HTP PHR199-55C User Manual

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Pioneer

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.

Versa-Flame

INSTALLATION

START-UP

MAINTENANCE

PARTS

Pioneer Appliance Models* Versa-Flame** Combination Appliance Models* PHR100-55 / 130-55 / 160-55 / 199-55 PHR130-55C / 160-55C / 199-55C

*A suffix of “LP” denotes propane gas

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 02717-04 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 appliance, 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.

The latest version of the National Electrical Code, NFPA No. 70. LP- 325 REV. 3.21.14

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The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death. Damage or failure of this product (or the system in which it is installed) due to unauthorized use IS NOT COVERED BY WARRANTY.

TABLE OF CONTENTS

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

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

B. IMPROPER COMBUSTION ....................................................................................................................................................... 7

C. GAS ............................................................................................................................................................................................ 7

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

E. APPLIANCE SYSTEM ................................................................................................................................................................ 8

F. CHECK/CONTROL HYDRONIC WATER CHEMISTRY ............................................................................................................. 8

G. VERSA-FLAME DHW HEAT PACK WATER QUALITY ............................................................................................................. 9

H. FREEZE PROTECTION FLUIDS AND WINTERIZING .............................................................................................................. 9

PART 2 – BEFORE YOU START .............................................................................................................................................. 10

A. WHAT’S IN THE BOX ............................................................................................................................................................... 10

B. HOW THE APPLIANCE OPERATES ....................................................................................................................................... 10

C. OPTIONAL EQUIPMENT ......................................................................................................................................................... 11

PART 3 – PREPARE APPLIANCE LOCATION ........................................................................................................................ 12

A. BEFORE LOCATING THE APPLIANCE .................................................................................................................................. 12

B. LEVELING ................................................................................................................................................................................ 13

C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 13

D. RESIDENTIAL GARAGE INSTALLATION ............................................................................................................................... 13

E. EXHAUST VENT AND INTAKE PIPE....................................................................................................................................... 14

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE ........................................................................................................ 14

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ............................................................................... 14

F. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 15

G. REMOVING AN APPLIANCE FROM A COMMON VENT SYSTEM ........................................................................................ 15

PART 4 – PIPING ...................................................................................................................................................................... 18

A. GENERAL PIPING INFORMATION ......................................................................................................................................... 18

B. RELIEF VALVE ........................................................................................................................................................................ 18

C. BACKFLOW PREVENTER ...................................................................................................................................................... 19

D. SYSTEM WATER PIPING METHODS ..................................................................................................................................... 19

E. CIRCULATOR PUMPS ............................................................................................................................................................. 19

F. DHW HEAT PACK AND INDIRECT WATER HEATER SCALDING ......................................................................................... 19

G. HYDRONIC PIPING - CIRCULATORS, ZONE VALVES AND MULTIPLE APPLIANCES ....................................................... 20

H. FILL AND PURGE HEATING SYSTEM ................................................................................................................................... 20

I. ZONING WITH ZONE VALVES ................................................................................................................................................. 21

J. ZONING WITH CIRCULATORS ............................................................................................................................................... 21

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K. MULTIPLE APPLIANCES ......................................................................................................................................................... 21

L. CENTRAL HEATING PIPING DETAIL ...................................................................................................................................... 22

M. PIPING INTO THE DHW PACK ON THE VERSA-FLAME ...................................................................................................... 24

E. MIXING VALVE INSTALLATION .............................................................................................................................................. 25

O. VERSA-FLAME DHW PERFORMANCE .................................................................................................................................. 27

P. DHW PIPING WITH THE VERSA-FLAME ............................................................................................................................... 29

PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL............................................................................ 32

A. GENERAL ................................................................................................................................................................................ 32

B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE .................................................................................... 32

C. REQUIREMENTS FOR INSTALLATION IN CANADA ............................................................................................................. 33

D. EXHAUST VENT AND INTAKE PIPE LOCATION ................................................................................................................... 34

E. EXHAUST VENT AND INTAKE PIPE SIZING .......................................................................................................................... 35

F. LONGER VENT RUNS ............................................................................................................................................................. 35

G. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................ 36

H. VENTING DRAWINGS ............................................................................................................................................................. 37

1. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE ........................................................................................................ 37

2. VENTING THROUGH AN EXISTING SYSTEM ................................................................................................................................................. 41

3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ............................................................................... 43

I. CONDENSATE REMOVAL SYSTEM ........................................................................................................................................ 45

PART 6 – FIELD WIRING .......................................................................................................................................................... 46

A. INSTALLATION MUST COMPLY WITH: .................................................................................................................................. 46

B. FIELD WIRING ................................................................................................................................................................ ......... 48

C. LINE VOLTAGE WIRING FOR STANDARD APPLIANCE ....................................................................................................... 48

D. THERMOSTAT ......................................................................................................................................................................... 48

E. OUTDOOR SENSOR (OPTIONAL) .......................................................................................................................................... 49

F. INDIRECT SENSOR (OPTIONAL) ........................................................................................................................................... 49

G. 0-10 VOLT BUILDING CONTROL SIGNAL (OPTIONAL) ........................................................................................................ 49

H. UL353 LOW WATER CUT-OFF INTERFACE KIT (OPTIONAL) .............................................................................................. 49

I. WIRING OF APPLIANCE ALARM (OPTIONAL) ........................................................................................................................ 49

J. VERSA-FLAME WIRING FOR DHW PRIORITY WITH ZONE VALVES OR CIRCULATORS .................................................. 49

1. WIRING WITH ZONE VALVES .......................................................................................................................................................................... 50

2. WIRING WITH ZONE CIRCULATOR PUMPS ................................................................................................................................................... 50

K. WIRING OF CASCADE SYSTEM COMMUNICATION BUS (PIONEER ONLY) ...................................................................... 51

L. CASCADE MASTER PUMP AND SENSOR WIRING (PIONEER ONLY) ................................................................................ 51

M. CASCADE FOLLOWER PUMP AND SENSOR WIRING (PIONEER ONLY) .......................................................................... 51

PART 7 – GAS CONNECTIONS ............................................................................................................................................... 52

A. GAS PIPING ............................................................................................................................................................................. 53

B. GAS TABLE .............................................................................................................................................................................. 53

C. GAS VALVE ............................................................................................................................................................................. 54

PART 8 – START-UP PREPARATION...................................................................................................................................... 54

A. CHECK FOR GAS LEAKS ....................................................................................................................................................... 55

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B. CHECK/CONTROL HYDRONIC WATER CHEMISTRY ........................................................................................................... 55

C. VERSA-FLAME DHW HEAT PACK WATER QUALITY ........................................................................................................... 55

D. FREEZE PROTECTION (WHEN USED) .................................................................................................................................. 56

E. FILL AND TEST WATER SYSTEM .......................................................................................................................................... 57

F. PURGE AIR FROM THE HYDRONIC SYSTEM (PIONEER AND VERSA-FLAME) ................................................................ 57

G. PURGE AIR FROM DHW SYSTEM (VERSA-FLAME) ............................................................................................................ 57

H. CHECK THERMOSTAT CIRCUIT(S) ....................................................................................................................................... 57

I. FINAL CHECKS BEFORE STARTING APPLIANCE ................................................................................................................. 57

PART 9 – START-UP PROCEDURE ......................................................................................................................................... 58

A. OPERATING INSTRUCTIONS ................................................................................................................................................. 58

B. CASCADE SYSTEM................................................................................................................................................................. 58

C. ADJUSTING THE SET POINT ................................................................................................................................................. 59

D. STATUS MENU ........................................................................................................................................................................ 60

E. COMBUSTION SYSTEM TEST MODE .................................................................................................................................... 61

F. PURGE AIR FROM SYSTEM ................................................................................................................................................... 61

PART 10 – PROGRAMMING THE APPLIANCE ....................................................................................................................... 61

A. PROGRAM ACCESS ............................................................................................................................................................... 61

B. PROGRAM SYSTEM SETTINGS............................................................................................................................................. 61

PART 11 – SHUTDOWN ............................................................................................................................................................ 64

A. SHUTDOWN PROCEDURE ..................................................................................................................................................... 64

B. VACATION PROCEDURE ....................................................................................................................................................... 64

