HTP PHE199-119 User Manual

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Versa-Hydro

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual before installing. Perform steps in the order given. Failure to comply will result in substantial property damage, severe personal injury, or death.

INSTALLATION

START-UP

MAINTENANCE

PARTS

Versa-Hydro Appliance Models*

PHE130-55 / 199-55 PHE130-80 / 199-80

PHE130-119 / 199-119

*A suffix of “LP” denotes propane gas

“S” indicates solar models

“SNHX” indicates solar models without heat exchanger

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 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 fire department. Installation and service must be provided by a qualified installer,

service agency, or the gas supplier.

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The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property

damage.

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 with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, 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 Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official 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 officer or departmental official may be the AHJ.

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

FOR THE INSTALLER

This appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

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.

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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 specified in ANSI

Z21.10.3 – latest edition.

TABLE OF CONTENTS

PART 1 – GENERAL SAFETY INFORMATION .......................................................................................................................... 6

A. PRECAUTIONS .......................................................................................................................................................................... 6

B. IMPROPER COMBUSTION ........................................................................................................................................................ 6

C. GAS ............................................................................................................................................................................................ 6

D. WHEN SERVICING THE APPLIANCE ....................................................................................................................................... 7

E. APPLIANCE WATER .................................................................................................................................................................. 7

PART 2 – BEFORE YOU START ................................................................................................................................................ 7

A. WHAT’S IN THE BOX ................................................................................................................................................................. 7

B. HOW THE APPLIANCE OPERATES .......................................................................................................................................... 7

C. OPTIONAL EQUIPMENT ........................................................................................................................................................... 9

PART 3 – PREPARE APPLIANCE LOCATION .......................................................................................................................... 9

A. BEFORE LOCATING THE APPLIANCE ..................................................................................................................................... 9

B. LEVELING ................................................................................................................................................................................ 10

C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................. 10

D. RESIDENTIAL GARAGE INSTALLATION ................................................................................................................................ 11

E. EXHAUST VENT AND INTAKE PIPE ....................................................................................................................................... 11

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE ................................................................................. 11

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ........................................................ 11

F. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 12

G. REMOVING AN APPLIANCE FROM A COMMON VENT SYSTEM ........................................................................................ 12

H. WATER CHEMISTRY ............................................................................................................................................................... 13

PART 4 - DOMESTIC WATER PIPING ..................................................................................................................................... 16

A. TEMPERATURE AND PRESSURE RELIEF VALVE FOR DHW .............................................................................................. 16

B. DOMESTIC HOT WATER EXPANSION TANK ........................................................................................................................ 16

C. DOMESTIC WATER PIPING .................................................................................................................................................... 17

D. APPLIANCE PIPING ................................................................................................................................................................. 17

E. MIXING VALVE INSTALLATION .............................................................................................................................................. 17

F. AUXILIARY PIPING .................................................................................................................................................................. 19

PART 5 - HYDRONIC PIPING ................................................................................................................................................... 20

A. HYDRONIC HEATING MODULE PIPING ................................................................................................................................. 20

B. PRESSURE RELIEF VALVE FOR THE HYDRONIC SYSTEM ................................................................................................ 20

C. HYDRONIC EXPANSION TANK AND MAKE UP WATER ....................................................................................................... 20

D. HYDRONIC HEATING MODULE SYSTEM PIPING ................................ ................................................................................. 20

E. HYDRONIC HEATING MODULE OUTPUT .............................................................................................................................. 21

F. HYDRONIC PIPING .................................................................................................................................................................. 24

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PART 6 - VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ............................................................................ 28

A. GENERAL ................................................................................................................................................................................. 29

B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE .................................................................................... 29

C. REQUIREMENTS FOR INSTALLATION IN CANADA .............................................................................................................. 30

D. EXHAUST VENT AND INTAKE PIPE LOCATION.................................................................................................................... 31

E. EXHAUST VENT AND INTAKE PIPE SIZING .......................................................................................................................... 32

F. LONGER VENT RUNS ............................................................................................................................................................. 32

G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 33

H. VENTING DRAWINGS ............................................................................................................................................................. 34

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE ................................................................................. 34

2. VENTING THROUGH AN EXISTING SYSTEM ................................ ........................................................................................... 38

3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ........................................................ 40

I. CONDENSATE REMOVAL SYSTEM ........................................................................................................................................ 42

PART 7 - FIELD WIRING ................................................................................................ ........................................................... 43

A. FIELD WIRING COMPLIANCE REQUIREMENTS ................................................................................................................... 43

B. FIELD WIRING.......................................................................................................................................................................... 43

C. LINE VOLTAGE WIRING .......................................................................................................................................................... 43

D. LOW VOLTAGE WIRING ......................................................................................................................................................... 43

E. FIELD CONNECTION BOARD ................................ ................................ ................................................................................. 43

F. INTERNAL WIRING .................................................................................................................................................................. 45

PART 8 - GAS CONNECTION ................................................................................................................................................... 47

A. GAS SUPPLY ........................................................................................................................................................................... 47

B. GAS PIPING ............................................................................................................................................................................. 47

C. GAS TABLE .............................................................................................................................................................................. 47

D. GAS VALVE .............................................................................................................................................................................. 48

E. HOW TO VERIFY COMBUSTION ............................................................................................................................................ 49

PART 9 - START-UP PROCEDURE ......................................................................................................................................... 49

A. FILL AND PURGE DHW ........................................................................................................................................................... 49

B. FILL AND PURGE HYDRONIC HEATING LOOP ..................................................................................................................... 50

C. PURGE AIR FROM HYDRONIC HEATING MODULE ............................................................................................................. 50

D. APPLIANCE PUMP CONTROL TO ASSIST IN PURGING AIR FROM SYSTEM LOOPS ....................................................... 51

E. PROGRAMMING THE TOTAL SYSTEM CONTROL ............................................................................................................... 51

PART 10 - CONTROL OVERVIEW ........................................................................................................................................... 53

A. NAVIGATION OF THE DISPLAY .............................................................................................................................................. 53

B. PROGRAMMING THE CONTROL ............................................................................................................................................ 54

C. APPLIANCE SETTING PROGRAM NAVIGATION MENU ....................................................................................................... 54

D. PROGRAMMING THE SYSTEM SETTING .............................................................................................................................. 55

E. SYSTEM SETTING PROGRAM NAVIGATION ........................................................................................................................ 55

F. CONTROL STATUS MENU ...................................................................................................................................................... 56

PART 11 - SHUTDOWN ............................................................................................................................................................ 57

A. SHUTDOWN PROCEDURE ..................................................................................................................................................... 57

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INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.

USER – This manual is for use only by a qualified heating installer/service technician. Have this appliance serviced/inspected by a qualified service technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS APPLIANCE SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the appliance is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified 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 fire 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 flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Do not obstruct the flow of combustion and ventilating air. Adequate air is necessary for safe operation. Failure to keep the vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

B. VACATION PROCEDURE ........................................................................................................................................................ 57

C. FAILURE TO OPERATE ........................................................................................................................................................... 57

PART 12 - TROUBLESHOOTING ............................................................................................................................................. 58

A. APPLIANCE ERROR CODE ..................................................................................................................................................... 58

B. APPLIANCE ERROR ................................................................................................................................................................ 58

C. APPLIANCE FAULT ................................................................................................................................................................. 58

D. APPLIANCE CONTROL FAULT CODES ................................................................................................................................. 58

PART 13 – MAINTENANCE ...................................................................................................................................................... 66

MAINTENANCE NOTES .................................................................................................................................................................. 69

HTP CUSTOMER INSTALLATION RECORD FORM ...................................................................................................................... 70

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Unit 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. Do not install this appliance directly on carpeting. For installation on combustible flooring. Use only Category IV vent systems.

