUT on the display. The unit will not restart until it cools suciently and a technician repairs the cause of overheating and resets the unit. During this lockout fault, the pump will be on as indicated on the second line of the display in an eort to cool down the appliance.

This display indicates that the ue temperature limit switch of the unit has tripped. This is a serious safety issue, as indicated by the red fault light and LOCKOUT ashing on the display. The unit will not restart until the ue cools suciently and a technician repairs the cause of the problem and pushes the RESET button on both the device and the display. During this lockout fault, the pump will be on as indicated on the second line of the display.

F02 indicates the top temperature sensor of the tank has failed. This code indicates a serious safety issue by the red fault light and LOCKOUT ashing on the display. The unit will not restart until a technician replaces the sensor and resets the unit. During this lockout fault, the circulator pump will be on as indicated on the second line of the display.

F03 indicates the bottom temperature sensor of the unit has failed. This code indicates a serious safety issue by the red fault light and LOCKOUT ashing on the display. The unit will not restart until a technician replaces and resets the unit. During this lockout fault, the pump will be on as indicated on the second line of the display.

4. Remove the 12 pin Molex connector from the eld wiring board. If the message clears, then the problem is with external low voltage wiring. Examine the external low voltage sensor wiring for shorts to ground and repair as necessary. If message is still present, disconnect the UL 353 low water cuto to see if message clears. Replace faulty part. Check low voltage wire harness in appliance for shorts to ground.

5. Remove the 20 pin Molex from the ECS board. If the message clears, examine the wiring to the heating module and fan for shorts or grounds and repair as necessary.

6. If message only occurs when the burner tries to light, check gas valve for excessive current draw.

7. If message is present with the low voltage harness disconnected from the 926 control board, replace the 926 control board.

1. Check central heating pump operation.

2. If the circulator pump is running, ensure there is water in the system and that water is moving through the system as intended. Ensure that all ball valves and or zone valves are open or closed as intended.

3. Observe the temperature/pressure gauge. If the water is not hot and this message is displayed, check the wiring to the water eco sensor and repair if necessary.

4. If the wiring is intact, water is not excessively hot and this code is still present, replace the eco sensor.

1. Check the ue for obstructions or any sign of damage (especially signs of excessive heat). Repair as necessary.

2. Push the red reset button on the ue temperature switch located on CPVC vent elbow. NOTE: Switch temperature must be less than 90°F to reset.

3. Press RESET on the display. Run the unit and check the ue temperature by using an external thermometer in the ue pipe. If the ue temperature is below 190°F and the switch trips, replace the switch. If the ue temperature is excessive, check and adjust the combustion controls on the unit.

1. Check the electrical connection to the thermistor on the outlet manifold. Verify 5 VDC by checking the Molex connector. If no 5 VDC, check harness. If harness is OK, replace control. NOTE: Verify thermistor values by referencing chart in this manual.

2. Replace thermistor if necessary.

1. Check the electrical connection to the thermistor. Check the wire harness. If harness is OK, replace control. NOTE: Verify thermistor values by referencing chart in this manual.

2. Replace thermistor if necessary.

LP-314 Rev. 2.3.17

Page 48

TOP TEMP HIGH PUMP ON F05

BOT TEMP HIGH PUMP ON F06

NO FLAME ON IGN PUMP ON F09

FLAME LOSS PUMP ON F10

F05 indicates the top temperature of the

tank is excessive. If accompanied by the

illuminated red fault light and LOCKOUT

ashing on the display, this code indicates the

temperature on the top sensor has exceeded

230oF and a serious safety issue exists. The

unit will not restart until a technician repairs

the cause of excessive temperature and

resets the unit.

If the red fault light is not illuminated and this

message is displayed, the top temperature of

the tank is at or above 210oF. The message will

clear automatically when the temperature

drops below 194oF. While this message or

lockout fault is displayed, the pump will be

on as indicated on the bottom line.

F06 indicates the bottom temperature of the

tank is excessive. If this code is accompanied

by the illuminated red fault light and

LOCKOUT ashing on the display, then

the temperature on the bottom sensor has

exceeded 230oF and a serious safety issue

exists. The appliance will not restart until a

technician repairs the cause of the excessive

temperature and resets the unit.

If the red fault light is not illuminated and

this message is displayed the bottom

temperature of the tank is at or above 210oF.