C. FAILURE TO OPERATE .......................................................................................................................................................... 64

PART 12 – TROUBLESHOOTING ............................................................................................................................................ 64

A. APPLIANCE ERROR CODE .................................................................................................................................................... 64

B. APPLIANCE ERROR ................................................................................................................................................................ 64

C. APPLIANCE FAULT ................................................................................................................................................................. 64

D. NO HOT WATER (DHW) (VERSA-FLAME) ............................................................................................................................. 64

PART 13 – MAINTENANCE ...................................................................................................................................................... 69

MAINTENANCE NOTES........................................................................................................................................................................................ 73

HTP CUSTOMER INSTALLATION RECORD FORM ............................................................................................................................................. 74

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Front must have room for service, 24” recommended. (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. Category IV vent systems only.

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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.

Be sure to disconnect electrical power before opening appliance cabinet. Failure to do so could result in an electrical shock that could result in serious injury or death.

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. IMPROPER COMBUSTION

C. GAS

Should overheating 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.

D. WHEN SERVICING THE APPLIANCE

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

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E. APPLIANCE SYSTEM

 Thoroughly flush the system (without appliance connected) to

remove sediment. The appliance can be damaged by build-up or corrosion due to sediment. HTP recommends a suction strainer in all systems.

 Do not use petroleum-based cleaning or sealing compounds in

the system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

 Do not use “homemade cures” or “patent medicines”. Substantial

property damage, damage to the appliance, and/or serious personal injury may result.

 Continual fresh make-up water will reduce appliance life. Mineral

buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen from make-up water can cause internal corrosion in system components. Leaks in the appliance or piping must be repaired at once.

F. CHECK/CONTROL HYDRONIC WATER CHEMISTRY

Water pH between 6.0 and 8.0

1. Maintain appliance water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by a water treatment company.

2. If the pH differs from above, consult local a water treatment company for treatment required.

Hardness less than 7 grains

Consult local water treatment companies in circumstances of unusually hard water (above 7 grains hardness).

Chlorine concentration less than 100 ppm

1. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm.

2. Do not use the appliance to directly heat swimming pool or spa water.

3. Do not fill appliance or operate with water containing chlorine in excess of 100 ppm.

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Chemical imbalance of your water can cause severe damage to your appliance and associated equipment, and may also affect efficiency. You may have to have your water quality professionally analyzed to determine whether you need 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. Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years. Failure of a heat exchanger due to lime scale build-up on the

heating surface, low pH or other imbalance IS NOT covered by the warranty.

NEVER use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems, with this appliance. Use only

inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Clean system to remove sediment

1. You must thoroughly flush the system (without the appliance connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment.

2. For zoned systems, flush each zone separately through a purge valve. (If purge valves and isolation valves are not already installed, install them to properly clean the system.)

3. Flush system until water runs clean and you are sure piping is free of sediment.

G. VERSA-FLAME DHW HEAT PACK WATER QUALITY

Water Hardness

Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water. The concentration of these salts is expressed in mg/L, ppm or grains per gallon, as a measure of relative hardness of water. 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 when the water is heated and cause accelerated lime and scale accumulation on a heat transfer surface.

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 a water heater. 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

H. FREEZE PROTECTION FLUIDS AND WINTERIZING

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Consider appliance piping and installation when determining appliance location. Do not place the appliance in an area where it will be prone to freezing.

To winterize the appliance, drain the entire system. Pump two gallons of non-toxic, NSF food grade, FDA rated GRAS (Generally Recognized As Safe) propylene glycol into the tank. Consult the glycol manufacturer for specific instructions on concentration percentage as well as freeze and burst protection methods. Check the concentration of antifreeze to assure protection is adequate to protect the bottom of the appliance from freezing.

NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty.

PART 2 – BEFORE YOU START

A. WHAT’S IN THE BOX

Also included with the appliance:

 Pressure and Temperature Gauge  30 psi Temperature and Pressure Relief Valve  Intake PVC Tee with Screens  Exhaust PVC Coupling with Screens  Installation Manual  Warranty  Outdoor Sensor (Part # 7250P-319)

B. HOW THE APPLIANCE OPERATES

Condensing Technology maximizes efficiency by measuring the needs of your heating system through the use of sensors and a control unit. The appliance uses data gathered by these sensors to intelligently deliver highly efficient hydronic heating.