B. IMPROPER COMBUSTION

C. GAS

Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

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D. WHEN SERVICING THE APPLIANCE

 To avoid electric shock, disconnect electrical supply before performing maintenance.  To avoid severe burns, allow appliance to cool.

E. APPLIANCE WATER

 Do not use petroleum-based cleaning or sealing compounds in a system serviced by this appliance. Gaskets and seals in the

system may be damaged. This can result in substantial property damage.

 Do not use “homemade cures” or “patent medicines”. Substantial property damage, damage to appliance, and/or serious

personal injury may result.

PART 2 – BEFORE YOU START

A. WHAT’S IN THE BOX

Also included with the appliance:

 Intake PVC Tee with Screens  Exhaust PVC Coupling with Screens  Temperature and Pressure Relief Valve  Installation Manual  Warranty  Solar Addendum (Solar Models Only)  Outdoor Sensor (Part # 7250P-319)  Mixing Valve (Part # 7100P-315)

B. HOW THE APPLIANCE OPERATES

The Versa Hydro with Total System Control is truly revolutionary, providing high efficiency central heating and domestic hot water from one appliance. Total System Control manages system needs, assuring maximum comfort and efficient 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.

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High Efficiency Heat Exchanger

The highly efficient 90/10 copper nickel heat exchanger provides direct energy transfer from the combustion gases into domestic water. Hot gases travel from the primary circuit to heat the combustion walls, which then transfer heat directly into the water. The secondary circuit then transfers the last bit of energy to the bottom of the tank, where the hot gases are converted to water vapor, giving the appliance a combustion efficiency of 98% and thermal efficiency of up to 96%.

Modulating Combustion System

The modulating combustion system is designed to regulate firing rate based on heat demand. Total System Control monitors tank operation, system parameters, and controls the firing rate of the burner, providing only the energy required to satisfy both the domestic hot water and central heating needs.

Total System Control

Total System Control automatically manages the needs of both 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 the system parameters to provide design flexibility.

Hydronic Heating Module

The hydronic heating module connects to the storage tank through two dip tubes. The first dip tube draws heated water from the top of the storage tank and circulates it through a brazed plate heat exchanger that transfers 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 flow 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 vents in plastic pipe. Use only the approved venting material outlined in the venting section (Part 8) of this manual. Vent size can vary from 2” to 3” depending on the appliance input rate. The venting system requires an exhaust vent and intake pipe. Special attention should be taken when selecting vent location. Vents can run horizontally or vertically, depending on system design. Support the vents as shown in Venting, Part 8.

Burner

The burner is constructed of high grade stainless steel and uses pre-mixed air and gas to provide a wide range of firing rates.

Condensate Drain Connection

This is a condensing high efficiency appliance, and therefore has a condensate removal system. Condensate is nothing more than water vapor derived from combustion products. Appliance condensate is similar to that of an automobile when it is initially started.

It is very important that the condensate line slopes away from the appliance, down to a suitable drain. If the condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200, available from HTP).

A condensate filter, if required by local authorities, will neutralize the condensate, and can be made up of lime crystals, marble or phosphate chips. This filter can be purchased from HTP (p/n 7450P-212) and installed in the field.

It is also very important that the condensate line not be exposed to freezing temperatures or any other type of blockage. Plastic pipe must be the only material used for condensate line. Steel, brass, copper, or other materials will be subject to corrosion or deterioration.

In a long, horizontal condensate line, a second vent may be necessary to prevent vacuum lock. Also, an increase in pipe size and support of the condensation line may be necessary to allow condensate to drain properly.

Spark Ignition

The burner flame is ignited by applying high voltage to the system spark electrode. This causes a spark from electrode to ground.

Outdoor Sensor

The outdoor sensor monitors outdoor temperature and adjusts the set point to provide greater efficiency.

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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.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the appliance 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 appliance or components due to incorrect operating conditions IS NOT covered by product warranty.

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 influenced 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 the heat exchanger and other 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.

C. OPTIONAL EQUIPMENT

Below is a list of optional equipment available from HTP:

 3” Stainless Steel Outside Termination Vent Kit (V1000)  4” Stainless Steel Outside Termination Vent Kit (V2000)  2” PVC Concentric Vent Kit (Part # KGAVT0501CVT)  3" PVC Concentric Vent Kit (Part # KGAVT0601CVT)  3” Polypro Vent Kit (Part # 8400P-001)  3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)  System Sensor (Part # 7250P-324)  Alarm System (Part # 7350P-602) to monitor any failure  PC Connection Kit (Part # 7250P-320)  Condensate Neutralizer (Part # 7450P-212)  Outdoor Sensor (Part # 7250P-319)  Versa-Hydro Solar Kit (Part # 7100P-220)

NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system efficiency.

PART 3 – PREPARE APPLIANCE LOCATION

A. BEFORE LOCATING THE APPLIANCE

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, Part 3, Section F.  Avoid continuously high levels of humidity  Never close existing ventilation openings  Ensure a minimum 1” clearance around hot water and exhaust vent pipes

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This appliance is certified for indoor installations only. Do not install the appliance outdoors. Failure to install this appliance indoors could result in substantial property damage, severe personal injury, or death.

Failure to keep appliance area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

In order for the condensate to properly flow out of the collection system, the area where you locate the appliance must be level. Location must also fully support the weight of the filled appliance.

A catch pan must be installed to protect the surrounding area from possible leaking water damage.

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 flammable liquids.

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  Location that could cause the system and appliance to freeze and leak.  Incorrectly-sized expansion tank

6. Clean and flush system when reinstalling an 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

C. CLEARANCES FOR SERVICE ACCESS

Figure 1 - If you do not provide the minimum clearances shown above, it might not be possible to service the appliance without removing it from the space.

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The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the appliance. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

Failure to vent the appliance properly will result in serious 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 the first 3’ from the appliance.

D. RESIDENTIAL GARAGE INSTALLATION

PRECAUTIONS

If the appliance is located in a residential garage, per ANSI Z223.1:

 Mount the bottom of the appliance a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices

are well off the floor.

 When raising the appliance, be certain to fully support its entire filled weight.  Locate or protect the appliance so it cannot be damaged by a moving vehicle.

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 Venting, Part 8 in 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.

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE

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 piping can be routed through the building and properly terminated. Different 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, Part 8 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 1.

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED 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 1.

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 sufficient 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 1) 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.

Unconfined 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. See Figure 22, p. 41 for details.

Confined 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.

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When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.

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.

Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death.

You must pipe outside air to the appliance air intake. Ensure that the intake air will not contain any of the contaminants below. Contaminated air will damage the appliance, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake near a swimming pool. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants.

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

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

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).

should have a free area of one square inch per 1,000 Btu/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2).

If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section, Part 6 of this manual.

F. PREVENT COMBUSTION AIR CONTAMINATION

Install intake piping for the appliance as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

Table 1 – Contaminant Table

G. REMOVING AN APPLIANCE FROM A COMMON VENT SYSTEM

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Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment. HTP recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the appliance, as water quality will affect the reliability of the system. Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty.

CLASSIFICATION

MG/L OR PPM

GRAINS/GAL

Soft

0 – 17.1

0 - 1

Slightly Hard

17.1 – 60

1 – 3.5

Moderately Hard

60 – 120

3.5 – 7.0

Hard

120 – 180

7.0 – 10.5

Very Hard

180 and over

10.5 and over

Figure 2

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 deficiencies 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 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 fireplace 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 flame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance 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 in the National Fuel Gas Code, ANSI Z 223.1.

H. WATER CHEMISTRY

Outlined below are water quality parameters which need to be met in order for the system to operate efficiently for many years.