The message will clear automatically when

the temperature drops below 194oF. During

the time that this message or lockout fault is

displayed, the pump will be on as indicated

on the bottom line of the display.

The unit tried to ignite four times during

a call for heat and failed all four times. F09

indicates a serious safety issue. The unit

will not restart until a technician repairs the

cause of no ignition and resets the display.

The red fault light and LOCKOUT will ash

on the display. During this lockout fault, the

pump will be on as indicated on the bottom

line.

The ame was lost while the unit was lit 3

times during 1 demand call. The red fault

light and LOCKOUT ashing on the display

indicate a serious safety issue. The unit

will not restart until the technician repairs

the cause of ame loss and resets the unit.

During this lockout fault, the pump will be on

as indicated on the bottom line of the display.

1. Check the electrical connection to the thermistor on the outlet manifold. Verify 5 VDC by checking in Molex connector. If not 5 VDC, check harness. If harness is OK, replace control. NOTE: Verify thermistor values by referencing the resistance table in this manual.

2. Replace thermistor if necessary.

1. Watch the igniter through the observation window.

2. If there is no spark, for natural gas units check the spark electrode for the proper gap. Use 2 quarters together as a gauge to check gap spacing.

3. Remove any corrosion from the spark electrode and ame rectier probe.

4. If there is a spark but no ame, check the gas supply to the appliance.

5. If there is a ame, check the ame sensor.

6. Check for any ue blockage or condensate blocks.

1. Monitor gas pressure to the unit while in operation.

2. Ensure the ame is stable when lit.

3. Check to see if the display readout changes from “GAS VALVE ON” to “RUN” a few seconds after the appliance ignites.

4. Check the FLAME signal on the status display. It should be above 1.0 when the unit is ring.

5. If the signal reads less than 1 microampere, clean the ame rectier and spark probe.

6. If the problem persists and the ‘FLAME” signal is still less than 1.0, replace the ame probe and spark igniter probe.

7. The ame signal should be steady after the unit has been ring for 1 minute and is normally at 5.0 to 9.0. If not steady, disassemble the burner door and check the burner and its sealing gaskets.

LP-314 Rev. 2.3.17

Page 49

FALSE FLAME SIG PUMP ON F11

FAN SPEED ERROR PUMP ON F13

PROGRAM ERROR PUMP OFF F31

CONTROL PROGRAMED PP

Table 19 - Fault Codes

F11 indicates ame when the control is not telling the unit to run. The red fault light and LOCKOUT ashing on the display indicate this code is a serious safety issue. The unit will not restart until a technician repairs the cause of the lockout and resets the unit. During this lockout fault, the pump will be on as indicated on the second line of the display.

The fan speed had been more than 30% faster or slower than the control commanded speed for more than 10 seconds. The red fault light and ashing LOCKOUT on the display indicate a serious safety issue. The unit will not restart until the technician repairs and resets the unit. During this lockout fault, the pump will be on as indicated on the second line of the display.

There was an error while programming the control. The control’s memory could be corrupt. The appliance control will not function in this state and the pump will be o. The only way to recover from this error is to reprogram the control. If this error occurs at any time other than when a technician is servicing the unit, the control has failed and must be replaced.

The control has been programmed by a technician or the factory. After programming, the control was left in a locked out mode. Press RESET to begin use of the control.

1. Look into the window. If there is ame, turn the gas o to the unit at the service valve and replace the gas valve.

2. If the ame signal on the status menu is greater than

1.0 when the burner is not lit, replace the spark igniter and the ame rectication probe.

3. If the ame signal is not present after turning o the gas supply, check the gas valve electrical connection.

4. Check for condensate backup. Repair the condensate system as necessary. If condensate has partially lled the combustion chamber, the refractory wall may be damaged and should be replaced.

5. Turn the gas on at the service valve after corrective action is taken.

1. Check the combustion air fan wiring.

2. Measure the DC voltage from the red fan wire to ground while it is connected to the fan. It should be between 24 to 40 volts. If it is lower than 24 volts, check for excessive external loads connected to the sensor terminals. Disconnect the 5 pin plug from the fan and check the voltage on the red wire again. If it is now between 24-40 volts, replace the fan. If it is still below 24 volts replace the appliance control board.

Control must be reprogrammed. If reprogramming does not solve problem, control must be replaced.

Press RESET for at least one second.

Part 11 - Maintenance

In unusually dirty or dusty conditions, care must be taken to keep appliance cabinet door in place at all times. Failure to do so VOIDS the warranty.

Allowing the appliance to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in appliance failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

Hydrogen gas can build up in a hot water system served by this appliance that has not been used for a long period of time (generally two weeks or more). When opening a hot water faucet in a system that has been out of use for a time, keep all ignition sources (electrical appliances, open ame, etc.) away from the faucet. If hydrogen is present, there will be a sound of air escaping as water begins to ow. Allow the water to run for a few minutes to dissipate built up hydrogen from the system. Failure to follow these instructions can result in property damage, personal injury, or death.

The appliance requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended. Periodic maintenance should be performed once a year by a qualied service technician to assure that all the equipment is operating safely and eciently. The owner should make necessary arrangements with a qualied heating contractor for periodic maintenance of the appliance. Installer must also inform the owner that the lack of proper care and maintenance of the appliance may result in a hazardous condition.

It is extremely important that whenever work is performed on the plumbing system that either:

• The appliance is powered o, or,

• The appliance is valved o and isolated from the plumbing

system. Failure to take these measures could result in a dry-ring condition.

LP-314 Rev. 2.3.17

Page 50

follow “Shutdown Procedure”.

The appliance must be full of water and the system fully purged BEFORE powering the appliance. Performing any work in the plumbing system without either powering o the appliance or isolating the appliance through the use of shut-o valves could result in a condition referred to as “dry-ring”. Dry-ring the appliance will damage the heat exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by appliance warranty.

Upper Sensor

(7100P-004)

Outdoor Sensor

(7250P-319)

Outside

Temperature

(oF)

-22 171800 32 32550

-13 129800 41 25340

-4 98930 50 19870

5 76020 59 15700

14 58880 68 12490

23 45950 77 10000

32 36130 86 8059

41 28600 95 6535

50 22800 104 5330

59 18300 113 4372

68 14770 122 3605

77 12000 131 2989

86 9804 140 2490

95 8054 149 2084

104 6652 158 1753

113 5522 167 1481

Table 20 - Sensor Temperature Resistance

Resistance

(ohms)

High / Low

Temp Sensor

Temp. (oF)

Lower Sensor

(7100P-005)

Clip-On Sensor

(7100P-172)

Resistance (Ohms)

176 1256

185 1070

194 915

202 786

212 667

C. Failure to Operate

Should the burner fail to light, the control will perform two more ignition trials prior to entering a lockout state. Note that each subsequent ignition trial will not occur immediately. After a failed ignition trial, the blower must run for approximately 10 seconds to purge the system. Therefore, a time period of approximately 40 to 90 seconds will expire between each ignition trial. If the burner lights during any one of these three ignition trials, normal operation will resume. If the burner lights, but goes o in about 4 seconds, check the polarity of the wiring. See electrical connection section of this manual. If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout state indicates that a problem exists with the appliance, the controls, or the gas supply. Under such circumstances, a qualied service technician should be contacted immediately to properly service the appliance and correct the problem. If a technician is not available, pressing RESET will remove the lockout state so additional trials for ignition can be performed. The unit will try to relight once every 6 minutes.

D. Important Notice

It is extremely important that whenever work is performed on the plumbing system that either:

• The appliance is powered o, or,

• The appliance is valved o and isolated from the

plumbing system. Failure to take these measures could result in a dry-ring condition.

Part 12 - Shutdown

A. Shutdown Procedure

If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70oF and wait for the burner to shut o. Continue to wait for the combustion blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 40 to 90 seconds. After combustion gases are purged turn o electrical power to the appliance.

B. Vacation Procedure

If there is danger of freezing, change the set point to 70oF. DO NOT turn o electrical power. If there is no danger of freezing,

LP-314 Rev. 2.3.17

Page 51

7 19

LP-314-K

01/23/1701/23/17

Item

6 THUMB SCREW - HYDRONIC MODULE COVER 7100P-149

7 FLEX LINE - EXCHANGER SIDE (w/NUTS, WASHERS) 7100P-171

CONTROL BOARD DISPLAY (w/MEMBRANE, BOARD,

HOUSING, CABLE)

18 55-80 GAL. HYDRONIC MODULE BACKPLATE 7100P-156

Description

( EDIS PMUP - ENIL XELF91

Replacement

Part #

012SVHCTIWS PMET EULF HGIH21

7100P-266

0041PTEVLAV FEILER ERUSSERP DNA ERUTAREPMET12

1-258-P0007ROSNES FFO-TUC RETAW WOL1

600-P0017HCTIWS YTEFAS PMET HGIH2

400-P0017ROSNES ERUTAREPMET REPPU3

231-P0017REGNAHCXE TAEH ETALP DEZARB4

440-P0068TUN PPSB - REHSAW GNILAES5

500-P0017ROSNES ERUTAREPMET REWOL8

411-P0017)UTB K031( TELNI RIA - GNILPUOC "29

301-P0017)UTB K991( TELNI RIA - GNILPUOC

121-P0017ESOH ETASNEDNOC01

512-P0527ESOH ETASNEDNOC - PMALC11

451-P0527BRAB ESOH .S.S31

401-P0017TELNI RIA - TUN GNILPUOC41

462-P0017TENIBAC CITSALP .LAG 08-5551

562-P0017TENIBAC CITSALP .LAG 991

780-P0057HCTIWS REWOP71

531-P0017ETALPKCAB ELUDOM CINORDYH .LAG 991

561-P0017)SREHSAW ,STUN/w

131-P0017PMUP ELUDOM GNITAEH CINORDYH02

271-P0017ROSNES ERUTAREPMET EPIP NO-PILC22

431-P0017REVOC ELUDOM CINORDYH .LAG 08-5532

631-P0017REVOC ELUDOM CINORDYH .LAG 991

Figure 28 - Replacement Parts

LP-314 Rev. 2.3.17

Page 52

Figure 29 - Control Board Replacement Parts

LP-314 Rev. 2.3.17

Page 53

Figure 30 - Replacement Parts - Combustion System

LP-314 Rev. 2.3.17

Page 54

Part 13 - Installation Checklist

Before Installing Yes No

Is there enough space to ensure proper installation?

Does installation location allow for proper service clearances?

Are water and gas lines properly sized and set at proper pressures for the installation?

Is appliance location as near the exhaust vent / intake pipe terminations as possible?

Have combustible materials been cleared from the installation location?

Is there a drain close to the appliance?

Water Piping Yes No

Does appliance loop piping meet the minimum sizing requirements listed? NOTE: Smaller piping will cause performance problems.

Has water chemistry been checked?

Does water chemistry meet requirements?

If water chemistry does not meet requirements, have treatment measures been put in place?

Has the system been cleaned and ushed?

Install Exhaust Vent and Intake Piping Yes No

Has the appliance been vented with the approved materials listed in this manual or to meet local codes?

Is air supply sucient for proper appliance operation?

Is total vent piping length within the maximum vent length restriction listed in this manual?

Have venting lengths been minimized?

Are terminations properly spaced from windows, doors, and other intake vents?

Have all vent terminations been installed at least one foot above exterior grade and one foot above normal snow accumulation level?

Is vent piping properly supported?

Has vent piping been checked for leaks?

Has the exhaust vent line been pitched back to the appliance at a rate of 1/4” per foot?

Have the exhaust vent and intake pipes been properly installed to the appliance?

Install Condensate Piping / Tubing and Components Yes No

Have all condensate components included with the appliance been installed?

Is the condensate line piped with approved materials listed in this manual?

Has the condensate line been routed to a laundry tub or other drain?

Install Gas Piping Yes No

Is the gas supply line a minimum of 3/4” in diameter?

Is the gas supply line length and diameter adequate to deliver the required BTUs?

Has gas supply line pressure been measured?

Does the gas type match the type indicated on the appliance rating plate?

Has a union and shut-o valve been installed?

Relief Valve Yes No

Is the Temperature and Pressure Relief Valve properly installed and discharge line run to open drain?

Is the discharge line protected from freezing?

Wiring Yes No

Has the power and control been wired per appliance wiring diagram, this manual?

Is the electrical connection polarity within appliance requirements?

Does the power supply voltage agree with the appliance rating plate?

Is the branch circuit wire and fusing or circuit breaker of proper size?

Are electrical connections tight and properly grounded?

LP-314 Rev. 2.3.17

Page 55

Start-Up, Adjust, and Test Yes No

Has the appliance been started?

If necessary, has the appliance gas valve been adjusted?

Has the installation been customized per installation location requirements?

Have all customized system parameters been tested?

Has proper appliance operation been conrmed?

Final Installation Approvals

Signed by Technician Date

Table 21 - Installation Checklist

Part 14 - Maintenance Report

In unusually dirty or dusty conditions, care must be taken to keep appliance cabinet door in place at all times. Failure to do so VOIDS the warranty.

When servicing or replacing any components of this appliance be certain that:

• The gas is o.

• All electrical power is disconnected.

In addition, when servicing or replacing components of this appliance in direct contact with appliance water:

• There is no pressure in the appliance. Pull the release on the relief valve to relieve pressure in the appliance.

• Appliance water is not hot.

Failure to follow these precautions could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by appliance warranty. Allowing the appliance to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in appliance failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

The appliance must be full of water and the system fully purged BEFORE powering the appliance. Performing any work in the plumbing system without either powering o the appliance or isolating the appliance through the use of shuto valves could result in a condition referred to as “dry-ring”. Dry-ring the appliance will damage the heat exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by appliance warranty.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied service

The appliance has wire function labels on all internal wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.

LP-314 Rev. 2.3.17

Page 56

Inspection Activities Date Last Completed

Piping 1st Year 2nd Year 3rd Year 4th Year*

Near appliance piping

Vent

Gas

System 1st Year 2nd Year 3rd Year 4th Year*

Visual Do a full visual inspection of all system components.

Functional Test all functions of the system (Heat, Safeties).

Temperatures

Electrical

Connections Check wire connections. Make sure connections are tight.

Smoke and CO Detector

Circuit Breakers Check to see that the circuit breaker is clearly labeled. Exercise circuit

Chamber / Burner 1st Year 2nd Year 3rd Year 4th Year*

Combustion

Chamber

Spark Electrode Clean. Set gap at 1/4” Clean probe with plumbers cloth to remove

Flame Probe Check ionization uA (see Status Menu). Record high re and low re.

Condensate 1st Year 2nd Year 3rd Year 4th Year*

Neutralizer Check condensate neutralizer. Replace if necessary.

Condensate Pipe Disconnect condensate pipe. Clean out dirt. Fill with water to level

Gas 1st Year 2nd Year 3rd Year 4th Year*

Pressure Measure incoming gas pressure (3.5” to 10” WC for Natural Gas, 8” to

Pressure Drop Measure drop in pressure on light o (no more than 1” WC).

Check Gas Pipe for Leaks

Combustion 1st Year 2nd Year 3rd Year 4th Year*

CO / CO2 Levels Check CO and CO2 levels in exhaust. See manual for ranges. Record

Safeties 1st Year 2nd Year 3rd Year 4th Year*

ECO (Energy Cut Out)

Water Pressure Switch

Sensors Check wiring. Verify through ohms reading.

Final Inspection 1st Year 2nd Year 3rd Year 4th Year*

Check List Verify that you have completed entire check list. WARNING: FAILURE

Homeowner Review what you have done with the homeowner.

Table 22 - *Continue annual maintenance beyond the 4th year as required.

Check appliance and system piping for any sign of leakage; make sure pipes are properly supported.

Check condition of all vent pipes and joints. Ensure the vent piping terminations are free of obstructions and blockages.

Check gas piping. Test for leaks and signs of aging. Make sure all pipes are properly supported.

Verify safe settings on appliance or anti-scald valve.

Verify programmed temperature settings.

Verify devices are installed and working properly. Change batteries if necessary.

breaker.

Check burner tube and combustion chamber coils. Clean according to maintenance section of manual. Vacuum combustion chamber. Replace any gaskets that show signs of damage.

oxides.

Clean probe with plumbers cloth to remove oxides.

of outlet and reinstall. (NOTE: Verify the ow of condensate, making sure that the hose is properly connected during nal inspection.)

14” WC for Propane).

Check piping for leaks. Verify that all are properly supported.

at high and low re.

Check continuity on ue and water ECOs. Replace if corroded.

Check operation and for signs of leakage. Replace if corroded.

TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

LP-314 Rev. 2.3.17

Page 57

Versa Hydro™ Combined Appliance

Limited Warranty

For Residential and Commercial Use

HTP warrants each Versa Hydro™ Combined Appliance to be free from defects in material and workmanship according to the following terms, conditions and time periods. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original owner of the Versa Hydro™, and is non-transferable.

Residential Use Warranty (1 year – Parts, 12 years – Tank)

“Residential” setting shall mean appliance usage in a single family dwelling, or usage in a multiple family dwelling, provided that the appliance services only one (1) dwelling in which the original consumer purchaser resides on a permanent basis and domestic hot water operating temperatures do not exceed 140oF.

Commercial Use Warranty (1 year – Parts, 5 years – Tank)

Appliances used in a commercial setting shall mean any usage

not falling within the denition of a “residential” setting.

COVERAGE

A. HTP warrants that it will repair or replace, at its option, any defective or malfunctioning component of the Versa Hydro™ Combined Appliance that is found to have failed due to

manufacturer’s defect during the rst year after installation.

Replacement components will be warranted for ninety (90) days.

B. 1. Residential Use - During the rst through seventh year after

the date of installation, HTP will repair or replace, at its option, any defective Versa Hydro™ found to have failed due to leaking heat exchanger, tank, or brazed plate exchanger.

2. Commercial Use - During the rst through fth year after the

date of installation, HTP will repair or replace, at its option, any defective Versa Hydro™ found to have failed due to leaking heat exchanger, tank, or brazed plate exchanger. C. Residential Use ONLY - During the eighth through twelfth year after the date of installation, HTP will repair or replace, at its option, any defective Versa Hydro™ found to have failed due to leaking heat exchanger, tank, or brazed plate exchanger, at a cost to the purchaser equal to the following percentages of the manufacturer’s list price in effect at the date of replacement.

Year of Claim 8 & 9 10 & 11 12

Percentage to be paid by

purchaser

D. The replacement appliance will be warranted for the unexpired portion of the applicable warranty period of the original appliance.

E. If government regulations, industry certication, or similar

standards require the replacement appliance or part(s) to have features not found in the defective appliance or part(s), you will be charged the difference in price represented by those required features. If you pay the price difference for those required features and/or to upgrade the size and/or other features available on a new replacement appliance or part(s), you will also receive a complete new limited warranty for that replacement appliance or part(s). F. In the event of a leakage of water of a replacement appliance due to defective material or workmanship, malfunction, or failure to comply with the above warranty, HTP reserves the right to refund to the original purchaser the published wholesale price available at the date of manufacture of the original appliance. G. If, at the time of a request for service the purchaser cannot provide a copy of the original sales receipt or the warranty card registration, the warranty period for the Versa Hydro™ shall then be deemed to have commenced thirty (30) days after the

25 % 50 % 75 %

date of manufacture of the Versa Hydro™ and NOT the date of installation of the Versa Hydro™. H. This warranty extends only to Versa Hydro™ Combined Appliances utilized in heating applications that have been properly installed based upon manufacturer’s installation instructions. I. HTP will NOT accept claims from the purchaser for labor costs incurred as a result of the repair, replacement, removal, or reinstallation of a Versa Hydro™ or any component thereof. J. It is expressly agreed between HTP and the original consumer purchaser that repair, replacement, or refund are the exclusive remedies of the original consumer purchaser.

OWNER RESPONSIBILITIES

To avoid the exclusion list in this warranty, the owner or installer must:

1. Maintain the appliance and all related heating components in accordance with the maintenance procedures listed in the appliance manual. Preventive maintenance can help to avoid any unnecessary appliance breakdown and keep it running at

optimum efciency.

2. Check condensate lines to conrm that all condensate drains

properly from the unit.

3. Keep the appliance free of damaging scale deposits.

4. Make provisions so if the appliance or any component part or

connection thereto should leak, the resulting ow of water will

not cause damage to the area in which it is installed.

5. Operate the appliance as pressures below those shown on the rating plate and on the pressure relief valve.

6. Have a vacuum relief valve and temperature and pressure relief valve bearing the listing marks of the American Society of Mechanical Engineers (ASME) installed with the storage tank assembly in accordance with federal, state, and local codes.

7. Use the appliance in an open system, or in a closed system with a properly sized and installed thermal expansion tank.

WARRANTY EXCLUSIONS

HTP does not warrant:

1. Service trips to teach how to install, use, or maintain this appliance, or to bring the installation into compliance with local building codes and regulations.

2. All labor charges incurred by any person in connection with the examination or replacement of parts claimed by the purchaser to be defective.

3. Any failed components of the heat system not manufactured by HTP as part of the appliance.

4. Appliances repaired or altered without prior written approval of HTP so as to affect adversely their reliability.

5. Damages, malfunctions, or failures resulting from improper installation (e.g. failure to install the appliance in accordance with applicable building codes/ordinances, or in accordance with good plumbing and electrical trade practices) or failure to maintain and operate the appliance in accordance with the printed instructions that accompany the unit.

6. Damages, malfunctions, failures or performance problems caused by improper sizing of the appliance, gas supply line, venting connection(s), combustion air openings, use of the heat pack for high temperature (over 160oF) applications, electric service voltage, wiring, fusing, or inadequately sized expansion device or piping.

7. Damages, malfunctions, or failures resulting from failure to operate the appliance at pressures not exceeding the working pressure shown on the rating plate.

8. Failure to operate the appliance in an open system, or in a closed system with a properly sized expansion tank.

9. Damages, malfunctions, or failures caused by operating the

appliance with modied, altered, or unapproved parts.

LP-314 Rev. 2.3.17

Page 58

10. Any damages, defects or malfunctions resulting from, or repairs necessitated by, improper installation or maintenance,

misuse, abuse, accident, negligence, freezing, Acts of God (ood, re, wind, lightning, etc.) and the like.

11. Damages, malfunctions, or failures caused by improper conversion from natural gas to LP gas or LP gas to natural gas.

12. Any damage or failure resulting from hard water scale buildup in the appliance (e.g. on the tank heat exchanger tubes or brazed plate exchanger).

13. Any damage or failure resulting from corrosive or contaminated air, including, but not limited to, sheetrock particles, plasterboard particles, dirt or dust, being introduced into the appliance or its components including, but not limited to, the inside tank heat exchanger tubes or brazed plate exchanger.

14. Any damage or failure resulting from improper water chemistry. WATER CHEMISTRY REQUIREMENTS (RESIDENTIAL USE) – Water pH between 6.5 and 8.5. Operating temperatures not exceeding 140oF. Hardness less than 12 grains (200 mg/L). Chloride concentration less than 100 ppm (mg/L). TDS less than 500 ppm (mg/L). (COMMERCIAL USE) - Water pH between

6.5 and 8.5. Hardness less than 7 grains (120 mg/L). Chloride concentration less than 100 ppm (mg/L). TDS less than 500 ppm (mg/L).

15. Any damages, malfunctions, or failures resulting from the use of dielectric unions.

16. Components of the appliance that are not defective, but must be replaced during the warranty period as a result of reasonable wear and tear.

17. Components of the appliance that are subject to warranties, if any, given by their manufacturers, HTP does not adopt these warranties.

18. Appliances moved from their original installation location.

19. Damages, malfunctions, or failures caused by subjecting

appliances to pressures or ring rates greater than those specied

on the rating label.

20. Appliances that have had their rating labels removed.

21. Any unit purchased from an unauthorized dealer or any online retailer.

22. Units installed outside the fty states (and the District of

Columbia) of the United States of America and Canada.

SERVICE, LABOR AND SHIPPING COSTS

This warranty does not extend to shipping charges, delivery expenses, or administrative fees incurred by the purchaser in repairing or replacing the Versa Hydro™. This warranty does

not extend to labor costs beyond the coverage specied in this

warranty document.

LIMITATIONS OF YOUR HTP WARRANTY AND REMEDIES

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM HTP’S NEGLIGENCE, ACTUAL OR IMPUTED. THE REMEDIES OF THE PURCHASER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL DAMAGES, SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, PROPERTY DAMAGE, LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF HTP TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE. NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES, REMEDIES OR THIS LIMITATION WILL BE BINDING UPON HTP. UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF HTP. THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL PURCHASER OF A

VERSA HYDRO™ ONLY.

NO OTHER WARRANTIES

Your HTP Warranty gives you specic legal rights, and you may

also have other rights that vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you. These are the only written warranties applicable to the Versa Hydro™ manufactured and sold by HTP. HTP neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said Versa Hydro™ Combined

Appliances. HTP reserves the right to change specications or

discontinue models without notice.

PROCEDURES FOR WARRANTY SERVICE REQUESTS

Any claim for warranty assistance must be made promptly. Determine if the Versa Hydro™ is “in-warranty” (that is, within the applicable warranty period) by reviewing a copy of the original sales receipt. You must present a copy of the original sales receipt for a warranty service request. If your Versa Hydro™ is “in-warranty”, contact the retailer from whom the appliance was purchased (or the installer) for assistance. Be prepared to provide the retailer or installer with a copy of your original receipt, complete model and serial numbers, and the date of installation of your Versa Hydro™, in addition to explanation of your problem. Warranty coverage is subject to validation of “in-warranty” coverage by HTP claims department personnel. All alleged defective or malfunctioning parts must be returned to HTP via the local distribution channels where original purchase was made. NOTE: Any parts or appliances returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied.

If all warranty conditions are satised, HTP will provide

replacement parts to the retailer. If you have questions about the coverage of this warranty, please contact HTP at the following address or phone number: HTP, 272 Duchaine Blvd, New Bedford, MA, 02745, Attention: Warranty Service Department, 1(800) 323-9651.

LP-314 Rev. 2.3.17

Page 59

Maintenance Notes

LP-314 Rev. 2.3.17

Page 60

Customer Installation Record Form

The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.

Customer’s Name

Date of Installation

Installation Address

Product Name / Serial Number(s)

Comments

Installer’s Code / Name

Installers Phone Number

Signed by Installer

Signed by Customer

Installation Notes

IMPORTANT

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

LP-314 Rev. 2.3.17

HTP PHE130, PHE199 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Part 1 - General Safety Information

C. When Servicing the Appliance

D. Appliance Water

E. Freeze Protection

A. Improper Combustion

B. Gas

F. High Elevation Installations

G. Water Temperature Adjustment

Part 2 - Before You Start

A. What’s in the Box

B. How the Appliance Operates

C. Optional Equipment

Part 3 - Prepare the Appliance

A. Locating the Appliance

B. Leveling

C. Clearances for Service Access

D. Residential Garage and Closet Installations

E. Exhaust Vent and Intake Pipe

1. Direct Vent of Exhaust and Intake

F. Carbon Monoxide Detectors

G. Prevent Combustion Air Contamination

Part 4 - Domestic Hot Water and Hydronic Piping

A. Plumbing

1. System Domestic Water Piping

2. Appliance Domestic Water Piping

B. Scalding

C. Mixing Valve Installation

D. Auxiliary Connections

E. Temperature and Pressure Relief Valve for DHW

G. Potable Expansion Tank

H. Hydronic Heating Module Piping

I. Pressure Relief Valve for the Hydronic System

J. Hydronic Expansion Tank and Make-Up Water

K. Hydronic Heating Module System Piping

L. Hydronic Heating Module Output

M. Applications

N. Filling the Appliance

Part 5 - Venting and Condensate Removal

A. General

B. Approved Materials for Exhaust Vent and Intake Pipe

C. Additional Requirements for Installation in Canada

D. Exhaust Vent and Intake Pipe Location

E. Exhaust Vent and Intake Pipe Sizing

G. Exhaust Vent and Intake Pipe Installation

F. Longer Vent Runs

H. Applications

1. Direct Vent Installation of Exhaust and Intake

2. Venting Through an Existing System

I. Condensate Removal System

Part 6 - Wiring

A. Field Wiring

B. Line Voltage Wiring

C. Low Voltage Wiring

D. Alarm Connections

E. Optional 0-10 Volt Building Control Signal

F. Customer Connection Board

G. Internal Wiring Diagram

Part 7 - Gas Connections

A. Gas Piping

B. Gas Table

C. Gas Valve

Part 8 - Start-Up Preparation

A. Fill and Purge DHW

B. Fill and Purge Hydronic Heating Loop

C. Purge Air from Hydronic Heating Module

D. Using the Control to Assist in Purging System Loops

E. Programming the Total System Control

Part 9 - Start-Up Procedures for the Installer

A. Navigation of the Display

B. Programming the Control

C. Programming the System Setting

D. System Setting Program Navigation

E. Control Status Menu

F. Resetting the Maintenance Schedule

G. Test Mode

Part 10 - Troubleshooting