Heat Exchanger

The highly efficient combustion heat exchanger flows exhaust gas through the primary section into the secondary heat exchanger section, where the coldest water on the bottom of the tank extracts the last residual amount of energy.

Modulating Combustion System

Modulation during central heating operation is based on the supply temperature. The set point used for the control depends upon the programmed central heating curve. The slope of the heating curve can be changed by the installer. The control monitors the system, regulating burner output during operation to match system demand, effectively increasing efficiency and providing substantial fuel savings.

Gas Valve

The gas valve senses suction from the blower, allowing gas to flow only if combustion air is flowing.

Swirl Plate System

The Swirl Plate on the gas valve controls air and gas flow into the burner, assuring better mixing for improved combustion.

Combination Top High Temperature Sensor

This sensor monitors supply temperature. The control module adjusts appliance firing rate, correcting supply temperature.

Bottom Water Temperature Sensor

This sensor monitors return water temperature. The control module reduces or increases appliance input accordingly.

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Control

The integrated control system monitors return and supply water temperature. The control system regulates the unit’s BTU output by controlling fan speed, allowing the unit to deliver only the amount of heated energy required.

Burner

Constructed with metal fiber and stainless steel, the burner uses pre-mixed air and gas, providing a wide range of firing rates.

Electrical Field Connections with Terminal Strips

The cabinet allows easy access to the line voltage and low voltage terminal strips, which are clearly marked to facilitate wiring to the appliance.

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To control the temperature of low temperature heating circuits when using an indirect fired water appliance, a thermostatic mixing valve is required. Failure to install a thermostatic mixing valve could result in property damage.

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. The 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 554200, available from HTP).

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

It is also very important that the condensate line is not 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.

A second vent may be necessary to prevent a condensate line vacuum lock in a long, horizontal line. Also, an increase in pipe size may be necessary to drain properly. Support of the condensation line may be needed to avoid blockage of flow.

Spark Ignition

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

Outdoor Sensor

The outdoor sensor allows the installer to make the appliance even more efficient by basing temperature delivered to the central heating circuits on outdoor temperature. (See Optional Equipment, Section C).

(Optional) Indirect Tank Sensor – Indirect Priority

The indirect sensor allows the installer to operate the appliance with two temperatures: one for central heating and the other for the SuperStor Indirect Water Appliance. This allows the user to increase water temperature supplied to the indirect to get faster recovery by prioritizing flow at a higher rate than may be needed for central heating. NOTE: This application requires two separate circulators. (See Optional Equipment, Section C).

VERSA-FLAME DHW MODULE

The Versa-Flame combines all of the capabilities of the Pioneer with an integrated domestic hot water (DHW) module built into the appliance. Features include:

Brazed Plate Heat Exchanger

When the system calls for DHW, hot heat transfer fluid is drawn from the top of the appliance through the brazed plate heat exchanger. The heat exchanger consists of a series of thin corrugated plates brazed together in counter flow channels of alternating hot and cold fluids. This counter flow system provides optimal heat transfer to the DHW system.

Circulation Pump

Draws hot heat transfer fluid from the top of the appliance through the brazed plate heat exchanger and returns the cooler heat transfer fluid to the bottom of the appliance.

Flow Switch

Senses flow into the brazed plate heat exchanger and turns on the pump when flow is greater than .5 gpm. The flow switch will shut down the pump when flow is less than .5 gpm.

Thermostatic Mixing Valve

Accurately controls the temperature of DHW by mixing cold water with the hot water leaving the heat exchanger. The installer can adjust DHW temperature by manually adjusting the valve.

C. OPTIONAL EQUIPMENT

Below is a list of optional equipment available from HTP:

 System Sensor (Part # 7250P-324)  Indirect Tank Sensor (Part # 7250P-325)  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)

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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, 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.

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.