Water Hardness

Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in water. The concentration of these salts is expressed in mg/L, ppm, or grains per gallon as a measure of relative water hardness. Grains per gallon is the common reference measurement used in the U.S. water heater industry. Hardness expressed as mg/L or ppm may be divided by 17.1 to convert to grains per gallon. Water may be classified as very soft, slightly hard, moderately hard, or hard based on its hardness number. The minerals in the water precipitate out as the water is heated and cause accelerated lime scale accumulation on a heat transfer surface. This lime scale build-up may result in premature failure of the heat exchanger. Operating temperatures above 135oF will further accelerate the build-up of lime scale on the heating surface and may shorten the service life of the appliance.

Water that is classified as hard and very hard must be softened to avoid heat exchanger failure. See below for further information about water hardness.

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If the hardness of the water exceeds the maximum level of 7 grains per gallon, water should be softened to a hardness level no lower than 5 grains per gallon. Water softened as low as 0 to 1 grain per gallon may be under-saturated with respect to calcium carbonate, resulting in water that is aggressive and corrosive.

pH of Water

pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water pH. The pH scale ranges from 0 to

14. Water with a pH of 7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water pH higher than 7 is considered alkaline. A neutral pH (around 7) is desirable for most potable water applications. Corrosion damage and appliance failures resulting from water pH levels of lower than 6 or higher than 8 ARE NOT covered by the warranty. The ideal pH range for water used in a storage tank or a water heater system is 7.2 to 7.8.

Total Dissolved Solids

Total Dissolved Solids (TDS) is a measurement of all minerals and solids dissolved in a water sample. The concentration of total dissolved solids is usually expressed in parts per million (ppm).

Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system. Most high TDS concentrations precipitate out of the water when heated. This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of an appliance. This scale accumulation can also impede the ability of the heat exchanger to transfer heat into the water. A heat exchanger damaged or blocked by lime/scale accumulation must be replaced.

The manufacturer of the appliance has no control of water quality, especially TDS levels in your system. Total dissolved solids in excess of 2,000 ppm will accelerate lime and scale formation in the heat exchanger. Heat exchanger failure due to total dissolved solids in excess of 2,000 ppm is a non-warrantable condition. Failure of an appliance due to lime scale build up on the heating surface IS

NOT covered by the warranty. Hardness: 7 grains

Chloride levels: 100 ppm pH levels: 6-8 TDS: 2000 ppm Sodium: 20 mGL

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UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the plastic components come to room temperature.

Figure 3 – Specifications and Dimensions

Remove all sides of the shipping crate to allow the heater to be lifted into its installation location.

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Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death.

DO NOT pipe this water heater with black iron, galvanized steel, steel, or lead pipe. Doing so will result in premature product failure and property damage, and WILL VOID the product warranty.

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 floor 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 shutoff valve may be installed between the relief valve and heater or in the discharge line. Do not plug or place any

obstruction in the discharge line.

 Test the operation of the relief valve after filling 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 heater “off” 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, under any circumstances, thread a cap or plug into the relief valve! Explosion, serious injury or death may result. Relief valve piping must be directed to the floor or an open drain, but not connected.

The expansion tank must be suitable for hot potable water.

PART 4 - DOMESTIC WATER PIPING

A. 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.

There must be a 6" space between the outlet of relief valve piping and drain or floor. Do not hook up to drain system directly without an air space. The relief valve must be checked periodically for proper operation.

B. DOMESTIC HOT WATER EXPANSION TANK

A potable hot water expansion tank is required to offset the expansion as the water is heated. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent water flowing back into city mains. Some local codes require back flow 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.

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Never use dielectric unions or galvanized steel fittings on any domestic water or auxiliary connections. Use only copper or brass fittings. Thread sealant must be used on all connections.

The mixing valve provided with this appliance must be installed on the hot water outlet connection to reduce the risk of scalding. This mixing valve only reduces the risk of scalding injury.

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!

APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS

120oF

More than 5 minutes

125oF

1 ½ to 2 minutes

130oF

About 30 seconds

135oF

About 10 seconds

140oF

Less than 5 seconds

145oF

Less than 3 seconds

150oF

About 1 ½ seconds

155oF

About 1 second

Table 2

C. 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 certified 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 fitted 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.

Recommend to the user that the mixing valve be checked annually to ensure its continued function.

D. APPLIANCE PIPING

The domestic inlet and outlet ports on the appliance are 1” NPT connections. We recommend the installation of shut-off 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 fittings. Teflon 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.

E. MIXING VALVE INSTALLATION

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.

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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 an 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) in the system. This valve will reduce point of discharge temperature in branch supply lines. This appliance was shipped with an ASSE approved thermostatic mixing valve. Install this valve according to the directions in the mixing device container. 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.

The mixing valve is certified to ASSE 1017. It is not to be used to provide anti-scald service resulting from system pressure fluctuations, and should not be used where more sophisticated compensating temperature controls are required.

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.

Mixing Valve Specification

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 Differential 27oF (15oC)

(Between Hot Supply and Outlet) Factory Set Locking Ring 120oF Max.1 Allowable Supply Pressure Variation +/- 20%2 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.

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 flow operation, the outlet temperature may vary slightly more.

Differential pressure at the valve inlet should be within a 2 to 1 ratio under normal flow conditions. Inline fittings, 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 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.

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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 death or serious injury.

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 temperature and clockwise to decrease temperature, as shown in Fig. 4.

Figure 4 – Adjusting the Mixing Valve

2. Once the desired outlet temperature has been achieved, refit 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.

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 filter or strainer to be fitted to the system. Contact a plumbing professional for appropriate materials and installation.

F. AUXILIARY PIPING

Auxiliary connections are provided to connect to an air handler, plate exchanger or other additional devices. Auxiliary ports can also be used for recirculation line connections. These connections must be installed in accordance with all local and national codes or any applicable prevailing standards. Auxiliary connections are 1” on all models. Never use dielectric unions or galvanized steel fittings. Use only copper or brass fittings. Teflon sealant must be used on all connections. The top port has a dip tube that draws hot water from the dome of the unit and the bottom port dip tube returns the water to bottom of the unit.

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Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death.

Figure 5 – Hydronic Heating Module

PART 5 - HYDRONIC PIPING

A. 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 flows 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 efficiency low mass boilers.

NOTE: Do not connect hydronic heating module to air handler units. This module may not be applied to air handler applications.

B. 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 floor drain.

C. 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 flow preventer. Normal system pressure is 15 psi.

D. 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 efficiency. In the system piping, heating

coils in air handler, flow 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 specifically formulated to include inhibitors that will prevent the glycol from attacking the metallic system components. Make certain that the system fluid 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”.

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Never block the outlet of the safety relief valve.

3. Install a balance and purge valve (or shut off drain valve) on the system return to purge air out of the zone at start-up.

4. Install a back flow 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 specific information related to expansion for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of system to blow out the system if needed. NOTE: The hydronic heating module cannot be drained completely of water without purging the unit with an air pressure greater than 15 psi but not exceeding 40 psi. If winterizing the unit it is recommended, use glycol on the closed loop hydronic side only.

10. The relief valve is installed at the factory. A pipe discharge line should be installed to release 6” above a drain, so discharge will be visible when pressure is relieved. The pipe size must be the same size as the relief valve outlet.

E. HYDRONIC HEATING MODULE OUTPUT

Hydronic heating module output is based on the burner input and the flow 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 flow rate needed to achieve the rated output from the module. This example is 12 GPM.

Step 3

Select the correct circulator to meet the flow and resistance requirements for the system design. To calculate this, you must determine the flow 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 Figure 6, Figure 7, and Figure 8).

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Figure 6

Figure 7

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Figure 8

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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.

F. HYDRONIC PIPING

Figure 9 – LP-314-3 NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow 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 flow 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 WATER HEATER 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 ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

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Figure 10 – LP-314-PIPING-1

NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow 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 flow 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 WATER HEATER 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 ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

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Figure 11 – LP-314-PIPING-2

NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow 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 flow 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 WATER HEATER 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 ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

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Figure 12 – LP-314-PIPING-4 NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow 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 flow 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 WATER HEATER 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 ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

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

Figure 13 – LP-314-PIPING-5

NOTES:

1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow 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 flow 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 WATER HEATER 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 ONLY. THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT AND DETAILING REQUIRED BY LOCAL CODES.

PART 6 - VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL

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This appliance is certified 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 below carefully. Failure to do so will result in substantial property damage, severe personal injury, or death.

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

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 flue adapter. Failure to do so could result in property damage, severe personal injury, or death.

Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent 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.

APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or Intake

pipe and fittings

PVC schedule 40/80

ANSI/ASTM D1785

PP, CPVC, and PVC venting must be ULC-S636 Certified. IPEX is an

approved manufacturer in Canada,

supplying vent material listed to

ULC-S636.

PVC-DWV*

ANSI/ASTM D2665

CPVC schedule 40/80

ANSI/ASTM F441

Polypropylene

ULCS636

Stainless Steel AL29-4C

Certified for Category IV and direct vent appliance venting

Certified for Category IV and direct

vent appliance venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements &

Primers

CPVC

ANSI/ASTM F493

A. GENERAL

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 water heater must be vented with materials, components, and systems listed and approved for Category IV appliances.

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 or the

pipe must be insulated. The insulation must have an R value sufficient to prevent freezing of the condensate.

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

B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE

Table 3

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 The exhaust and intake components installed with this appliance must be used for near appliance piping BEFORE

transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID appliance warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.  DO NOT use Foam Core Pipe in any portion of the exhaust piping from this water heating appliance.  DO NOT connect PVC/CPVC to PP without an approved vent connector.  When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the appliance vent connection, and at the

termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

 *PVC-DWV for air intake applications ONLY.

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

DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in Table 3. Failure to do so 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 glued, properly supported, and the exhaust vent must be pitched a minimum of ¼” 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.

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.

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. REQUIREMENTS FOR INSTALLATION IN CANADA

1. Installations must be made with a vent pipe system certified 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 first three (3) feet of vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings. Cellular foam core piping may be used on air inlet piping only.

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D. EXHAUST VENT AND INTAKE PIPE LOCATION

Figure 14 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 14 NOTES:

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 water heater 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 direct-vent 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 water heaters 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 specified in this manual.  The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.  The flue products coming from the exhaust vent will create a large plume when the boiler is in operation. Avoid venting in

areas that will affect 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.  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.

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The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine 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 floor 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 requirements for detectors and alarms could result in property damage, severe personal injury, or death.

FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS

FITTINGS OR PIPING

EQUIVALENT FEET

2”

3”

4”

90 DEGREE ELBOW*

5’

3’

45 DEGREE ELBOW

3’

1’

COUPLING

0’

AIR INLET TEE

0’

STRAIGHT PIPE

1’

CONCENTRIC VENT KIT

3’

N/A

V500 2” VENT KIT

1’

N/A

V1000 3” VENT KIT

N/A

1’

V2000 4” VENT KIT

N/A

1’

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

MODEL

MAXIMUM TOTAL EQUIVALENT

LENGTH AT STANDARD VENT

CONNECTION

REDUCING COUPLING

MAXIMUM TOTAL EQUIVALENT LENGTH AT

MAXIMUM INCREASED VENT SIZE

PHE130

85’ @ 2”

3” X 2”

125’ at 3”

PHE199

200’ @ 3”

4” X 3”

200’ at 4”

E. EXHAUST VENT AND INTAKE PIPE SIZING

1. The exhaust vent and intake pipe size is 2" for the PHE130 and 3" for the PHE199.

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

a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table, Table 4:

Table 4 - *Friction loss for long radius elbow is 1’ less. NOTE: Consult Polypropylene venting instructions for friction loss and pressure drop equivalents.

b. For example: If the vent size is 2”, and the exhaust vent has two 90° 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 90° elbows, one 45° elbow and 10 feet of PVC pipe, the following calculation applies: Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. Finally, if a concentric vent kit is used we find: Total Equivalent Length = 20 + 23 + 3 = 46 feet. The total equivalent length is 46 feet which is well below the maximum of 85 feet.

3. The minimum total equivalent length is 16 equivalent feet.

F. LONGER VENT RUNS

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

a. The maximum total equivalent length for increased diameter vent pipes is 125 feet for 2” transitioning to 3” pipe

(this number includes the minimum 15 total equivalent feet necessary for transition), and 200 maximum total equivalent feet for 3” transitioning to 4” pipe (including the minimum 15 total equivalent feet necessary for transition).

b. Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe.

Table 5 – Vent Sizing – Diameter and Length

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Total maximum total equivalent length of increased diameter exhaust vent and intake pipe must not exceed the lengths defined in this manual. 125 maximum total equivalent feet for 2” increased to 3” diameter vent pipe; 200 maximum total equivalent feet for 3” increased to 4” diameter vent pipe. 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

WATER APPLIANCE)

TEL OF OVERSIZED VENT PIPE (FT.)*

MAXIMUM TEL OF ALL VENT PIPE (FT.)

125

77-1/2

117-1/2

60-1/2

110-1/2

103

8-1/2

88-1/2

NONE 0 85

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.

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

Table 6 – TEL = Total Equivalent Length *Oversized vent pipe diameter is 1” or greater than factory supplied connection.

G. EXHAUST VENT AND INTAKE PIPE INSTALLATION

1. Use only solid PVC or CPVC 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 fittings.

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.

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

6. To prevent water leakage, install adequate roof flashing where the pipe enters the roof.

7. 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.

8. 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.

9. 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.

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

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

12. 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.

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

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

15. A screened inlet air tee is provided with the appliance to be used as an outside intake termination. Table 7 lists optional intake air/exhaust vent terminations available from HTP:

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VENT TERMINATION KITS

DESCRIPTION

STOCK CODE

2” PVC CONCENTRIC VENT TERMINATION KIT

KGAVT0501CVT

3” PVC CONCENTRIC VENT TERMINATION KIT

KGAVT0601CVT

2” STAINLESS STEEL VENT TERMINATION KIT

V500

3” STAINLESS STEEL VENT TERMINATION KIT

V1000

4” STAINLESS STEEL VENT TERMINATION KIT

V2000

3” POLYPRO VENT KIT

8400P-001

Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated vent piping could result in property damage, serious personal injury, or death due to flue gas leakage.

Table 7

H. VENTING DRAWINGS

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE

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 1.

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Figure 15 – Sidewall Venting – LP-314-C, LP-314-D - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

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Figure 16 – Concentric Venting - LP-314-E, LP-314-J - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

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Figure 17 – NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

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All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the appliance to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot intervals on the vent pipe. Boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.

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

Figure 18 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. 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.

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.

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Contractors must check state and local codes before installing 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 significantly to installation costs.

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, severe personal injury, or death.

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 concentric vent

kits. Refer to Concentric Vent Kit installation manual (LP-166) for further concentric venting information and instructions. Concentric venting through an existing system must run vertically through the roof. See Table 4 for proper minimum vent sizing. Use

only the approved venting materials specified in Table 3 for piping the system. All instructions listed in Part 6 - Venting apply. See Figures 19-1 and 19-2 for venting demonstrations.

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.

F. Maintain 12” minimum clearance

above highest anticipated snow level or grade (whichever is greater).

Figure 19 – 1, 19 – 2 Concentric Venting NOTE: Drawing is meant to demonstrate system venting ONLY.

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VENT / AIR INLET SIZE

MINIMUM EXISTING VENT / CHASE SIZE

2”

4”

3”

5”

4”

7”

Figure 20 – Venting as a Chase

Figure 21 – LP-325-X

Table 8 – Minimum Vent / Chase Sizing VENTING AS A CHASE

When venting as a chase, follow all instructions included in Part 6 – Venting of this manual, as well as the previous Concentric Venting section. See Figure 20 for chase venting demonstration.

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.

F. Maintain 12” minimum clearance above highest anticipated snow level or

grade (whichever is greater).

3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE

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 sufficient 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 21) 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.

When drawing combustion air from inside a conventionally constructed building to a confined 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 floor. Each opening should have a free area of one square inch per 1,000 Btu/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2).

If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual. See Figure 22.

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Figure 22

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The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the 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 overflow 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 filter if required by local codes.

I. CONDENSATE REMOVAL SYSTEM

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 efficiency appliance has a condensate removal system. Condensate is water vapor derived from combustion products, similar to 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 filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate. This can be installed in the field and purchased from HTP (p/n 7450P-212).

Plastic pipe 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 a condensate line vacuum lock if a long horizontal run is used. An increase in condensate line diameter may be necessary to allow condensate to drain properly. Support of the condensate line may be necessary to avoid blockage of the condensate flow.

Figure 23 – Installation of Condensate Line - LP-314-BB

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. THIS WILL REDUCE VACUUM LOCK.

2. PLASTIC PIPE SHOULD BE THE ONLY MATERIAL USED FOR THE CONDENSATE LINE. STEEL, BRASS, COPPER, OR OTHER MATERIALS WILL BE SUBJECT TO CORROSION OR DETERIORATION.

3. NEVER install condensate lines outside. It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage. 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 flow.

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ELECTRICAL SHOCK HAZARD – For your safety, to avoid possible electrical shock hazard, turn off electrical power supply at service entrance panel before making any electrical connections. Failure to do so can result in severe personal injury or death.

NOTE: Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only TEW 105 oC wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

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.

To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off 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.

PART 7 - FIELD WIRING

A. FIELD WIRING COMPLIANCE REQUIREMENTS

INSTALLATION MUST COMPLY WITH:

1. National Electrical Code and any other national, state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

B. FIELD WIRING

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

C. LINE VOLTAGE WIRING

1. Connect the normal incoming power to the terminals marked as shown in Figure 25. 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 25). 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. Please note that the solar pump connectors on the field connection board are not functional at this time.

D. LOW VOLTAGE WIRING

1. Make all low voltage connections to the terminal strip located on the field connection board (shown in Figure 24) as outlined below.

2. The room thermostat should be connected to the terminals marked T STAT (shown in Figure 24). 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 influence 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 efficiency. 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 affected by direct sunlight but will be exposed to varying weather conditions. Connect the outdoor sensor to terminals marked “Outdoor” in Figure 24.

E. FIELD CONNECTION BOARD

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Figure 24 – Hydronic heating module

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F. INTERNAL WIRING

Figure 25 – Internal connection diagram

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Figure 26 – LP-314-R

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It is of extreme importance that this unit be properly grounded. Prior to making any electrical connections, It is very important that the building system ground is inspected by a qualified electrician. Make certain that electrical power is only turned on when the unit is completely filled with cold water.

Failure to follow all precautions in this section could result in fire, explosion, or death!

Failure to isolate gas line while leak testing 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 flame (match, lighter, etc.) to check gas connections.

Figure 27

PART 8 - GAS CONNECTION

A. GAS SUPPLY

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 (WC). As stated in the National Fuel Gas Code, the entire piping system, gas meter, and regulator must be sized properly to prevent

pressure drop greater than .5” WC. This information is listed on the unit

rating plate. It is very important that you are connected to the type of gas noted on the

rating plate: “LP” for liquefied petroleum, propane gas, or “Nat” for natural or

city gas. Prior to turning the gas supply on, all gas connections must be approved by the local gas supplier or utility in addition to the governing authority. Do not remove the reducing coupling attached to the gas

valve! Per the National Fuel Gas Code, it is mandatory that this fitting be used for connection to a field fabricated drip leg as shown in the illustration at left.

Ensure that the entire gas line to the connection at the appliance is no

smaller than ¾”. 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. In order to do this, you must turn off the factory and field-installed gas cocks. This will minimize the possibility of damaging the appliance gas valve.

B. GAS PIPING

1. Run the gas supply line in accordance with all applicable codes.

2. Locate and install manual shutoff valves in accordance with state and local requirements.

C. GAS TABLE

Refer to the following table 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” water column:

Table 9

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

Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.

Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death.

It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. To avoid excessive pressure drop, the gas piping must be sized for the proper flow and length of pipe. Both the gas meter and regulator must be properly sized for the

total gas load. If you experience a pressure drop greater than 1” WC, the

meter, regulator, and/or gas line is undersized or needs service. By removing the cap, you can attach a manometer to the incoming gas drip leg. 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 installed 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 or size the lines will result in ignition failure. This problem is especially noticeable in NEW

LP installations and empty tank situations. This can also occur when a utility company shuts off 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 service feature, the gas valve in this appliance has a flanged connection to the swirl plate and blower.

D. GAS VALVE

Figure 28 – LP-314-M

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Do not do a gas conversion on this unit without an officially approved conversion kit and instructions supplied by HTP. Failure to do so could result in serious injury or death.

COMBUSTION SETTINGS ON ALL MODELS

Natural Gas

Propane LP

Fan Speed

Low

Ignition

High

Low

Ignition

High

Carbon Monoxide PPM

1 – 10

2 - 15

2 – 20

1 – 10

2 - 15

2 – 20

Carbon Dioxide (CO2)

8 - 10%

8 – 10%

8 - 10%

8 ½ - 10 ½%

9 - 11%

FAN SPEEDS

BTU

IGNITION

MIN

MAX

130,000

3000

2000

7300

199,000

3000

2000

9100

FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This boiler does not have 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 boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any boiler.  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 fire department.  Turn off gas shutoff valve (located outside of the boiler) 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 qualified service technician. Force or attempted repair may result in a fire or explosion.

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

5. The boiler shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler 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.

Ensure the appliance is full of water before firing 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.

E. HOW TO VERIFY COMBUSTION

To activate service mode, press the up arrow ▲ and ENTER key together for 1 second. The unit will go through the ignition sequence. Press ▲ to increase, or ▼ to decrease fan speed.

To leave service mode, press ▲ and ▼ simultaneously.

Table 10

Table 11

PART 9 - START-UP PROCEDURE

A. FILL AND PURGE DHW

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Never use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems. Use only freeze-prevention fluids certified by fluid manufacturer as specified for use with stainless steel hydronic heating module heat exchanger and verified in fluid manufacturer’s literature.

Thoroughly clean and flush any system that has used glycol before connecting to the stainless steel hydronic heating module heat exchanger. Provide MSDS material data safety sheet on fluid used to owner.

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

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

The power must remain off 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 filling of the tank and inspect for any leaks in the system which may occur and need to be repaired. Shut off faucet once all evidence of air is purged from the water stream.

B. FILL AND PURGE HYDRONIC HEATING LOOP

Freeze Protection (When Used)

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

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

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

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

5. Close manual 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 (See Part 3, Section H). 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 from 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 fill and during start-up and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

7. The system may have residual substances that could affect water chemistry. After the system has been filled and leak tested, verify that water pH and chlorine concentrations are acceptable by sample testing.

C. PURGE AIR FROM HYDRONIC HEATING MODULE

a. 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. b. Close the ball valves below the purge and drain valve. c. Close zone isolation valves. d. Open quick-fill valve on make-up water line. e. Open purge valve.

f. 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 flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are

purged.

g. Close the quick-fill valve and purge valve and remove the hose. Open all isolation valves. Watch the system pressure rise to

correct cold-fill pressure. It is recommended that you put the pumps into manual operation to assist in purging the circuits.

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D. APPLIANCE PUMP CONTROL TO ASSIST IN PURGING AIR FROM SYSTEM LOOPS

Before powering up the control assure the thermostat connection is disconnected on the field connection board. Apply power to the appliance (Note: The appliance will fire 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 ▼ and ENTER keys simultaneously and hold for 1 second. The display will read:

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

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 specific needs of the system, verify that the system is ready for operation. Be certain that:

 The Domestic Hot Water system is filled with water that meets the qualifications and all air is purged.  The mixing valve supplied is properly installed.  The Hydronic Heating System is filled with water and meets all qualifications 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 section discusses how to program a few of the major sections of the control parameters for optimum system performance. See the control overview section 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 first 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.

3. Use the  key to move the blinking zero to the left most zero. Next, use ▲ and ▼ to log in 600, the access code. Press ENTER confirm the code and access Appliance Setting Program Navigation menu.

4. Once the code is confirmed, 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 ▼ on the display. Once a new value has been selected, press ENTER to store the new value.

5. The first 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.

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.

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.

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, Part 10.

9. A proper outdoor reset curve should be set to further optimize system performance and efficiency. Figure 29 shows how each function will affect system performance. The values in Figure 29 show the system default.

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Figure 29

10. Press and hold ENTER for 4 seconds until you see the screen to log in the access code.

11. Use the  and  arrow keys to move the blinking zero to the left and right. Next, use the ▲ and ▼ 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 confirmed, 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 off 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 ▼ 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 first 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 ▼ 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 ▼ to adjust to your designed temperature. To store the new value press ENTER. NOTE: This should be the same value entered in step 5.

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ENTER MENU CODE 000

15. Press  once to scroll to Function 7 - “MAX OUTDOOR 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 ▼ 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 final 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 ▼ 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, Part 10.

18. Insure that there is no air lock or blockage in the tank side loop of the hydronic heating module. To do this, press and hold ▼ 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 flow is confirmed, press ▲ and ▼ 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 off.

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 Part 4, Section E.

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 10 - CONTROL OVERVIEW

The control monitors the safety sensors of the appliance to assure safe and efficient operation. It has many features to address configurations 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 fit 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 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:

One of the zeroes will be blinking. Use the ▲▼ arrow keys to change the blinking digit to the correct value. Use the   arrow keys to select the next digit to change and again use the ▲▼ 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 ▲▼ 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.

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SCREEN

DESCRIPTION

ENTER MENU CODE 000

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

ENTER MENU CODE 600

Using the arrow keys, log in Access Code “600”. To confirm the code, press ENTER to access Program navigation menu.

SCREEN

DESCRIPTION

CENTRAL HEATING 140 oF

Function: Adjusts the central heating designed supply set point. Default: 140oF (Range: 50oF to 170oF).

HEATING DELTA T 20 oF

Function: Adjusts the heating system designed delta T set point. Default: 20oF (Range: 5oF to 30oF).

DHW SET POINT 119 oF

Function: Allows the user to adjust the DHW set point from 95oF 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, Part 4, for further setup and operation details.

BURNER RUN OFFSET 5 oF

Function: Allows the user to adjust the degree offset from the current target tank temperature where the burner will ignite 1oF to 18oF (Factory default 5oF).

TEMP DISPLAY C OR F oF

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

SCREEN

DESCRIPTION

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

Function: Changes the clock from 12 hour mode (8:45 PM) to 24 hour mode (20:45). To change to 24 hour mode, press the ENTER key. The letter (A or P) after the time will blink. Press the up or down arrow key once and the letter will disappear. Press the ENTER key to save the new setting.

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

Function: Allows the user to adjust the hour setting.

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

Function: Adjusts the minute setting.

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

Function: Adjusts the day of week.

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

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

ARROW Keys – The right and left arrow keys ( ) are used to navigate between the default Display and Status Display. The  

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.

ARROW Keys – The up and down (▲▼) 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 ▲▼ 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 firing. Make sure any input (such as the thermostat) is turned off, so the appliance will remain idle and allow programming.

Table 12 – Accessing the Control

C. APPLIANCE SETTING PROGRAM NAVIGATION MENU

Once the code is confirmed, the user can now start to set the Appliance Settings. Use the arrow keys on the display to navigate through the Appliance Setting Program. To change a setting, press ENTER. Appliance settings can be increased by pressing ▲ and decreased by pressing ▼ on the display. Listed below are the appliance settings that can be programmed into the control. The first three are the most important to program correctly in order for the total system control to operate the appliance at optimum efficiency.

Table 13 – Appliance Settings Clock Settings

(Note: The clock will reset if the appliance is powered off for more than a week.)

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

Function: Adjusts the year setting.

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

Function: Adjusts the month setting.

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

The clock is set.

SCREEN

DESCRIPTION

ENTER MENU CODE 000

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

ENTER MENU CODE 925

Using the arrow keys on the display, log in your System Menu Access Code “925”. To confirm code, press ENTER to access system setting program navigation menu.

SCREEN

DESCRIPTION

Function 1

Factory Program Mode

MODE 1 PHOENIX

This screen indicates that the control is configured correctly. Do not change this setting.

Function 2

Max Tank Temp

MAX TANK TEMP 2 180 oF

Sets the overall tank temperature maximum limit. Factory default 180oF (Range 95oF to 185oF).

Function 3

DHW Offset Temp

OFFSET 3 0oF

Not Used.

Function 4

Warm Weather Shutoff

WARM WEATHER OFF 4 68 oF

Warm Weather Shutoff disables the heating module and the Total System Control will then optimize for domestic hot water only. Warm Weather Shutoff will occur if the programmed outdoor temperature is exceeded by the current outdoor sensor temperature. Factory default 68oF (Range 41oF to 122oF).

Function 5

Min Outdoor Temp

MIN OUTDOOR TEMP 5 5 oF

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

Function 6

Max Supply Temp

MAX SUPPLY TEMP 6 140 oF

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

Function 7

Max Outdoor Temp

MAX OUTDOOR TEMP 7 68 oF

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

Function 8

Min Supply Temp

MIN SUPPLY TEMP 8 120 oF

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

Function 9

Min Tank Temp

MIN TANK TEMP 9 68 oF

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

Function 10

CH Post Pump Time

CH POST PUMP TIME 10 0 MINUTES

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

Table 14 – Clock Settings NOTE: The clock does not automatically adjust for Daylight Savings Time, and requires manual adjustment.

D. PROGRAMMING THE SYSTEM SETTING

NOTE: Programming the control is not possible when the unit is firing. Make sure any input (such as the thermostat) is turned off, so the boiler will remain idle to allow programming.

Table 15 – System Settings

E. SYSTEM SETTING PROGRAM NAVIGATION

Once the System Menu Access Code is confirmed, the user can start to set the System Parameters Menu. Use the arrow keys on the display to navigate through the different program settings. To change an appliance setting, press ENTER. Increase system settings by pressing ▲ and decrease by pressing ▼ on the display.

Listed below are the system settings that can be programmed into the control.

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Function 11

DHW Priority

DHW PRIORITY 11 30 MINUTES

Allows the user to set DHW priority time, which is the amount of time to shut down the hydronic heating module when the system control senses a large domestic hot water usage. Factory default 30 minutes (Range 0 to 60 minutes).

Function 12

Error Outdoor Sensor

ERROR OUTD SENSOR 12

Allows the user to set 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 (Selection ON/OFF/PHOEN ON).

Function 13

Error System Sensor

ERROR SYSTEM SENS 13 ON

Allows the user to set 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 (Selection ON/OFF).

NOTE: Press ENTER to store system parameters.

Function 14

Service Schedule

SERVICE SCHEDULE 14 OFF

Allows the user to program the appliance maintenance schedule by selecting a service date or time based on the appliance run hours. Factory default OFF (Selection - Date or Run Hours). NOTE: Without setting this function, Functions 33 through 36 will not display.

Function 15

Year

SERVICE SCHEDULE 15 YEAR 00/00/2000

This parameter sets the year of the next service reminder.

Function 15

Hours

SERVICE SCHEDULE 15 10000’s 000000h

This parameter sets the 2 left digits of the amount of run hours until the next service reminder. If you selected the run hour function, you will need to program 10,000 hours.

Function 16

Month

SERVICE SCHEDULE 16 MONTH 00/00/2000

If you selected the date function, you will need to program the month.

Function 16

Hours

SERVICE SCHEDULE 16 10000’s 000000h

This parameter sets the 2 middle digits of the amount of run hours until the next service reminder.

Function 17

Day

SERVICE SCHEDULE 17 DAY 00/00/2000

Sets the day in the date function.

Function 17

Hours

SERVICE SCHEDULE 17 10000’s 000000h

Sets the 2 right digits of the amount of run hours until the next service reminder.

Function 18

Telephone Number

TELEPHONE # 18 000 000 0000

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

SCREEN

DESCRIPTION

TOP TANK 160oF BOT TANK 123oF

This screen displays the actual temperature that the top and bottom tank sensors are measuring.

Press the ▼ key once.

CH TARGET 140oF CH SUPPLY 122oF

This screen displays the current central heating temperature set point on the top line. NOTE: If an outdoor sensor is used, this temperature set point may vary from what was set in the Appliance Settings Screen. The bottom line is the actual temperature measured by the hydronic heating module supply sensor.

Press the ▼ key once.

CH DEMAND OFF OUTDOOR 55oF

The top line of this screen 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 display will read “OFF”. If the contacts are jumped, this line will display “ON” in place of the temperature. NOTE: To ensure a properly installed sensor, be sure that this temperature reading is similar to the current outdoor conditions.

Press the ▼ key once.

DHW SETING 119oF TANK TARGET 160oF

The top line of this screen 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 the total system control that is based on environment and system conditions.

Press the ▼ key once.

FLAME 0.0uA FAN SPEED 3497 RPM

The top line displays the boiler flame current. The bottom line displays appliance fan speed.

Press the ▼ key once.

Table 16 – System Setting Program Navigation

F. CONTROL STATUS MENU

The controller also has the ability to review the status of the system. To access the status screens, press the  key. Once the first value is displayed, press the ▲ or ▼ keys to access additional information. At any point you may press RESET to exit the Status screen.

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POWER ON 0h INPUT 0kBTU

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

Press the ▼ key once.

DHW USE 0% CH USE 1%

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

Press the ▼ key once.

GOOD IGNIT 0x CH CYCLE 0x

The top line of this display indicates the number of times the burner has turned on over the appliance lifetime. The bottom line indicates the number of times the heating module has cycled for central heating demand.

Press the ▼ key once.

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

This screen displays the last lockout fault of the appliance control. The top line will alternate between the words

“FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred.

Press the ▼ key once.

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

This screen displays the second oldest lockout fault of the appliance control. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred.

Press the ▼ key once.

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

This screen displays the third oldest lockout fault of the appliance control. The top line will alternate between the

words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault

occurred.

Press the ▼ key once.

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

This screen displays the fourth oldest lockout fault of the appliance control. The top line will alternate between the

words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault

occurred.

Press the ▼ key once.

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

This screen displays the fifth oldest lockout fault of the appliance control. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred.

Press the ▼ key once.

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

This screen displays the sixth oldest lockout fault of the appliance control. The top line will alternate between the

words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault

occurred.

Press the ▼ key once.

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

This screen displays the seventh oldest lockout fault of the appliance control. The top line will alternate between

the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault

occurred.

Press the ▼ key once.

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

This screen displays the eighth oldest lockout fault of the appliance control. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred.

Press the ▼ key once.

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

This screen displays the ninth oldest lockout fault of the appliance control. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred.

Press the ▼ key once.

FAULT HISTORY 10 08/28/2009 10:01A

This screen displays the tenth oldest lockout fault of the appliance control. The top line will alternate between the

words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault

occurred.

Table 17 – Control Status Menu

PART 11 - SHUTDOWN

A. SHUTDOWN PROCEDURE

If the burner is operating, lower the set point value to 70oF and wait for the burner to shut off. Then, wait for the combustion blower to stop so all latent combustion gases are purged from the system. This should take 40 to 90 seconds. After the combustion blower and burner have stopped operating, disconnect the electrical supply.

B. VACATION PROCEDURE

If there is danger of freezing, change the set point to 70oF. DO NOT turn off electrical power! If there is no danger of freezing, follow Shutdown Procedure, Part 11, Section A.

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

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

 The gas is off.  All electrical power is disconnected.

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

 There is no pressure in the appliance. (Pull the release on the relief valve to relieve pressure.)  Appliance water is not hot.  Electrical power is disconnected.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

during any one of these three ignition trials, normal operation will resume. If the burner lights, and goes off in about 4 seconds, check the polarity of the wiring. See Electrical Connection Section in Part 7.

If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout indicates that a problem exists with the appliance, the controls, or the gas supply. Under such circumstances, a qualified service technician should be contacted immediately to properly service the appliance and correct the problem. If a technician is not available, pressing RESET once will remove the lockout state so additional trials for ignition can be performed.

PART 12 - TROUBLESHOOTING

A. APPLIANCE ERROR CODE

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.

However, it may also be the result of a condition that the controller has evaluated as not safe to restart the appliance. In this case, the boiler control will be locked out, the red FAULT light will be lit steadily, and the message “LOCKOUT” will be displayed on the readout on the lower line. The appliance will not start until a qualified technician has repaired the fault 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 that more serious problems will occur soon.

B. APPLIANCE ERROR

When an error condition occurs, the controller will display a description and code on the display readout. These error messages and their recommended corrective actions are described in Section D, Appliance Control Fault Codes.

C. APPLIANCE FAULT

1. When a fault condition occurs, the controller will illuminate the red FAULT light and display a fault message in the display. The alarm output will also be activated. Most fault conditions also cause the CH pump to run in an attempt to cool the appliance.

2. Note the fault message that is displayed and refer to the Fault Code section for an explanation of the fault 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 recurrence of the fault message.

D. APPLIANCE CONTROL FAULT CODES

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This 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.

SCREEN

DESCRIPTION

POSSIBLE REMEDY

Fault Code FOU Outdoor Sensor Failure

OUTDOOR SENSOR FOU PUMP ON

This indicates that the outdoor sensor is defective, shorted or open, or the outdoor temperature is below –40oF. NOTE: The installer must choose YES in 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.

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

Fault Code E07 CH Sensor Failure

CH SENSOR FAIL PUMP ON

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.

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 Section 12.

3. Replace thermistor if necessary.

Table 18

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Fault Code ECS NOT CONNECTED

ECS NOT CONNECTED PUMP OFF

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.

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.

Fault Code TEMPER BLOCKING

TEMPER BLOCKING PUMP ON 12:31P

This indicates a temporary hold on the burner ignition, and occurs when the top tank sensor is above the set point and the bottom of the tank is substantially cooler than the top. This is a temporary hold on the burner only and all other functions will remain functioning properly. This error will clear itself when either the top tank temperature drops below the set point or the bottom temperature rises.

Fault Code E19

LINE VOLTAGE E19 PUMP OFF

This display indicates that 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.

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

Fault Code FLU

HI FLUE PRESS FLU PUMP ON

This display indicates that there is excessive flue pressure. This code will reset automatically after the high pressure condition is resolved. The second line indicates the status of the pump.

1. Assure that the flue 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 flue switch and connect the wires to the new switch BEFORE running unit.

Do not use a jumper to remedy this error. A faulty switch MUST be replaced. Failure to do so could result in serious injury or death.

Fault Code LEO

LOW WATER LEVEL LEO PUMP OFF

This display indicates that there is a 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 off.

1. Assure that there is adequate pressure and flow from the cold water inlet by slightly opening the drain valve near the tank.

2. Assure 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.

Fault Code LOU

24 VOLT LOW LOU PUMP ON

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

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 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.

4. Remove 12 pin Molex connector from the field 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 cutoff to see if message clears. Replace faulty part. Check low voltage wire harness in boiler 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.

Fault Code F00

WATER HIGH TEMP F00 PUMP ON

This display indicates that the water in the tank has overheated. This is a serious safety issue, as indicated by the red fault light and the flashing the word LOCKOUT on the display. The unit will not restart until it cools sufficiently 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 effort to cool down the boiler.

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.

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Fault Code F01

FLUE TEMP F01 PUMP ON

This display indicates that the flue temperature limit switch of the unit has tripped. This is a serious safety issue, as indicated by the red fault light and the word LOCKOUT flashing on the display. The unit will not restart until the flue cools down sufficiently 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.

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

2. Push the red reset button on the flue 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 flue temperature by using an external thermometer in the flue pipe. If the flue temperature is below 190°F and the switch trips, replace the switch. If the flue temperature is excessive, check and adjust the combustion controls on the unit.

Fault Code F02

TOP TEMP SENSOR F02 PUMP ON

This display indicates that the top temperature sensor of the tank has failed. This code indicates a serious safety issue by the red fault light and the word LOCKOUT flashing 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.

1. Check the electrical connection to the thermistor on the outlet manifold. Verify 5 VDC by checking in 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.

Fault Code F03

BOT TEMP SENSOR F03 PUMP ON

This display indicates that the bottom temperature sensor of the unit has failed. This code indicates a serious safety issue by the red fault light and the word LOCKOUT flashing 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.

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.

Fault Code F05

TOP TEMP HIGH F05 PUMP ON

This display indicates the top temperature of the tank is excessive. If accompanied by the illuminated red fault light and LOCKOUT flashing on the display, then this code indicates that 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.

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 Part 12.

2. Replace thermistor if necessary.

Fault Code F06

BOT TEMP HIGH F06 PUMP ON

This display indicates that the bottom temperature of the tank is excessive. If this code is accompanied by the illuminated red fault light and LOCKOUT flashing on the display, then the temperature on the bottom sensor has exceeded 230oF and a serious safety issue exists. The boiler 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 then the bottom temperature of the tank is at or above 210oF. The message will clear automatically when the temperature drops below 194o F. 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.

2. Replace thermistor if necessary.

Fault Code F09

NO FLAME ON IGN F09 PUMP ON

The unit tried to ignite four times during a call for heat and failed ignition all four times. This code 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 word LOCKOUT will flash on the display. During this lockout fault, the pump will be on as indicated on the bottom line.

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 flame rectifier probe.

4. If there is a spark but no flame, check the gas supply to the boiler.

5. If there is a flame, check the flame sensor.

6. Check for any flue blockage or condensate blocks.

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Fault Code F10

FLAME LOSS F10

The flame was lost while the unit was lit 3 times during 1 demand call. The red fault light and the word LOCKOUT flashing on the display indicate a serious safety issue. The unit will not restart until the technician repairs the cause of flame loss and resets the unit. During this lockout fault, the pump will be on as indicated on the bottom line of the display.

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

2. Assure that the flame is stable when lit.

3. Check to see if the display readout changes from “GAS

VALVE ON” to “RUN” within a few seconds after the boiler

ignites

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

5. If the signal reads less than 1 microampere, clean the flame rectifier and spark probe.

6. If the problem persists and the ‘FLAME” signal is still less

than 1.0, replace the flame probe and spark igniter probe.

7. The flame signal should be steady after the unit has been firing 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.

Fault Code F11

FALSE FLAME SIG F11 PUMP ON

There is flame when the control is not telling the unit to run. The red fault light and the word LOCKOUT flashing on the display indicate that this code is 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.

1. Look into window. If there is flame, turn the gas off to the unit at the service valve and replace the gas valve.

2. If the flame signal on the status menu is greater than 1.0 when the burner is not lit, replace the spark igniter and the flame rectification probe.

3. If the flame signal is not present after turning off the gas supply, check the gas valve electrical connection.

4. Check for condensate backup. Repair the condensate system as necessary. If condensate has partially filled 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.

Fault Code F13

FAN SPEED ERROR F13 PUMP ON

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 flashing LOCKOUT on the display indicates 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.

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 boiler control board.

Fault Code F31

PROGRAM ERROR F31

There was an error while programming the control. The control’s memory could be corrupt. The boiler control will not function in this state and the pump will be off. 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.

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

Fault Code PP

CONTROL PROGRAMED PP

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.

Press RESET for at least one second.

Table 19 – Fault Codes

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Figure 30

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Figure 31 – LP-314-G

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Figure 32

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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 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.

INSPECTION ACTIVITIES

DATE LAST COMPLETED

PIPING

1st YEAR

2nd YEAR

3rd YEAR

4th YEAR*

Near appliance piping

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

Vent

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

Gas

Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.

SYSTEM

Visual

Do a full visual inspection of all system components.

Functional

Test all functions of the system (Heat, Safeties)

Temperatures

Verify safe settings on appliance or Anti-Scald Valve

Temperatures

Verify programmed temperature settings

ELECTRICAL

Connections

Check wire connections. Make sure they are tight.

Smoke and CO detector

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

Circuit Breakers

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

CHAMBER/BURNER

Combustion Chamber

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

Spark Electrode

Clean. Set gap at ¼”.

Flame Probe

Clean. Check ionization in uA (d7 on status menu in Start-up Procedures). Record high fire and low fire.

CONDENSATE

Neutralizer

Check condensate neutralizer. Replace if necessary.

Condensate hose

Disconnect condensate hose. Clean out dirt. Fill with water to level of outlet and re-install. (NOTE: Verify the flow of condensate, making sure that the hose is properly connected during final inspection.)

GAS

Pressure

Measure incoming gas pressure (3.5” to 10” W.C. for Natural Gas, 8” – 14” W.C for LP)

Pressure Drop

Measure drop in pressure on light off (no more than 1” W.C.)

Check for gas leaks

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

COMBUSTION

CO/CO2 Levels

Check CO and CO2 levels in Exhaust (See Start-up Procedures for ranges). Record at high and low fire.

SAFETIES

ECO (Energy Cut Out)

Check continuity on Flue and Water ECO. Replace if corroded.

Water Pressure Switch

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

Thermistors

Check wiring. Verify through ohms reading.

FINAL INSPECTION

Check list

Verify that you have completed entire check list. WARNING: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

Homeowner

Review what you have done with the homeowner.

PART 13 – MAINTENANCE

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 qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified 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.

Table 20 - *Continue annual maintenance beyond the 4th year as required.

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MAINTENANCE NOTES

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Customer’s Name:

Installation Address: Date of Installation:

Installer’s Code/Name: Product Serial Number(s):

Comments: Installer’s Phone Number:

Signed by Installer:

Signed by Customer:

HTP 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.

IMPORTANT: Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the

system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative.

Distributor/Dealer: Please insert contact details.

LP-314 REV. 3.24.14

HTP PHE199-119 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual