HTP PHE199-119 User Manual

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

LP-314 REV. 3.24.14

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.

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

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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.

LP-314 REV. 3.24.14

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

LP-314 REV. 3.24.14

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.

LP-314 REV. 3.24.14

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.

LP-314 REV. 3.24.14

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.

LP-314 REV. 3.24.14

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.

LP-314 REV. 3.24.14

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.

LP-314 REV. 3.24.14

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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