 3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)  U.L. 353 Compliant Low Water Cut-Off Interface Kit with Manual Reset (Part # 7350P-601)  Alarm System (Part # 7350P-602) (to monitor any failure)  PC Connection Kit (Part # 7250P-320)  Condensate Neutralizer (Part # 7450P-212)  Vision 2 Temperature Mixing Control (Part # 7250P-322)

These additional options may be purchased through your HTP distributor. 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

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.

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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 appliance when filled with water (650 lbs).

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the appliance. The appliance cover must be securely fastened to prevent the appliance from drawing air form the appliance room. This is particularly important if the appliance is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

Figure 1 – Recommended Service Clearances

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

If you do not provide the minimum clearances shown, it may not be possible to service the appliance without removing it from the space.

D. RESIDENTIAL GARAGE INSTALLATION

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

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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.

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

 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.

 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 5 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 21 for installation diagram.

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 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 5 of this manual.

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Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty, and may result in severe personal injury or death.

Failure to provide an adequate fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death. To prevent combustion air contamination, see Table 1.

Ensure that the intake air will not contain any of the contaminants listed in Table 1. 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.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing 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).

Figure 2 - CO Warning Label

F. PREVENT COMBUSTION AIR CONTAMINATION

Install intake air 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

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

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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.

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Figure 3 – Dimensions

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UNCRATING APPLIANCE – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Remove all sides of the shipping crate to allow the appliance to be lifted into its installation location.

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

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

The building piping system must meet or exceed the piping requirements in this manual.

Use two wrenches when tightening water piping at the appliance. Use one wrench to prevent the appliance return or supply line from turning. Failure to prevent piping connections from turning could cause damage to appliance components.

The appliance control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the water level in the appliance. Some codes/jurisdictions may require additional external controls.

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 appliance or in the discharge line. Do not plug or place any

obstruction in the discharge line.

 Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve

discharges freely. If the valve fails to operate correctly, replace with a new properly rated relief valve.

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.

Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or boiler. Failure to follow this instruction can lead to premature failure of the boiler system. Such failures ARE NOT covered by warranty.

PART 4 – PIPING

Plumbing of this appliance should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The appliance may be connected to an indirect storage tank to supply domestic hot water. HTP offers 30/45/60/80/119 gallon size indirect storage tanks in Stainless Steel or 50/80/119 in Glass Lined construction. These indirect storage tanks will be directly connected to the supply and return connection.

A. GENERAL PIPING INFORMATION

B. RELIEF VALVE

Install supplied pressure and temperature relief valve. Connect discharge piping to a safe disposal location, following the guidelines on the next page. Replacement is available. See parts list.

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Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual appliance failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY.

DO NOT install automatic air vents on closed type expansion tank systems. Air must remain in the system and return to the tank to provide an air cushion. An automatic air vent would cause air to leave the system, resulting in improper operation of the expansion tank.

To control the temperature of low temperature heating circuits when using an indirect fired water heater, a thermostatic mixing valve is required. Failure to install a thermostatic mixing valve when using an indirect fired water heater could result in damage the heating circuits. Such damage IS NOT covered by warranty.

C. BACKFLOW PREVENTER

Use a backflow preventer specifically designed for hydronic appliance installations. This valve should be installed on the cold water fill supply line per local codes (see Piping Details).

D. SYSTEM WATER PIPING METHODS

EXPANSION TANK AND MAKE-UP WATER

1. Ensure that the expansion tank is sized to correctly handle appliance and system water volume and temperature. The appliance volume is 55 gallons.

2. The expansion tank must be located as shown in the Appliance Piping Details, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

3. Connect the expansion tank on the suction side of the circulator. Always install the system fill connection at the same point as the expansion tank connection to the system.

4. Most chilled water systems are piped using a closed type expansion tank.

E. CIRCULATOR PUMPS

SIZING SPACE HEAT SYSTEM PIPING

1. See piping details in this manual. Special attention must be paid when connecting an indirect storage tank, as temperature delivered to low temperature circuits may be higher than desired. The use of thermostatic mixing valves is required to protect these circuits.

2. Size the piping and components in the space heating system using recognized design methods.

F. DHW HEAT PACK AND INDIRECT WATER HEATER SCALDING

These appliances can deliver scalding water. Be careful whenever using hot water to avoid scalding injury. Certain appliances, such as dishwashers and automatic clothes washers may require increased water temperature. By setting the thermostat on this appliance to obtain the increased water temperature required by these appliances, you may create the potential for scald injury.

To protect against injury, you should install a mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

Table 2 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

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Table 2

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

G. HYDRONIC PIPING - CIRCULATORS, ZONE VALVES AND MULTIPLE APPLIANCES

This appliance is designed to function in a closed loop 15 PSI System. A factory installed low water cut off will ensure that you have adequate water in the system. We have also included a T&P gauge which allows the user to monitor system pressure and outlet temperature from the appliance.

Install the appliance so the gas ignition system components are protected from water (dripping, spraying, etc.) allowing clearance for basic service of circulator replacement, valves and other parts. Observe minimum 1” clearance around all hot water pipes not protected by non-combustible materials.

On an appliance installed above radiation level, some states and local codes require a low water cut off device at the time of installation. If the appliance supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of appliance water in the coils during the cooling cycle. Chilled water medium must be piped in parallel with the appliance.

Basic steps are listed below which will guide you through the installation of the appliance.

1. Connect the system return marked “Return”.

2. Connect the system supply marked “Supply”.

3. Install purge and balance valve or shut off valve and drain on system return to purge air out of each zone.

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 nominal on the system return). Check temperature and pressure gauge which should read minimum pressure of 12 PSI.

6. Install a circulator as shown in piping details (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 manufacturer instructions for specific information relating to expansion tank installation. Size the expansion tank for the required system volume and capacity.

8. Install supply air vent to remove air when commissioning the appliance.

9. The safety relief valve is supplied with the appliance, and must be installed on the top ¾” NPT fitting marked “T&P”. Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Discharge 6” above the drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of safety relief valve.

H. FILL AND PURGE HEATING SYSTEM

 Attach the hose to either balance or purge hose connector or drain valve and run hose to nearest drain.  Close the other side of the balance and purge valve or the shut off valve after the drain.  Open first zone balance and purge or drain valve to let water flow out the hose. If zone valves are used, open the valves one

at a time manually. (NOTE: You should check valve manufacturer instruction prior to opening valves manually, so as not to damage any valves.)

 Manually operate fill valve regulator. When water runs out of the hose, while it’s connected to the balance and purge valve or

drain you will see a steady stream of water (without bubbles). Close balance and purge valve or drain to stop the water from flowing. Disconnect the hose and connect it to next zone to be purged.

 Repeat this procedure for additional zones (one at a time).

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For installation that incorporates standing iron radiation and systems with manual vents at high points, follow above section and, starting with the nearest manual air vent, open until water flows out. Then close vent. Repeat procedure, working your way toward furthest air vent.

NOTE: It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present. Annual cleaning of strainer may be necessary.

Use only inhibited propylene glycol solutions which are FDA RATED AS GRAS and specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

It is highly recommended that you carefully follow glycol manufacturer recommended concentrations, expansion requirements, and maintenance recommendations (pH additive break down, inhibitor reduction, etc.) You must carefully figure the additional friction loss in the system as well as the reduction in heat transfer coefficients.

Upon completion, make sure that the fill valve is in automatic position and each zone balance and purge or shut off is in an open position and zone valves are set for automatic operation.

Glycol in hydronic applications includes inhibitors that prevent it from attacking metallic system components. Make certain that system fluid is checked for the correct glycol concentration and inhibitor level.

The glycol solution should be tested at least once a year, or as recommended by the glycol manufacturer. Anti-freeze solutions expand more than water. For example: A 50% by volume glycol solution expands 4.8% in volume during a

temperature increase from 32oF to 180oF, while water expands 3% over the same temperature rise. Allowances must be made for expansion in system design.

A 30% mixture of glycol results in a BTU output loss of 15% with a 5% increase in head against the system circulator. A 50% glycol mixture results in a BTU output loss of 30% with a 50% increase in head against the system circulator.

I. ZONING WITH ZONE VALVES

1. Connect appliance to system as shown in the Piping Details diagrams. Properly size circulators for friction loss of zone valves and piping for proper operation.

2. Connect DHW (domestic hot water) piping to indirect storage water appliance as shown.

J. ZONING WITH CIRCULATORS

1. Connect appliance to system as shown in the Piping Details diagrams. Properly size each zone circulator for friction loss of each zone for proper operation.

2. Install a separate circulator for each zone.

3. Connect DHW piping to indirect storage water appliance as shown.

K. MULTIPLE APPLIANCES

1. All piping shown is reverse return to assure balanced flow through the connected appliances.

2. Connect DHW piping to indirect storage water appliance as shown.

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L. CENTRAL HEATING PIPING DETAIL

Figure 4 –Central Heating Detail – LP-325-F

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. The minimum pipe size for connecting a SuperStor Ultra Indirect Water Appliance is 1-inch.

3. The minimum pipe size for connecting the appliance is 1.25-inch

4. Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.

5. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F.

6. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

7. Winterization: When winterizing, put a drain valve on both the supply and return between the union and the shut-off connection.

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Figure 5 – Appliance with Indirect Water Heater Detail*

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. The minimum pipe size for connecting a SuperStor Ultra Indirect Water Appliance is 1-inch.

3. The minimum pipe size for connecting the appliance is 1.25-inch

5. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F.

6. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

7. Winterization: When winterizing, put a drain valve on both the supply and return between the union and the shut-off connection.

8. If a backflow preventer or no return valve is installed, a thermal expansion tank is required on the cold water inlet between the water heating appliance and the backflow preventer.

*THIS INSTALLATION IS SUITABLE FOR PIONEER HEATING APPLIANCES ONLY.

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

Figure 6 – Cascaded System

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. The minimum pipe size for connecting a SuperStor Ultra Indirect Water Appliance is 1-inch.

3. The minimum pipe size for connecting the appliance is 1.25-inch

5. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F.

6. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

7. Winterization: When winterizing, put a drain valve on both the supply and return between the union and the shut-off connection.

M. PIPING INTO THE DHW PACK ON THE VERSA-FLAME

Domestic water connections must be installed in accordance with all local and national plumbing codes or any applicable prevailing standards. The domestic inlet and outlet ports on the brazed plate heat exchanger are ¾” 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 appliance connections.

An approved ASSE 1017 mixing valve is provided with every appliance and must be installed on the domestic outlet to assure that hot water temperature does not vary more than +/– 5°F 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

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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!

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.

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 3

the user from scalding temperature. To properly install and set up the mixing valve, follow the pre-installation steps in this manual and 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.

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)

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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.

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.

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 7 – 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.

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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.

O. VERSA-FLAME DHW PERFORMANCE

Figure 8 – DHW Pack Performance on 130K BTU Models

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Figure 9 – DHW Pack Performance on 199K BTU Models

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P. DHW PIPING WITH THE VERSA-FLAME

Figure 10 – Versa-Flame Standard Installation

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F.

3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

4. A pressure relief valve or T&P valve may be required. Check with local codes.

5. This drawing refers to DHW piping only. For Central Heating piping, please refer to Part 5, Section L.

6. Winterization: When winterizing, pump a small amount of food grade glycol, FDA rated as GRAS (Generally Recognized As Safe) into the brazed plate heat exchanger.

7. In Massachusetts, a vacuum relief valve must be installed on the cold water line per 248 CMR.

8. If a backflow preventer or no return valve is installed, a thermal expansion tank is required on the cold water inlet between the water heating appliance and the backflow preventer.

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Figure 11 – Versa-Flame with Re-Circulating Line

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. A mixing valve is recommended if the DHW temperature is set above the factory setting of 119°F.

3. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

4. A pressure relief valve or T&P valve may be required. Check with local codes.

5. This drawing refers to DHW piping only. For Central Heating piping, please refer to Part 5, Section L.

6. Winterization: When winterizing, pump a small amount of food grade glycol, FDA rated as GRAS (Generally Recognized As Safe) into the brazed plate heat exchanger.

7. In Massachusetts, a vacuum relief valve must be installed on the cold water line per 248 CMR.

8. Recirculator pump must be sized to flow 0.6 GPM or greater to the appliance.

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Figure 12 – Versa-Flame with Storage Tank NOTES: