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MC Series Gas-Fired Circulating Heater

1. iS MUNCHKIN CONTENDER HEATER DIMENSIONS AND SPECIFICATIONS RUE A B c op t F J K L mM oN RELEE LOW HIGH FIRE PIPE PIPE SIZE CONN VOLUME 18 000 50 000 12 50 27 50 7 00 2 75 5 25 9 00 17 25 5 50 2 75 75 1 25 75 58 94 71 LBS 19 000 80 000 12 50 27 50 7 00 2 75 5 25 9 00 17 25 5 50 2 75 75 125 75 67 93 44 000 99 000 13 50 27 50 7 00 2 75 6 50 10 25 17 25 5 50 2 75 75 1 25 75 196 92 44 000 120 000 13 50 27 50 7 00 2 75 6 50 10 25 17 25 5 50 275 75 1 25 96 1 Tested to the ANSI ASHRA Standard 103 2 Tested to the ANSI ASHRAE Standard 103 with 90 return and 110 supply water Figure 1 Specifications LP 171 B Before considering location many factors need to be addressed Piping Venting and Condensation Removal are just a few of the issues that need attention prior to the installation of the heater Please read the entire manual as it could save time and money B LEVELING CAUTION In order for the condensate to properly flow out of the collection system the heater must be installed level The location
2. WARNING 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 DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE When installing a direct vent combustion air must be drawn from the outdoors directly into the appliance intake and exhaust must terminate outside There are two basic direct vent options detailed in this manual 1 Side Wall Venting and 2 Roof 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 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 WARNING 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 o
3. NOTE to H Provide 4 feet clearance from center line within a height of 15 feet above electrical meters gas meters gas regulators relief equipment exhaust fans and I Provide 4 feet horizontal clearance from electrical meters gas meters gas Always read and understand instruction manual regulators relief equipment exhaust fans and inlets In no case shall the exit LR 304 4 28 09 terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained J This water heater vent system shall terminate at least 3 feet 0 9 m above any forced air intake located within 10 ft 3 m NOTE This does not apply to the combustion air intake of a direct vent appliance K When venting with a two pipe system maximum distance between exhaust vent and intake pipe is 6 feet 1 8 m Minimum distance between exhaust vent and intake pipe on single direct vented appliance is 10 0 255 m center to center Minimum distance between exhaust vents and intake pipes on multiple water heaters is 10 0 255 m center to center L When adjacent to a public walkway locate exit terminal at least 7 feet above grade p chemical vapor emitting prod near unit According to NFPA 720 carbon monoxide detectors should be installed outside each sleeping area In addition e Total length of vent piping shall not exceed the limits specified in this manual e The vent piping for this direc
4. Use a backflow preventer specifically designed for hydronic heater installations This valve should be installed on the cold water fill supply line per local codes See piping details at the end of this section CAUTION All piping methods shown in this manual use primary secondary connection to the heater loop This is to avoid the possibility of noise or actuator problems in zone valves because of the high head heater circulator For other piping methods consult your local HTP representative or refer to separate piping details in this manual E SYSTEM WATER PIPING METHODS EXPANSION TANK AND MAKE UP WATER 1 Ensure expansion tank size will handle heater and system water volume and temperature Allow 3 gallons for the heater and its piping WARNING Expansion tanks must be sized according to total system volume This includes all length of pipe all fixtures appliances etc Failure to properly size system expansion could result in wasted time money and possible property damage personal injury or death CAUTION Undersized expansion tanks cause system water to be lost from relief valve and make up water to be added through fill valve Eventual failure can result due to excessive make up water addition SUCH FAILURE IS NOT COVERED BY WARRANTY 2 Expansion tank must be located as shown in Piping diagrams or following recognized design methods See tank manufacturer s instructions for detai
5. CAUTION Use a two wrench method when tightening gas piping near the heater and its piping connection One wrench to prevent the heater gas line connection from turning the second to tighten the adjacent piping Failure to support the heater gas piping connection could damage the heater beyond repair Such damage IS NOT covered by warranty C CHECK INLET GAS PRESSURE The gas valve is equipped with an inlet gas pressure tap that can be used to measure the gas pressure to the heater To check gas pressure perform the steps listed below 1 IMPORTANT Before you connect to the inlet pressure shut off the gas and electrical power to heater 2 Loosen the pressure tap with a small screwdriver Refer to Figure 29 for location 3 Each heater is equipped with a needle valve that will accept a 5 16 ID hose to connect to a digital manometer or liquid gauge designed to measure incoming pressure from 0 35 w c See Figure 29 4 Turn on the gas and power up the heater 5 Put the heater into manual test mode details on test mode are in Part 12 Section D In service mode monitor pressure to assure it does not drop below 1 inch from its idle reading If gas pressure is out of range or pressure drop is excessive contact the gas utility gas supplier qualified installer or service agency to determine correct action that is needed to provide proper gas pressure to the heater If Gas Pressure is within normal range proceed to Step 6 6
6. 68 D MAINTENANCE SCHEDULE FOR THE 2 444 2204 4000 00 0 000000 etnies 69 HEATER START UP REPORT ccssssssssscssessssesnssscssnscesssenscensessuenssunaesnacsenesnssanseansenansascauseesteanssanssanesanessaasancentenasssansnasauacanseansn 74 LEY epylediidue P 74 MAINTENANCE NOTES rcnt dee bo iet te dede dd te dedi dde Da ed Le de ea De ee ete Pee ett nre eed eek Deae de dad HTP CUSTOMER INSTALLATION RECORD esi PART 1 GENERAL SAFETY INFORMATION A PRECAUTIONS This heater is for indoor installations only Clearance to combustible materials O top bottom sides and back Front must have room for service 24 recommended A combustible door or removable panel is acceptable front clearance This heater has been approved for closet installation This heater is designed to be wall mounted Do not install on the floor Category IV vent systems only WARNING 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 Refer to user s information manual for your reference Have this heater serviced inspected by a qualified service technician annually FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS HEATER SERVICED INSPECT
7. Je Di optional high limit safety see note 6 L A JU Ay Da 2 De po AP A IT differential um pressure make up water A gt 1 Mac a 1 Dal a in MC SERIES Heater ILL Sensor Vision 1 system temperature sensor Vision 1 system Super Stor Ultra Indirect DHW Tank w drain plug Figure 14 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on
8. structurally support a large amount of weight seeping area Opere the ud unless it is 5 Purge all gas lines thoroughly to avoid start up issues with air in the Analyze the entire vent s to make li sure that condensate will not become Ines trapped in a section of vent pipe and Sectonal area of ihe vent 6 Sealing compound pipe dope must be used and approved for gas connections Apply sparingly and only to the male threads Care must be bn o 5 1 7 m ese hans Quin te Pai inet taken when applying compound to prevent blockage or obstruction of gas LR304 4 28 09 flow which may affect the operation of the heater WARNING Failure to apply pipe sealing compound as detailed above could result in substantial property damage severe personal injury or death CAUTION CSA UL listed flexible gas connections can be used when installing the heater Flexible gas connections have different capacities and must be sized correctly for the connected heater firing rates Consult with the flex line supplier to assure the line size is adequate for the job Follow local codes for proper installation and service requirements WARNING Never use an open flame match or lighter to check for gas leaks Use a soapy solution to test connection Failure to use a soapy solution test or check gas connection for leaks could result in substantial property damage severe personal injury or death
9. Series Gas Fired Circulating Heater ee N N INSTALLATION START UP MAINTENANCE PARTS Models MC50 MC80 MC99 MC120 ULTRA 4 Low NOx us Emissions Liste SCAQMD Rule 1146 2 CAUTION When installing models manufactured after July 7 2008 you will notice additional selections on the control installer menu that will not apply to this unit DO NOT CHANGE THESE FACTORY SETTINGS Refer to the Control Program Reference Chart within this manual for selections that apply to this model DA R This manual must be used by a qualified installer service technician Read all instructions in this manual before installing Perform steps in the given order Failure to comply could result in substantial property damage severe personal injury or death NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature NOTE TO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 120 Braley Rd P O Box 429 East Freetown MA 02717 0429 www htproducts com LP 171 Rev 3 3 15 WARNING IF THE INFORMATION THIS MANUAL IS FOLLOWED EXACTLY A FIRE 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 HEATER WHAT TO DO IF YOU SMELL GAS Do not try
10. Vision 1 system thermal trap Super Stor Ultra Indirect DHW Tank w drain plug Figure 12 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 30 MC Series Heater with optional VISION 1 system Drawing 2B zoning with valves Domestic water heating mode MC SERIES Heater mixing valve DHW temperature _ sensor Vision 1 syst
11. This number is the factory set point of the unit which is 180 degrees To change the temperature simply push either or on the display decreases and increases the heater temperature The temperature of the heater can be set as low as 50 Degrees or as high 180 Degrees These ranges are your minimum and maximum heater temperature ranges In addition to changing the temperature you may also change three more settings in this model 1 heater differential 2 indirect setting with Vision System option and 3 Celsius to Fahrenheit measurement Simply press to get to next value the heater differential setting will appear in the display ch and alternating value of 30 This allows the installer to adjust the activation of the burner based on the differential temperature setting of the heater The burner will not start until the outlet water temperature reaches a temperature equal to the setting for the heater minus the differential EX The heater is set to heat at 180 F degrees and the differential is set at 30 F The burner will not start until the outlet temperature of the system reaches 149 F degrees 180 30 F 150 F LP 171 Rev 3 3 15 62 adjust press either Decrease Value or Increase Value Ranges 5 F to 30 F Press again and you will see the Indirect Setting de and an alternative value of 119 with Vision Systems option To adjust press either Decrease Value or S Increase Value The final
12. 3 3 15 69 2 Using spray bottle filled with calcium and lime deposit remover spray liberally on the coils making sure the solution penetrates and funnels down through the condensate hose If the condensate hose is blocked let the chemical penetrate for at least 15 minutes or until it drains 3 Use the nylon stainless or brass brush do not use steel and scrub coils to remove any buildup Then vacuum the debris from the coils WARNING Follow above precautions 4 Spray the coils with clear water making sure to confine the spray to the area being cleaned try to avoid getting the back ceramic wall of the unit wet Flush the combustion chamber with fresh water At this point the heater should be ready to power back up Before powering up the heater follow the steps below a Re install the burner assembly b Replace the 4 10MM nuts to the burner plate c Re connect all wiring connections e Replace the 4 screws on the aluminum NPT connector on the gas valve Turn the gas back on IMPORTANT CHECK FOR GAS LEAKS f Re set thermostats IMPORTANT MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED 9 Turn the heater back on and observe condensate flow h Re connect the condensate hose to the outside connection WARNING Do not use solvents to clean any of the burner components The components could be damaged resulting in unreliable or unsafe operation Failure to do so could result in death or serious inju
13. AND COUPLING EXHAUST SCREEN PROVIDED INTO AND COUPLING EXHAUST STRAGI SOUS INSERT INLET EXHAUST SCREENS PROVIDED INTO EACH END OF TEE INSERT INLET EXHAUST EXTERIOR WALL INSERT INLET EXHAUST SCREEN PROVIDED INTO mac SCREENS PROVIDED INTO STRAIGHT COUPLING EACH END OF TEE COUPLING 12 OVER MAXIMUM SNOW LEVEL OR 24 NIKE WHICHEVER IS GREATER A D MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST BATONS ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP be LP 505 A LP 445 G 11 24 14 07 30 14 RIGHT SIDE VIEW INTAKE AIR VENT Figure 26 Two Pipe Roof and Sidewall Venting with Included Equipment Tee and Coupling NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WARNING vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three feet from the heater LP 171 Rev 3 3 15 48 ROOF VENTING WITH SIDEWALL VENTING WITH KIT CONCENTRIC VEN
14. Exit test mode then turn power off and shut off gas supply at the manual gas valve before disconnecting the hose from the gas monitoring device Tighten screw on the pressure tap and turn gas on Check for leaks with soapy solution Bubbles will appear on the pipe to indicate a leak is present LP 171 Rev 3 3 15 51 WARNING Ensure the pressure tap screw is properly tightened to prevent gas leaks Failure to do so could cause substantial property damage severe personal injury or death The gas piping must be sized for the proper flow and length of pipe to avoid pressure drop The gas meter and regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 w c 87 kPa the meter regulator or gas line may be undersized or in need of service You can attach a manometer to the incoming gas drip leg after removing the cap The gas pressure must remain between 3 5 87 kPa and 14 3 5 kPa during stand by static mode and while in operating dynamic mode If an in line high gas pressure regulator is used it must be installed a minimum of 10 feet from the heater It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition failure This problem is especially noticeable in NEW LP installations and empty tank situations This situation can also occur when a utility c
15. LP 171 Rev 3 3 15 SPECIAL ATTENTION BOXES 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 DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION 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 MC Series Gas Fired Heater 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 Jurisd
16. SENSOR OUT BUS COMMON BUS A RED BLUE BUS B auk BLuE DHW P2 Incoming LINE VOLT 4 Neutral CH PUMP P1 Hot CH PUMP P1 Neutral DHW PUMP P2 Hot DHW PUMP P2 FLOW SWITCH FIELD CONNECTIONS LOW VOLTAGE MC SERIES Internal Wiring Diagram BUS LINE COMMON OUTLET TEMP THERMISTOR FLOW SWITCH OR INDIRECT SENSOR 4 INLET TEMP THERMISTOR T STAT 8a 3 OPEN CONDENSATE SWITCH BLOCKED VENT PRES SWITCH m OPEN WATER PRES SWITCH BOILER LIMIT FUSE FLUE ECO BUS LINE B E BUS LINE INLET TEMP THERMISTOR FLOW SWITCH OR INDIRECT SENSOR OUTLET TEMP THERMISTOR EM t OPEN OUTDOOR SENSOR OUTDOOR SENSOR COMBUSTION BLOWER COMBUSTION BLOWER COMBUSTION BLOWER COMBUSTION BLOWER HIGH LIMIT SENSOR ECO WATER ECO WATER HIGH LIMIT SENSOR BOILER LIMIT FUSE FLUE ECO GAS VALVE CONDENSATE SWITCH BLOCKED VENT PRES SWITCH GAS VALVE RED WATER PRES SWITCH mT STAT COMBUSTION BLOWER hot COMBUSTION BLOWER neutral DHW PUMP DHW PUMP ALARM CENTRAL HEATING PUMP 07 COMB BLOWER GROUND SE UTILITY GROUND CENTRAL HEATING PUMP PET X6 4 GROUND BUS CH P1 GROUND FLAME RECTIFICATION PROBE 4 3 6 DHW P2 GROUND LINE VOLTAGE NEUTRAL OPEN GROUND BUS FLAME RECTIFICATION PROBE LP 171 L 01 25 13 Figure 31 NOTE A re
17. The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 24 Standard MC Series Heater Drawing 1C Preferred piping zoning with circulators Space heating mode space heating zone circuit see note 6 mixing valve MC SERIES i i er Super Stor Ultra indirect DHW Tank Figure 8 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation fla
18. of F To change value press or to choose the correct measurement adjustment in this mode is the Fahrenheit to Celsius measurement Press again and you will see t and alternating value C STATUS MENU Installers are also able to check the current status of heater parameters by pressing Iii for seconds Once activated the display will show alternating value of the actual outlet temperature Actual values are displayed for each function To view the next value press to go to the next displayed value Listed below are the values which can be displayed These values cannot be changed To exit this menu simply press to resume normal operation Function Value di Actual Temperature from outlet sensor d2 Actual Temperature from inlet sensor d3 If using a standard mechanical control the control will display J for closed for open If the sensor is connected to the SuperStor Indirect Fired Water Heater it will measure the actual temperature Vision option Function Value d4 Not used d5 Actual Temperature from the outdoor sensor Vision option d6 Actual Fan speed multiplied by 10 Example If fan speed displayed is RPM x 10 4100 actual fan speed d7 Actual lonization current read from Flame Rectification probe d8 Actual Status of the Central Heating Circulator Off On J Vision option d9 Actual Status of the Indirect Fired Circulator Off IN On Vision option d10
19. 1 for Canada Exit Terminals for Direct Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION FIGURE 22 NOTES A Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation level Snow removal may be necessary to maintain clearance B Provide a minimum of 1 foot distance from exhaust vent termination to any door operable window or gravity intake into any building C Provide a minimum of 1 foot distance from exhaust vent termination to any Breathing Hazard Carbon Monoxide Gas permanently closed door or window Do not operate heater if flood damaged D Provide a minimum of 4 feet vertical clearance from the exhaust vent to all Install vent system in accordance with local codes roof overhangs MM installation instructions E Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather and could result in blockage of the exhaust vent To prevent icicles from forming maintain 4 feet vertical clearance from the exhaust vent to all roof overhangs F Provide 4 feet clearance from the outside corner of vertical walls chimneys etc as well as horizontal corners created by roof overhangs Never operate the hoster unless K ie G Provide 6 feet clearance from the inside corner of vertical walls chimneys vented to the outdoors etc as well as horizontal corners created by roof overhangs s Anse HH
20. 3 5 WC and 14 WC during stand by static mode and while in operating dynamic mode at full output If an in line regulator is used it must be a minimum of 10 feet from the heater It is very important that the gas line is properly purged by the gas supplier or utility Failure to properly purge the lines or improper line sizing will result in ignition failure This problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines The gas valve must not be replaced with a conventional gas valve under any circumstances As an additional safety feature the gas valve in this heater has a flanged connection to the swirl plate and blower LP 171 Rev 3 3 15 GAS PIPING 1 Run the gas supply line in accordance with all applicable codes not operate heater if flood darnaged 2 Locate and install manual shutoff valves in accordance with state and Vand local es and ufacturers local requirements installation instructions Do not obstruct heater air intake or 3 In Canada the Manual Shutoff must be identified by the installing contractor Do not place chemical vapor emitti products near unit 4 It is important to support gas piping as the heater is not designed to pha 10 NEPA 730 Garbon
21. 6 0 and 8 0 1 Maintain heater water pH between 6 0 and 8 0 Check with litmus paper or have chemically analyzed by water treatment company 2 If pH differs from above consult local water treatment company for treatment needed Hardness less than 7 grains Consult local water treatment companies for unusually hard water areas 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 heater to directly heat swimming pool or spa water 3 Do not fill heater or operate with water containing chlorine in excess of 100 ppm Clean system to remove sediment 1 You must thoroughly flush the system without heater 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 Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions to verify inhibitor level and that other fluid characteristics are satisfactory 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over ti
22. UP PROCEDURES WITH VISION 1 OPTION The Vision option allows the user to have one temperature for central heating and another temperature for the SuperStor Ultra Indirect Fired Water Heater This enables the user to increase the temperature supplied to the indirect water heater by prioritizing flow at a higher temperature than may be needed for the central heating circuits this will require two separate circulators Once the indirect LP 171 Rev 3 3 15 63 water heater is satisfied the Vision system will switch back to the central heating circuit to continue to heat the living space temperature based on outside temperature This gives you a higher comfort level and further increases heater efficiency A PROGRAMMING THE VISION OPTION The Vision option allows the installer to set the system limits and heat curve for the heater These system limits should not be changed by the user For future reference it is important to document your settings within this manual after you program the system parameters B VISION 1 PROGRAM ACCESS Press and and simultaneously for three seconds to begin You will notice that the display will change to gg Then press down until you see on the display This is the pass code Press and hold for 1 second to confirm the pass code is correct If the pass code is entered incorrectly the controller program function will be cancelled and the control returns to normal operation If the
23. above open the manual air vent on the front of the heat exchanger as shown in Fig 31 to further assist in removing air from the system 10 When all air is removed and water runs freely from the end of the hose return air vent to the closed position shown in Fig 31 Cut the tie wrap and remove the tube Please make sure warning tag is left in place Stop the pump from running by pressing and 21 together 11 Reconnect the thermostat and DHW sensor wires to the appropriate terminals on the low voltage terminal strip and fire the heater 12 If heater makes ping sounds SHUT DOWN IMMEDIATELY and repeat the procedure outlined above until all the air is out of the system To avoid overheating and damage to the heat exchanger it is recommended that the heater temperature be brought up slowly if air purging had been a problem E PURGE AIR FROM WATER SYSTEM 1 Purge air from system a Connect a hose to the purge valve and route hose to an area where water can drain and be seen b Close the heater or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water makeup line e Open purge valve f One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purg
24. adapters specifically designed for the purpose by the manufacturer Failure to follow these directions will result in substantial property damage severe personal injury or death Table 4 Approved Materials for Exhaust Vent and Intake Pipe WARNING DO NOT mix components from different venting systems The vent system could fail causing leakage of flue products into the living space Use only the approved pipe and fitting materials and primer and cement specifically designed for the material used as listed in Table 4 Failure to do so could result in property damage severe personal injury or death WARNING Exhaust vent adaptors are not designed as load bearing devices and must not be used to support exhaust vent piping All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the heater to allow drainage of condensate Failure to properly support vent piping and follow the information in this statement could result in product damage severe personal injury or death NOTE The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air CAUTION High heat sources sources generating heat 100 37 or greater such as stove pipes space heaters etc may damage plastic components of the boiler as well
25. as described is Paragraph Heater Fault 9 180 F C HEATER FAULT n 1 When a fault condition occurs the controller will illuminate the red fault indication 12 68 F light and display a fault code in the format Example on the display module 1 DER 2 Note the fault code and refer to Table 15 for an explanation of the fault code along 14 30 Min with several suggestions for corrective actions 15 0 16 0 3 Press the reset key to clear the fault and resume operation Be sure to observe the 17 0 operation of the unit to prevent a recurrence of the fault 18 1 19 180 F Table 13 WARNING When servicing or replacing any components of this heater be certain that e The gas is off electrical power is disconnected When servicing or replacing parts that are in direct contact with heater water be certain that e There is no pressure in the heater Pull the release on the relief valve Do not rely on the pressure gauge reading e heater water is not hot e electrical power is off WARNING DO NOT USE THIS HEATER IF ANY PART HAS BEEN SUBMERGED IN WATER Immediately call a qualified service technician The heater MUST BE replaced if it has been submerged Attempting to operate an heater 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 t
26. between the space exhaust Support all vent piping per in which the appliance remains connected to the common venting system located hara E A Melt pod not place chemical vapor emitti and other spaces in the building Turn on clothes dryers and any appliances not oducts near unit i 1 Accordi to NFPA 720 carbon monoxide connected to the common venting system Turn on any exhaust fans such as used FPA 7 on range hoods and bathroom exhausts at maximum speed Do not operate a mmer exh fan Cl Il firepl mpers Never the heater unless it is summer exhaust fan Close all fireplace dampers Nove operate to make 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 Figure 3 6 After it has been determined that each appliance remaining connected to g 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 m
27. both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 32 Series Heater with optional VISION 1 system Drawing 3A zoning with circulators Space heating mode EN D 52 make up water 1 p limit safety A ae is is 1 E see noto 6 5 MC SERIES E at DHW 78 temperature i _ sensor Vision 1 system 1 pis gt es Outdoor temperature sensor Vision 1 system t purge thermal trap Super Stor Ultra indirect DHW Tank v drain Figure 15 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperat
28. degrees plus a differential 1 18 degrees Note It is recommended that you do not exceed 5 minutes on the DHW pump post purge cycle to avoid cooling down your DHW tank Indirect Sensor The Indirect Sensor connects to the heater main control Route wires from the terminal strip to the sensor or the mechanical control Honeywell part L4080b1395 not included in Vision Package into the control well located in the front of the water heater This will allow the installer to control the temperature of the indirect from the heater and give the indirect priority over the central heating circuit Once the indirect is satisfied the heater will then switch back to central heating if there is a call for heat If not the heater will then shut down WARNING Caution should be used to ensure neither of these terminals becomes connected to ground NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires routed in a grounded metal conduit If using shielded cable the shielding should be connected to the common ground of the heater WARNING Failure to use the correct sensor may result in tank temperature being either above or below set point and could result in decreased performance substantial property damage or heightened risk of injuries due to scalds DANGER MTL Water temperature over 125 degrees can cause
29. must also support the heater when it is full of water LP 171 Rev 3 3 15 12 CLEARANCES FOR SERVICE ACCESS See Figure 2 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the heater without removing it from the space 24 FRONT CLEARANCE CLEARANCE Figure 2 Required Clearances WARNING Space must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the heater The heater cover must be securely fastened to prevent the heater from drawing air form the heater room This is particularly important if the heater is in a room with other appliances Failure to comply with the above warnings could result in substantial property damage severe personal injury or death D RESIDENTIAL GARAGE CLOSET AND ALCOVE INSTALLATIONS CAUTION Check with your local Authority Having Jurisdiction for requirements when installing heater in a garage closet or alcove Please read the entire manual before attempting installation Failure to properly take factors such as heater venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury PRECAUTIONS If the heater is located in a residential garage per ANSI 2223 1 e Mount the bottom of the h
30. of lime crystals marble or phosphate chips that will neutralize the condensate This may be done by the installer or you may purchase a condensate neutralizer from HTP p n N1100 2 The heater is equipped with a 34 pipe connection that runs the condensation line to a local drain It is very important that the condensate line is sloped away from the heater and down to a suitable inside drain If the condensate outlet is lower than the drain you must use a condensate removal pump available at HTP 554200 This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert residents of a condensate overflow which if not corrected could cause property damage 3 If a long horizontal run is used it may be necessary to create a second vent to prevent a vacuum lock in the condensate line Do not expose the condensate to freezing temperatures 4 Do not expose the condensate to freezing temperatures 5 It is very important you support the condensation line to assure proper drainage FINAL CHECKS BEFORE STARTING 1 Read Startup Procedures within this manual for proper steps to start heater See Startup Report to record steps for future reference 2 Verify the heater and system are full of water and all system components are correctly set for operation LP 171 Rev 3 3 15 61 3 Fill condensate trap with water 4 Verify electrical connections are correct and securely
31. operation leading to fire explosion severe injury or death WARNING Strain on the gas valve and fittings may result in vibration premature component failure and gas leakage and result in fire explosion property damage severe personal injury or death WARNING Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring and Failure to follow this instruction could result in fire explosion property damage severe personal injury or death PART 9 FIELD WIRING WARNING To avoid electrical shock turn off all power to the heater prior to opening an electrical box within the unit Ensure the power remains off while any wiring connections are being made Failure to follow these instructions could result in component or product failure serious injury or death Such product failure IS NOT covered by warranty WARNING ELECTRICAL SHOCK HAZARD Turn off electrical power supply at service entrance panel before making any electrical connections Failure to do so can cause severe personal injury or death CAUTION Wiring must be N E C Class 1 If original wiring supplied with the heater must be replaced use only UL Listed TEW 105 C wire or equivalent Heater must be electrically grounded as required by National Electrical Code ANSI NFPA 70 Latest Edition CA
32. scalds APPROXIMATE TIME TEMPERATURE RELATIONSHIPS IN SCALDS NOTE If a relief valve discharges periodically this may 120 F More than 5 minutes be due to thermal expansion in a closed water supply 129 F 1 Ya to 2 minutes system DO NOT PLUG THE RELIEF VALVE An 130 F About 30 seconds expansion tank may be required 135 F About 10 seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1 2 seconds 155 F About 1 second Table 2 LP 171 Rev 3 3 15 17 Water temperature over 125 degrees can cause severe burns instantly or death from scalds Children disabled and elderly are 425 t 95 _ at highest risk of being scalded See instruction manual before Co _ setting temperature at water heater Feel water before bathing or TA showering Temperature limiting valves are available See chart below showing temperature burn rate C SEPARATE LOW WATER CUTOFF A low water cutoff may be required by state and local codes or by some insurance companies A low water cutoff is also required if the heater is installed above the piping level Check code requirements before installing the heater If required e Use an electrode probe type low water cutoff designed for hydronic installations e Install in a tee on the supply piping above the heater e Follow low water cutoff manufacturer s instructions D BACKFLOW
33. seat If the valve does not properly seat and continues to weep contact a qualified service technician to inspect the valve and system o lf water does not flow from the valve when you completely lift the lever the valve or discharge line be blocked Immediately shut the unit down per instructions on p 2 in this manual and call a qualified service technician to inspect the valve and system Water temperature over 125 degrees can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available See chart below showing temperature burn rate LP 171 Rev 3 3 15 LP 171 G 09 30 13 Description COMPOSITE MODULE gt Sas gt E REPLACEMENT PARTS Part 7500P 010 MC50 m Description 16 SCREWS 5 X 12MM COMBUSTION BLOWER HEATER LIMIT FUSE CONNECTION 7250P 478 7500P 012 MC80 17 GAS VALVE ADAPTER PLATE w SCREWS 7250P 644 7500P 014 99 120 18 SCREWS M4 X 12MM GAS VALVE ADAPTER PLATE CERAMIC TARGET WALL 7250P 160 19 AIR INTAKE ADAPTER BLOWER SIDE BURNER DOOR CERAMIC REFRACTORY 7500P 076 20 GAS VALVE SWIRL PLATE 7500P 105 7500P 184 99 120 7500P 091 MC50 BURNER DOOR w NUT
34. the required amount of heated energy and nothing more Flue Pipe Adapter The flue pipe adapter may be positioned so that the installer is able to find a position that will best facilitate the exhaust and combustion air pipe connections with the least number of elbows in even the most challenging of situations Burner Constructed of metal fiber and high grade stainless steel the burner uses pre mixed air and gas and provides a wide range of firing rates Electrical Field Connections with Terminal Strips The electrical cover plate allows access to the line voltage and low voltage terminal strips Attach line voltage conduits to the three holes at the right of the line voltage terminal strip for power CH pump and DHW pump Route low voltage wires through the opening to the left of the low voltage terminal strip see Field Wiring Instructions Part 9 Condensate Drain Connection As this is a condensing high efficiency appliance the unit has a condensate removal system Condensate is nothing more than water vapor derived from combustion products and similar to an automobile when it is initially started It is very important that the condensate line slopes away from the heater and down to a suitable inside drain If the condensate outlet on the heater is lower than the drain you must use a condensate removal pump kit p n 554200 available from HTP In addition local authorities may require a condensate neutralizer to neutralize the condensate C
35. 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 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped If you cannot reach your gas supplier call the fire with an ignition device which automatically lights the department burner Do not try to light the burner by hand C Use only your hand to turn the gas control knob BEFORE OPERATING smell all around the appliance Never use tools If the handle will not turn by hand area for gas Be sure to smell next to the floor don t try to repair it call a qualified service technician because some gas is heavier than air and will settle on Force or attempted repair may result in a fire or the floor explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Immediately call a qualified service technician Do not try to light any appliance to inspect the appliance and to replace any part of the control system and any gas control which has b
36. use an open flame match lighter etc to check gas connections Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 5 psi or less and a pressure drop of 3 inch water column Nominal Iron Internal Pipe Size Diameter Inches Inches 10 20 30 40 50 60 70 80 90 100 125 150 175 200 BTU s 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 PerHour 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 x 1 1 380 1 050 730 590 500 440 400 370 350 320 305 275 250 225 210 1 000 1 1 610 1 600 1100 890 760 670 610 560 530 490 460 410 380 350 320 Table 8 It is recommended that a soapy solution be used to detect leaks Bubbles will appear on the pipe to indicate a leak is present The gas piping must be sized for proper flow and length of pipe to avoid excessive pressure drop Both the gas meter and the gas regulator must be properly sized for the total gas load If you experience a pressure drop greater than 1 WC the meter regulator or gas line is undersized or in need of service You can attach a manometer to the incoming gas drip leg by removing the cap The gas pressure must remain between
37. vent piping the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe Heater venting must be readily accessible for visual inspection for the first three feet from the heater PART 8 GAS PIPING WARNING Failure to follow all precautions in this section could result in fire explosion severe injury or death A GAS CONNECTION Connect the gas supply to the system following state and local plumbing codes Use the supplied ball valve at the inlet to the system Make sure the gas supply line fits as shown in Figure 28 LP 171 Rev 3 3 15 49 gas supply shall have a maximum inlet pressure of less than 14 water column 350 mm gt pound pressure 3 5 kPa minimum of 3 5 water column The entire piping system gas meter and regulator must be sized properly to prevent pressure drop greater than 0 5 WC as stated in the National Fuel Gas Code This information is listed on the rating plate NOTE Maximum inlet gas pressure must not exceed 14 w c 3 5 kPa GAS SUPPLY CONNECTION NOTE Installer must supply trap to meet local code requirements BACK VIEW It is very important that you are connected to the type of gas noted on the rating plate LP for liquefied petroleum propane gas or for MIN 3 4 natural or city gas You must not do a gas conversion without an approved gas conversion kit Prior to t
38. water content of the heater improper sizing of the heater with regard to heating system load will result in excessive cycling and accelerated component failure HTP DOES NOT warrant failures caused by improperly sized heater applications DO NOT oversize the heater to the system Modular heater installations greatly reduce the likelihood of heater oversizing B IMPROPER COMBUSTION CAUTION Do not obstruct combustion and ventilating air flow Adequate air must be provided for safe operation Failure to keep the exhaust vent and intake pipe clear of ice snow or other debris could result in property damage serious personal injury or death 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 heater D WHEN SERVICING THE HEATER Hazard Carbon Monoxide Gas Do not operate heater if flood damaged Install vent Yu in accordance with e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow heater to cool codes manufacturers T Do not obstruct heater air or HEATER SYSTEM manufacturers installation Do not use petroleum based cleaning or sealing compounds in a heater Do not place chemical vapor emitting system Gaskets and seals in the system may be damaged This can According to NFP
39. 22 AWG maximum to 100 feet or 18 AWG up to 150 feet Length of wire run cannot exceed 150 feet Outdoor Sensor NOTE If the system requires a fixed operating temperature the outdoor sensor is not required and should not be installed LP 171 Rev 3 3 15 56 Connected in the heater junction box the Outdoor Sensor allows the user to automatically change the temperature going to the central heating loop Route wires from the heater terminal strip to your outdoor sensor Place the sensor preferably to the north or northwest or to the side which will be affected by changing weather conditions outside NOTE Do not locate the sensor in the direct sunlight CAUTION The wire to outdoor sensor must not be laid closer than 6 to line voltage wiring 120 240 V and must never be in the same conduit NOTE For correct mounting procedures follow instructions provided with the sensor NOTE If sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires should be shielded or the wires routed in a grounded metal conduit If using shielded cable the shielding should be connected to the common ground of the heater Indirect Sensor Function The maximum run time on priority function for the SuperStor Ultra Indirect Fired Water Heater is from 1 60 minutes The water temperature can only be adjusted when using a sensor not a mechanical control Temperature adjustments are from 95 to 185
40. 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185 1070 194 915 203 786 212 667 Table 17 PART 15 MAINTENANCE MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is in safe efficient operation The owner can make necessary arrangements with a qualified heating contractor for periodic maintenance of the LP 171 Rev 3 3 15 68 heater Installer must also inform the owner that the lack of proper care and maintenance of the heater may result hazardous condition The installer should discuss the contents of the User s Information Manual with the owner WARNING BEFORE EACH HEATING SEASON a trained and qualified service technician should perform the inspections and maintenance procedures as identified in this manual In addition the maintenance and care of the heater outlined in this manual must be performed to assure maximum efficiency and reliability Failure to do so could result in substantial property damage serious personal injury or death WARNING The combustion chamber insulation in this product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline sil
41. A 720 ide result in substantial property damage detectors should be installed outside each e Do not use homemade cures or patent medicines Substantial iio property damage damage to heater and or serious personal injury may vented to the outdoors result Analyze the entire vent s to make sure that condensate will not become e Continual fresh make up water will reduce heater life Mineral buildup dere radice Vis open caes reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen by make up water can cause internal corrosion in system components Leaks in the heater or piping must be rend and waterstand Inotruction repaired at once e fyou have an old system with cast iron radiators thoroughly flush the System without heater connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment e When the heater is used to supply potable water do not connect it to any heating system or component s previously used with a non potable water heating heater NOTE Damages resulting from incorrect installation or from use of products not approved by HTP Inc ARE NOT covered by warranty F WATER CHEMISTRY e Sodium less than 20mGL LP 171 Rev 3 3 15 e Water pH between 6 0 8 0 o Maintain water pH between 6 0 and 8 0 Check with litmus paper or have it chemicall
42. ATERIALS FOR EXHAUST VENT AND INTAKE PIPE APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL Item Material Standards for Installation in United States Canada PVC schedule 40 80 ANSI ASTM D1785 PP CPVC and PVC venting PVC DWV ANSI ASTM D2665 must be ULC S636 Certified CPVC schedule 40 80 ANSI ASTM F441 IPEX is an approved Exhaust vent or Intake pipe manufacturer in Canada and fittings Polypropylene UL 1738 supplying vent material listed to ULC S636 Certified for Category IV and Certified for Category IV and Sanese ey direct vent appliance veniing direct vent appliance verting ANSI ASTM 02564 IPEX System 636 Cements ANSI ASTM F493 DA e e exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID appliance warranty PVC CPVC pipe and fittings of the same diameter are considered interchangeable Do NOT use Foam Core Pipe in any portion of the exhaust piping from this heater DO NOT connect PVC CPVC to PP without an approved vent connector When installing AL29 4C vent piping install a PVC to stainless adapter at the heater vent connection and at the termination when using an HTP PVC termination kit DO NOT mix AL 29 4C piping from different manufacturers unless using
43. AUST VENT AND INTAKE PIPE INSTALLATION 1 The 2 exhaust vent connection is located on the top right side of the unit and the intake is on the top left side Use only solid PVC or CPVC pipe AL29 4C Stainless Steel or a Polypropylene vent system approved for use with Category IV appliances FOAM CORE PIPING IS NOT APPROVED WARNING All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space 2 Remove all burrs and debris from joints and fittings 3 When using PVC or CPVC pipe all joints must be properly cleaned primed and cemented Use only cement and primer approved for use with the pipe material Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe NOTE DO NOT CEMENT POLYPROPYLENE PIPE 4 Ensure the vent is located where it will not be exposed to prevailing winds 5 In all roof venting applications exhaust discharge must point away from the pitch of the roof 6 If the exhaust vent is to be terminated in a walled off area such as a roof with a parapet wall ensure the exhaust vent terminates a minimum of 10 from nearest wall and extends level with or above the top of the wall This will ensure flue gas does not get trapped and possibly recirculated into the intake air pipe which could contaminate the combustion air 7 To prevent water leakage install adequate roof flashing where the pipe enters the roof 8 Do not locate ven
44. Actual Status bus communication connected not connected d11 Central Heating Set Point d12 Power On Hours in units d13 Total Central Heat Hours d14 Total Indirect dhw Hours 15 Passed Ignition Attempts D TEST MODE This function is intended to simplify the gas valve adjustment if needed Listed below are the recommended limits on each heater and the combustion settings Automatic modulation does not take place when the controller is in Test mode only temperature limitation based on the heater central heating set point The user will be allowed to increase or decrease the fan speed by pressing in either or To activate Test mode press and together for 1 second Once activated you will see in the display and the actual fan speed The measurement of the combustion levels should always be taken at the highest and lowest fan speed After 10 minutes the Test mode stops automatically To exit Test mode press IM and together for 1 second COMBUSTION SETTINGS ON ALL MODELS Natural Gas Propane LP Fan Speed Low Ignition High Low Ignition High Carbon Monoxide PPM 5 50 60 100 lt 150 5 50 60 140 lt 150 Carbon Dioxide CO2 8 10 8 Ve 10 8 V 10 gt 9 10 9 11 Table 9 FAN SPEEDS HEATER HIGH LOW IGNITION MC 50 3300 1250 3000 MC 80 4250 1200 4250 MC 99 4700 1500 3000 MC 120 5500 1500 3000 Table 10 PART 13 START
45. ED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH NOTE When inquiring about service or troubleshooting reference the model and serial numbers from the heater rating label LP 171 Rev 3 3 15 WARNING DO NOT USE THIS HEATER IF ANY PART HAS BEEN SUBMERGED WATER Immediately call a qualified service technician The heater MUST BE replaced if it has been submerged Attempting to operate a heater 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 heater could result in property damage severe personal injury or death NOTE Heater damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty A WARNING Be sure to disconnect electrical power before opening heater cabinet or performing service Failure to do so could result in an electrical shock that could result in property damage serious personal injury or death NOTE If the heater 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 CAUTION Due to the low
46. G MUST FORM A LOOP 6 IN DIAMETER TOP VIEW j 1 2 ID CLEAR FLEXIBLE TUBING LENGTH DETERMINED BY DISTANCE TO CONDENSATE LINE 171 5 08 21 06 DRAIN Figure 24 Piping Exhaust around Obstructions Suggested Condensate Removal E ROTATING THE FLUE ADAPTER The flue adapter on the top of the heater can be rotated 180 degrees to position the air inlet in the optimum location for most venting and air inlet needs The flue adapter MUST be positioned before the exhaust vent is connected to the adapter NOTE Once the exhaust vent is glued to the flue adapter it can no longer be moved NOTE DO NOT glue optional polypropylene vent system To rotate the flue adapter 1 Remove the black heater cover 2 Inspect the area where the white flue adapter mates to the black plastic heat exchanger You will notice two red wires and a plastic hose connected to the flue adapter These will limit the rotation range of the flue adapter 3 Grasp the entire white PVC flue adapter and rotate it in the direction that will cause the least strain on the hose and red wires until the air inlet is in the desired orientation After rotation is complete push downward on the flue adapter to be sure it is completely seated in the black plastic module LP 171 Rev 3 3 15 45 4 Check again to make sure the red wires and clear plastic hose connected to the flue adapter are properly connected and routed EXHA
47. H 7250P 152 S S BARBED FITTING w O RING 7250P 154 WATER PRESSURE SWITCH w O RING 7250P 081 3 4 5 6 7 O RING WATER PRESSURE SWITCH 7500P 100 8 CLEAR TUBING 3 16 ID X 5 16 OD 7000P 805 9 PRESSURE SWITCH ADAPTER w O RING 7500P 003 10 2 13 O Ring Water Pressure Switch Adapter 7500P 124 WATER PRESSURE SWITCH CLIP 7500P 077 12 SUPPLY RETURN MANIFOLD CLIP 7500 080 O RING SUPPLY RETURN MANIFOLD 7500P 026 14 THERMISTOR 7250P 059 15 16 HIGH LIMIT SENSOR 7500P 033 RELIEF VALVE 7250P 080 HIGH PRESSURE RELIEF VALVE 7250P 219 SUPPLY MANIFOLD ASSEMBLY w O RING 7500 029 17 18 RETURN MANIFOLD ASSEMBLY w O RING 7500P 030 19 TEMPERATURE PRESSURE GAUGE 7500P 098 HIGH PRESSURE TEMPERATURE PRESSURE GAUGE 7450P 222 20 FLOW SWITCH 7250P 517 21 1 4 X 1 1 4 X 3 4 NPT COPPER TEE N A LP 171 H 09 27 13 LP 171 Rev 3 3 15 73 LP 171 J 09 30 13 7 54 PA REPLACEMENT PARTS Item Description BLOCKED VENT PRESSURE SWITCH 7250P 150 SCREWS 8 32 X 3 8 BLOCKED VENT PRESSURE SWITCH 7500P 047 CONTROL BOARD w SCREWS 7350P 008 9 PIN S PIN WIRING HARNESS LOCATION ONLY 7500P 301 LOW VOLTAGE WIRING HARNESS LOCATION ONLY 7500P 053 7500P 073 SCREWS 6 CLAMP 7500P 069 CONDENSATE HOSE CLEAR 7500P 057 SCREWS 8 32 X 3 8 FILLER GAS INLET PLATE 7500P 047 SUPPLY RETURN FILLER PLA
48. IM S 2 ntt e dee ctt ct tec Ah cr 60 A CONDENSATE REMO VA As taal helo Nias ene icu eaae nie 60 I FINAL CHECKS BEFORE STARTING tr sees itr 60 PART 12 START UP 61 OPERATING INSTRUGCT QNS htt ee ees Sees ee ee ER a 61 B ADJUSTING THE SET POINT 2 tt gre bio e ne ti iu E eis 61 E Leni e deae 62 D TEST MODE ss trt atk ten dre er redet eal oes 62 PART 13 START UP PROCEDURES WITH VISION 1 OPTION 62 A PROGRAMMING THE VISION 63 B VISION 1 PROGRAM ACCESS 2 seis cad hie dele ee eh ee ed 63 C VISION 1 PROGRAM 63 PART 14 TROUBLESHOOTING 65 A ERROR CODE diipi te edits cota ad etn es Dakar ues late en et cd 65 BUREATER ERROR 2h eet RE Ae iets tevin HERE ee tbe Dee ee ea dune 65 CHEATER EAULT e e e id Ee e eiu itte e Le m gto d 65 PART 15 Dugdpuecq anana 67 A MAINTENANCE PROCEDURES tete te ete te eed a s tas 67 B MAINTENANCE SCHEDULE FOR THE SERVICE 7777 777 68 C COMBUSTION CHAMBER COIL CLEANING 5
49. LET GAS PRESSURE atti tte ett ftc e eet 50 D GAS VALVE dnte E eb ee a on A ee te dude den a ee te C 51 9 52 AZINSTALLATION MUST COMPLY WITHE 5 BOO eds 52 B EIEED WIRIINQ EU m e Reid 52 ests ere 52 D THERMOSTAT t en eb be ate ee IR e dede e a ee tec 52 PART 10 FIELD WIRING VISION 1 OPTION 55 PART 11 START UP 1 sensnm sain sinas snas snas karaa assa ass asma asma assa assa ass assa asas asa 57 A CHECK CONTROL WATER 7 57 B FREEZE PROTEGTION WEEN USED 4 2 cen tn rete e coit che efe ete e eg cede f te 58 C FILL AND TEST WATER SYSTEM iet td be debe e au a eie tg e detect 58 D AIR PURGING PROCEDURE FOR HEAT etnies 58 E PURGE AIR FROM WATER SYSTEM ale re OUVRIR HE 59 F CHECK FOR GAS LEAKS e dete s eb iR HR re Lente ete ie Pria eel Lt Bre teca 60 LP 171 Rev 3 3 15 G CHECK THERMOSTAT GIRGCU
50. S 7500P 078 7500P 092 MC80 NUTS M BURNER DOOR 7500P 067 BURNER 7500P 015 50 21 AIR INTAKE ADAPTER VALVE SIDE 7500P 016 MC80 22 GAS VALVE w SWIRL PLATE SCREWS 7500P 186 MC99 MC120 7500P 185 MC99 MC120 7250P 448 MC50 7500P 017 99 120 7250P 449 MC80 GASKET BURNER AIR GAS CHANNEL w TORX SCREWS TORX SCREWS AIR GAS CHANNEL 7500P 074 7500P 079 23 SCREWS M4 X 18MM GAS VALVE SCREWS M4 X 19MM GAS VALVE 7500P 180 MC99 MC120 7250P 716 MC50 7250P 717 MC80 GASKET FLAME REC SPARK ELECTRODE SCREWS M4 X 25MM GAS VALVE 7250P 718 99 120 FLAME RECTIFICATION PROBE w GASKET SPARK ELECTRODE w GASKET SCREWS M4 X 8MM PROBE ELECTRODE 7250P 069 24 O RING GAS VALVE PIPING ASSY 25 GAS VALVE PIPING ASSY w O RING SCREWS 7500P 095 26 SCREWS M5 X 12MM GAS VALVE PIPING ASSY 7500P 094 7500P 099 GASKET AIR CHANNEL TO COMBUSTION BLOWER 7500P 075 27 2 FLEX HOSE 25 LONG 7500P 189 MC99 MC120 COMBUSTION BLOWER w SCREWS Figure 34 7500P 195 28 24VAC GAS VALVE COIL ONLY GREY 7350P 624 71 LP 171 Rev 3 3 15 Figure 35 72 REPLACEMENT PARTS Item Description Part 1 FLUE OUTLET ASSEMBLY 7500 020 2 GASKET CONCENTRIC FLUE OUTLET 7500P 008 FLUE ECO w O RING 7250P 739 O RING BARBED FITTING amp PRESSURE SWITC
51. STAINLESS STEEL VENT TERMINATION KIT V2000 3 POLYPRO VENT KIT 8400P 001 Table 7 VENTING DRAWINGS 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 two basic direct vent options detailed in this manual 1 Side Wall Venting and 2 Roof 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 LP 171 Rev 3 3 15 47 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 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 WARNING Take extra precaution to adequately support the weight of vent pipes terminating through the roof Failure to properly support roof terminated vent piping could result in property damage serious personal injury or death due to flue gas leakage TWO PIPE ROOF oe m TEE INTAKE INSERT INLET EXHAUST TWO PIPE SIDEWALL VENTING WITH TEE INTAKE
52. SUGGESTED SETUP FOR CONDENSATE REMOVAL TO CONDENSATE REMOVAL FLOOR DRAIN TO OUTSIDE SOURCE 3 4 PIPE HANGER 3 4 PVC PIPE 3 4 PVC PIPE SSE ULM ES ween DETERMINED 3 4 PIPE BY DISTANCE TO FLOOR HANGER LENGTH DETERMINED BY ge ASSEMBLIES DISTANCE TO FLOOR J 3 4 PVC 3 4 PVC 90 ELBOW 90 ELBOW 2 SHOWN hala 3 4 SOCKET X j 1 2 NPT THREAD JB THREAD A PVC ADAPTER e VA THREAD PVC ADAPTER PVC ADAPTER 2 SHOWN N1100 CONDENSATE 1100 CONDENSATE NEUTRALIZER 3 8 TUBE X NEUTRALIZER HORIZONTAL LINES MUST 3 4 NPT BE INSTALLED WITH A 4 HORIZONATAL LINES MUST PITCH OF 1 4 PER FOOT In BE INSTALLED WITH A PITCH OF 1 4 PER FOOT CONDENSATE 3 4 NPT PVC NIPPLE j 3 8 ID TUBING 3 4 NPT FEMALE FLOOR DRAIN CUP ASSEMBLY PVC UNION DETAILS TS CONDENSATE A 3 4 SOCKET CONDENSATE NE LP 171 R CUP ASSEMBLY ADAPTER 08 10 06 Figure 23 Condensate Details NOTES 1 Condensate line must be pitched at least 1 4 per foot to properly drain If this cannot be done or a very long length of condensate hose is used you must increase the condensate line to a minimum of 1 ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in the drain line 2 Plastic pipe should be the only material used for the condensate line Steel brass copper or other materials will be su
53. T KIT B OVER MAXIMUM SNOW EXTERIOR WALL IS GREATER CONCENTRIC VENT KIT PART KGAVOSOI CVT 2 1 KGAVO601CVT 3 I VENT KIT PART V500 2 V1000 2000 4 EXHAUST MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP NOTE EXTENDED VENT RUNS WHEN LP 505 A TRANSITIONING TO A LARGER DIAMETER 07 30 14 MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE LP 505 C 11 24 14 SIDEWALL VENTING WITH CONCENTRIC VENT KIT IMPORTANT INTAKE LEG MUST BE FACING UP EXHAUST VENT KIT PART KGAVOSOICVT 2 INTAKE KGAVO0601CVT 3 MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP Figure 27 Venting with Optional Kits NOT INCLUDED WITH THE WATER HEATER NOTE These drawings are meant to demonstrate system venting only The installer is responsible for all equipment and detailing required by local codes WARNING vent pipes must be glued properly supported and the exhaust must be pitched a minimum of 74 per foot back to the heater to allow drainage of condensate When placing support brackets on
54. TE w SCREWS 7500P 022 MC50 MC80 7500P 023 MC99 MC120 LIP STYLE GROMMET 1 7500P 050 GAS INLET PLATE 7500P 043 px 7350009 CONTENDER COVER 7500P 027 MC50 MC80 Figure 36 LP 171 Rev 3 3 15 HEATER START UP REPORT 74 LIGHT OFF ACTIVITIES DATE COMPLETED 1 Fill the Check all piping and gas connections verify all heating system are tight Pressurize system 12 15 PSI PSI Add water to prime condensate cup What percentage of propylene glycol is 7 installed in the system 0 50 Verify near heater piping is properly supported 2 Check gas Leak test using locally approved methods pipe consult jurisdictional code book S incoming gas pressure 3 5 to 14 TS Static Mr the drop on light off No more than 1 S Dynamic 21 4 fnecessary carbon CO2 High Fire CO2 Low Fire a necesse caion ____ High Fire ____ Low Fire 4 Verify system Turn up thermostat to verify wiring connections operation 5 Record 7 ionization slats MENN uA High Fire uA Low Fire current 6 Record heating curve with optional Vision g 9 10 41 system settings One kit record steps 7 Indirect Verify safety and operation of the indirect dE dh water heater water heater record settings ct 8 Con
55. UST VENT AND INTAKE PIPE SIZING 1 The exhaust vent and intake pipe size is 2 or greater 2 The total equivalent length of exhaust vent and intake pipe should not exceed 85 for 2 and 125 for 3 a The equivalent length of elbows tees and other fittings are listed in the Friction Loss Table below FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS FITTINGS OR PIPING 2 EGUIVAEENPEEET 3 90 DEGREE ELBOW 5 5 45 DEGREE ELBOW 3 3 COUPLING 0 0 AIR INLET TEE 0 0 STRAIGHT PIPE 1 1 CONCENTRIC VENT 3 3 V500 2 VENT KIT 1 N A V1000 3 VENT KIT N A 1 Table 5 Friction loss for long radius elbow is 1 foot less NOTE Consult Polypropylene venting instructions for friction loss and pressure drop equivalents b For example If the exhaust vent has two 90 elbows and 10 feet of PVC pipe w we will caleulale Exhaust Vent Equivalent Length 2 x 5 10 20 feet NOTE EXTENDED VENT Further if the intake pipe has two 90 elbows one 45 elbow and 10 RUNS WHEN TRANSITIONING feet of PVC pipe the following calculation applies ALARGER DIAMETER Intake Pipe Equivalent Length 2 x 5 3 10 23 feet MUST ALWAYS TAKE PLACE VERTICAL POSITION i PREVENT CONDENSATE Finally if a concentric vent kit is used we find BLOCKAGE Total Equivalent Length 20 23 3 46 feet Therefore the total equivalent length
56. UTION In order to ease future servicing and maintenance it is advised to label all wires Wiring errors can cause improper and dangerous operation Failure to follow these instructions could result in property damage or personal injury A INSTALLATION MUST COMPLY WITH National Electrical Code and any other national state provincial or local codes or regulations In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes B FIELD WIRING For your convenience we have located the electrical connection of the heater on the front right hand side of the unit The electrical junc tion box has a 24 volt terminal compartment and 120 volt terminal compartment Each terminal connection is clearly marked to assure correct installation C LINE VOLTAGE WIRING 1 Connect 120 VAC power wiring to the line voltage terminal strip located inside the electric junction box as shown in Figure 31 2 Wire the Heater Primary Circulator P1 to the terminal strip See wiring diagram in this section D THERMOSTAT 1 Connect room thermostat or end switch 2 Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 3 Thermostat anticipator if applicable a If connected directly to heater set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See specifications of
57. VIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approval side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation LP 172 REV 02 16 06 Lr ist nev 0 3 15 78 MAINTENANCE NOTES LP 171 Rev 3 3 15 79 HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim After reading the important notes at the bottom of the page please also sign this document Customer s Name Installation Address Date of Installation Installers Code Name P
58. arm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the service of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified LP 172 REV 02 16 06 LP 171 Rev 3 3 15 77 3 SIGNAGE metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less t
59. as plastic vent pipe materials Such damages ARE NOT covered by warranty It is recommended to keep a minimum clearance of 8 from high heat sources Observe heat source manufacturer instructions as well as local state provincial and national codes laws regulations and ordinances when installing this boiler and related components near high heat Sources C REQUIREMENTS FOR INSTALLATION IN CANADA 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 Additionally you may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe from the heater flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings Cellular foam core piping may be used on air inlet piping only DA lt You must not use vent exhaust application vent is for intake applications ONLY Using vent an exhaust application will result in serious injury or death LP 171 Rev 3 3 15 41 D EXHAUST VENT AND INTAKE PIPE LOCATION CR CORNER DETAIL 1 179 08 12 13 EXHAUST VENT TERMINAL INTAKE PIPE TERMINAL DS TERMINAL IS NOT Figure 22 ANSI Z223 1 NFPA 54 for US and CAN CSA B149
60. ative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 34 Series Heater with optional VISION 1 system Drawing 3C zoning with circulators Space heating mode w submixing air handler low temperature manifold station EA make up water gt lt 4519 1 DJ A L MC SERIES fision 1 system temperature sensor Vision 1 system thermal trap Super Stor Ultra Indirect DHW Tank ee Figure 17 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with f
61. attached Inspect exhaust vent and intake piping for signs of deterioration from corrosion physical damage or sagging PART 12 START UP PROCEDURE WARNING FOR YOUR OWN SAFETY READ BEFORE OPERATING 1 This heater does not have pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 2 BEFORE OPERATING smell all around the heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any heater Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department Turn off gas shutoff valve located outside of the heater so that the handle is crosswise to the gas pipe If the handle will not turn by hand don t try to force or repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 4 Do not use this heater if any part has been under water Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control that has been damaged 5 The heater shall be installed so the gas ignition system components are protected from water dripping spraying rain etc durin
62. bject to corrosion or deterioration 3 NEVER install condensate lines outside It is very important that the condensate line is not exposed to freezing temperatures or any type of blockage Damages due to frozen or blocked condensate lines ARE NOT covered by warranty 4 Support of the condensate line may be necessary to avoid blockage of the condensate flow CAUTION If using a condensate pump select one approved for use with condensing heaters and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage CAUTION It is very important that the condensate piping be no smaller than 34 To prevent sagging and maintain pitch condensate piping should be supported with pipe supports and pitched 7 per foot to allow for proper drainage CAUTION The condensate line must remain unobstructed allowing free flow of condensate If condensate freezes in the line or if line is obstructed in any other manner condensate can exit from the tee resulting in potential water damage to property LP 171 Rev 3 3 15 44 EXHAUST PIPING AROUND OBSTRUCTIONS SUGGESTED SETUP FOR PIPING BUILDING AROUND BEAMS IN ORDER TO ELIMINATE CONDENSATION STRUCTURE i THE INTAKE VENT CAN BE ROTATED INTO ANY POSITION 7 P g j PIPING LENGTH HOSE BARB IA 7 i DETERMINED BY n DISTANCE NEEDED TO CLEAR BEAM TUBIN
63. by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 38 Series Heater with optional VISION 1 system Drawing 3G Multiple high temperature priority loads controlled with zone circulators Multiple low temperature load controls with zone circulators SERIES Heater 4 4 4 i 4 al trap wf drain plug rs Figure 21 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is respon
64. circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 28 PART 6 PIPING WITH OPTIONAL VISION 1 SYSTEM DHW PRIORITY WITH OUTDOOR RESET A VISION 1 SYSTEM PIPING It is important that the system piping is done correctly when using the Vision 1 System Follow the piping diagrams 2A through 3G when piping your heater All general piping practices should still be maintained B ZONING WITH ZONE VALVES USING VISION 1 1 Connect the heater to the system as shown in piping details 2A through 2C 2 Connect the DHW circulator P2 directly to the heater as shown in the piping details The heater circulator P1 will shut down when there is DHW demand C ZONING WITH CIRCULATORS USING VISION 1 1 Connect the heater to the system as shown in piping details 3A through 3G 2 Connect the DHW circulator P2 directly to the heater as shown in the piping details The heater circulator P1 will shut down when there is DHW demand LP 171 Rev 3 3 15 29 D PIPING DETAILS WITH THE VISION 1 SYSTEM Series Heater with optional VISION 1 system Drawing 2A Zoning with valves Space heating mode sees Se optional high limit safety E m ct make up water a Pod TD MC SERIES Heater valve DHW temperature sensor Vision 1 system OFF i P2
65. code is entered correctly the control will switch off the gas valve and purge fan while showing a solid J in the display The display will than show a Mf alternating to This first function verifies that the control will address the requirements of the indirect water heater VISION 1 PROGRAM NAVIGATION Next you will have to press to move through each function To increase or decrease a value you will need to press either or to change the default values If there is no key action for 1 minute the display returns to normal operation Changes are effective immediately but not directly stored until the key is pressed down for 3 seconds then the new values are stored Listed below are the varieties of functions the installer can program into the Vision System NOTE The heater cannot be programmed when there is a call for heat See Table 12 in Part 13 to set outdoor reset curve START UP PROCEDURES WITH VISION 1 OPTION DEFAULT FUNCTION FUNCTION VALUE DESCRIRTION 1 de Not Applicable 2 149 F Not Applicable Maximum domestic delivery water temperature set point the installer will program for indirect water heater NOTE 3 160 F Does not apply if used with mechanical control Range 95 F to 160 F 4 36 F Not Applicable Allows the installer to change the differential in the indirect water heater Does not apply if used with mechanical 5 7 control Range 1 F to 18 F Allows the installer to c
66. dition LP 171 Rev 3 3 15 75 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING 15 YEAR 2 YEAR 3 YEAR 4 YEAR Near heater piping Check heater and system piping for any sign of leakage make sure they are properly supported Vent Check condition of all vent pipes and joints Gas Check Gas piping test for leaks and signs of aging Make sure all pipes are properly supported SYSTEM Visual Do full visual inspection of all system components Functional Test all functions of the system Heat Safeties Temperatures Verify safe settings on heater or Anti Scald Valve Temperatures Verify programmed temperature settings ELECTRICAL Connections Check wire connections Make sure they are tight Smoke and CO detector Verify devices are installed and working properly Change batteries if necessary Circuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Spark Electrode Clean Set gap at 7 Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if necessary Condensate hose Disconnect condensate ho
67. dulating Combustion System Modulation during operation is based on supply temperature and desired temperature set point The set point used for the control depends upon the programmed central heating curve The heating curve slope can be changed by the installer to better fit system needs The control monitors the system to regulate burner output during operation to match system demand This increase in efficiency allows for substantial fuel savings Gas Valve The gas valve senses suction from the blower allowing gas to flow only if the gas valve is energized and combustion air is flowing Swirl Plate System The gas valve swirl plate controls air and gas flow into the burner assuring better mixing for improved combustion Supply Water Temperature Sensor This sensor monitors heater output water temperature system outlet supply The control module adjusts the heater firing rate so the outlet supply temperature is correct Return Water Temperature Sensor This sensor monitors the return water temperature system inlet return The control module reduces or increases heater input depending on how close the inlet return water temperature is to the outlet water temperature Temperature and Pressure Gauge Allows the user to monitor system temperature and pressure Control The integrated control system monitors inlet return and outlet supply water temperature and regulates fan speed to regulate the unit s BTU output This allows the unit to deliver
68. e alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 26 Multiple MC Series Heaters Drawing 1E Preferred piping zoning with circulators Space heating mode see note 6 mixing valve cold water MC SERIES LI 4 LJ outdoor temperature sensor Super Stor Ultra indirect DHW Tank Figure 10 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves ca
69. e heater resulting in possible substantial property damage severe personal injury or death NOTE DAMAGE TO THE HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY Refer to the limited warranty for complete terms and conditions G REMOVING AN EXISTING HEATER FROM AN EXISTING COMMON VENT SYSTEM A DANGER Do not install the heater 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 LP 171 Rev 3 3 15 14 WARNING Failure to follow all instructions can result flue gas spillage and carbon monoxide emissions causing severe personal injury or death When removing an existing heater follow the steps below with each appliance remaining connected to the common venting system in operation while other appliances remaining connected to common venting system are not operating 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch to n n determine if there is blockage leakage corrosion or other deficiencies that could Do not operate heater if flood damaged cause an unsafe condition installation instructions NS y Do not obstruct heater air intake 3 If practical close all building doors windows and all doors
70. e may need to increase to 1 Support of the condensate line may be necessary to avoid blockage of the condensate flow Failure to add a second vacuum break could result in condensate backup improper heater operation and nuisance shutdowns 4 DANGER The condensate trap assembly MUST BE PROPERLY INSTALLED when operating the heater Operating the heater without the condensate trap assembly will cause flue gases to leak and result in serious personal injury or death NOTE Check with your local gas company to determine if combustion condensate disposal is permitted in your area In the state of Massachusetts condensate must be neutralized before entering a drain CONDENSATE NEUTRALIZATION Condensate from the heater is slightly acidic with a pH of 3 2 4 5 To avoid long term damage to the drainage system and to meet local code requirements HTP recommends neutralizing the condensate with a Condensate Neutralizer Kit p n N1100 The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the water vapor The neutralizer kit should be checked annually and the limestone chips replenished if necessary When replacing the limestone chips take care to ensure chips are no smaller than to avoid blockage in condensate piping for piping details refer to condensate neutralizer installation instruction LP 171 Rev 3 3 15 43 CONDENSATE PIPING CONDENSATE PIPING W PUMP SUGGESTED SETUP FOR
71. e operation at risk Ensure that the heater installation location adheres to the information included in this manual Failure to do so could result in property damage serious personal injury or death CAUTION Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty 1 Installation Area Mechanical Room Operating Conditions e Ensure ambient temperatures are higher than 32 F 0 C and lower than 104 F 40 C e Prevent the air from becoming contaminated by the products places and conditions listed in this manual Part 3 Section F e Avoid continuously high levels of humidity e Never close existing ventilation openings CAUTION The service life of the heater 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 heater components these environments heaters must not be installed using direct vent systems which draw outdoor air for combustion Such heaters must be installed using room air for combustion Indoor air will have a much lower relative humidity and hence potential corrosion will be minimized WARNING This heater is certified for indoor installations only D
72. eam of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 36 MC Series Heater with optional VISION 1 system Drawing 3E zoning with circulators Space heating mode 3 different supply temperatures 3 way manually set mixing valve PA air handler higher temp low temperature manifold station variable speed injection mixing Y 1 temperature manifold station SSS MC SERIES Heater p sensor Vision 1 system OFF eL Gr 2 Vision 1 system Super Stor Ultra thermal trap Indirect DHW Tank w drain plug Figure 19 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is re
73. eater a minimum of 18 above the floor of the garage to ensure the burner and ignition devices are well off the floor e or protect the heater so it cannot be damaged by a moving vehicle WARNING For closet or alcove installations a two pipe venting system must be used Failure to follow this warning could result in substantial property damage severe personal injury or death WARNING The space must be provided with correctly sized combustion ventilation air openings for all other heaters located in the space with the heater Do not install the heater in an attic Failure to comply with these warnings could result in substantial property damage severe personal injury or death NOTE For installations using room air for combustion refer to the heater venting section Part 6 in this manual E EXHAUST VENT AND INTAKE PIPE The appliance is rated ANSI Z21 13 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed for pressurized venting NOTE The venting options described here and further detailed in the Venting section of 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 LP 171 Rev 3 3 15 13 DA Failure to vent the appliance properly will result serious personal injury or death
74. eater and cause property damage and or personal injury Verify that the heater is securely mounted before leaving unsupervised Failure to comply with the above and properly mount the heater could result in substantial property damage severe personal injury or death The wall must be vertically plumb and capable of carrying the weight of the heater and its related components The building frame studs must be 16 on center If not you must use 1 2 minimum plywood 24 x 48 fastened with at least 14 12 x 3 3 16 x 3 round head tapping screws to the frame of the building to provide proper support for the heater Alternate methods of mounting must not be used ex toggle bolts hollow wall anchors or any other fastener other than 12 x 3 3 16 x 3 round head tapping screws CAUTION If the heater is not vertically plumb improper and unsatisfactory operation may occur causing excessive condensation build up nuisance fault codes and unnecessary maintenance D INSTALLATION STEPS 1 Prior to lifting the heater onto the wall use the enclosed template to level and locate the 2 primary 12 x 3 3 16 x 3 round head tapping screws leaving about 1 4 between the screw head and the wall surface to allow for access to the keyway slot located in the back of the heater panel It is extremely important that the line on the template is level when locating the first 2 screws Failure to do so will result in an uneven or out
75. ect the external system piping circulators and system components and fittings Immediately call a qualified service technician to repair any leaks WARNING Have gas leaks fixed at once by a qualified service technician Failure to comply could result in substantial property damage severe personal injury or death e Operate pressure relief valve o Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water WARNING To avoid water damage or scalding due to relief valve operation a discharge line must be connected to the valve outlet and directed to a safe place of disposal This discharge line must be installed by a qualified service technician or heating plumbing installer in accordance with this manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge o Read the temperature and pressure gauge to ensure the system is pressurized Minimum is 10 psi Maximum is 25 psi Lift the relief valve top lever slightly allowing water to relieve through the valve and discharge piping o If water flows freely release the lever and allow the valve to seat Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain If the valve weeps lift the lever again to attempt to clean the valve
76. ed Until Corrected 1 Disconnect the system sensor from the wiring and measure its resistance Compare the measured resistance to the table in this manual to see if it corresponds to the temperature of the sensor If the resistance does not agree with the sensor replace the sensor 2 If the resistance is OK disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter Repair or replace as necessary The line voltage frequency is out of range Until Corrected Inspect power wiring to boiler and repair as necessary If connected to line voltage notify the power company If connected to an alternate power source such as generator or inverter make sure the line voltage frequency supplied by the device is 60 Hz Water Pressure Switch is Open Until Corrected 1 Assure that the system pressure is above 10 psig 2 Check for leaks in the system piping Blocked Vent Pressure Switch open Condensate Cup Full Condensate Cup not present Until Corrected 1 Check the flue vent to be sure it is not blocked or damaged 2 Check the blocked vent pressure switch operation by applying a jumper If the switch is not functioning properly replace it 3 If the condensate cup is excessively full check the condensate piping system for piping and proper drainage Repair as necessary If the condensate cup is not excessively full and is in place remove the cup and chec
77. ed After all the zones are purged open the manual air vent on the top of the heat exchanger as illustrated in Figure 33 Purge out all air that may have accumulated in the header to avoid air entrapment in the system LP 171 Rev 3 3 15 60 WARNING Never open the manual air vent while the heater is hot Allow heater to cool to room temperature to avoid scalding while purging g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents j Refill to correct pressure CHECK FOR GAS LEAKS WARNING Before starting the heater and during initial operation smell near the floor and around the heater for gas odorant or any unusual odor Remove heater front door and smell interior of heater enclosure Do not proceed with startup if there is any indication of a gas leak Repair any leak at once WARNING Propane heater only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can face and the gas may no longer
78. ed loop 15 psi system An optional water pressure switch ensures adequate pressure in the system The heater will not operate without a minimum of 10 psi water pressure This assures you that if the system does have a leak the heater will lock out PRO on the display before it damages the heat exchanger The included temperature and pressure gauge allows the user to monitor the system pressure and outlet temperature from the heater It is important to note that the heater has a minimal amount of pressure drop that must be calculated when sizing the circulators Each installation must also have an air elimination device that will remove air from the system Observe minimum 1 clearance around all un insulated hot water pipes when openings around pipes are not protected by non combustible materials On a heater installed above radiation level some states and local codes require a low water cut off device See Part C this section If the heater supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle Chilled water medium must be piped in parallel with the heater CAUTION The heater should not be operated as a potable hot water heater Operating this heater as a potable water heater will VOID warranty 1 Connect the system return marked Heater In 2 Connect the system supply marked Heat
79. een Do not touch any electric switch under water do not use any phone in your building immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS STOP Read the safety information above 5 Remove front cover Set the thermostat to lowest setting 6 Turn gas shutoff valve clockwise to off Handle will be vertical do not force Turn off all electric power to the appliance Wait five 5 minutes to clear out any gas If you then This appliance is equipped with an ignition device smell gas STOP Follow B in the safety which automatically lights the burner Do not try to information above on this label If you don t smell light the burner by hand gas go to next step Turn gas shutoff valve counterclockwise to on SAS SHUT OFF VALVE Handle will be horizontal Install Front Cover Turn on all electric power to appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS APPLIANCE 1 Set the thermostat to lowest setting 4 Turn gas shutoff valve clockwise to off Handle will 2 Turn off all electric power to the appliance if service is be vertical Do not force to be performed 5 Install Front Cover 4
80. em 4 temperature Im 1 5 sensor i zo aeeevessseued Vision 1 system thermal trap Tank w drain plug Figure 13 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 31 Series Heater with optional VISION 1 system Drawing 2C zoning with valves Space heating mode w submixing low temperature manifold station air handler
81. ente o rai d dt quo ct eb Pte to eos cote e 7 F WATER CHEMISTRY et Re AA eL aee A e em o Ret e e s 7 GG WINTERIZING 2 242 mene he tite i d aet qt diced e AD p o d EE e Beide 8 PART 2 BEFORE XR SX RR EXE P RR C RE REX EV d SA C EC Ra 8 A WHAT S IN THE BOK teret ea eee de th e eo eee abe eode evt decedat Sistine a P 8 B HOW THE HEATER OPERATES nn tee dtp ebat da eqs c cb es cere hd 8 OPTIONAL EQUIPMENT 5o mE A En Rene euni n Een 10 PART 3 PREPARE HEATER _ 10 BEFORE LOCATING THE HEATER ined EURCRDI DROP PH gs 10 B EEVELING o Ee Ree ERE etie et ERES tet e I d e RE dee d d Ead e CER 11 Q GLEARANGES FOR SERVIGE AGGESS ente bet c tret Eh at pe t m de e rbd es cci e 12 D RESIDENTIAL GARAGE CLOSET AND ALCOVE 12 E EXHAUST VENT AND INTAKE PIPE nde tette tei ih n lei otra eda De rp eger cce 12 F PREVENT COMBUSTION AIR 13 REMOVING AN EXISTING HEATER FROM AN EXISTING COMMON VENT 13 PART4 PREPARE HEATER 14 a E de aa E a a a a a aa S aa a Aea a De
82. equires two separate circulators You must follow the piping wiring and programming instructions located in the Vision One section of this manual LP 171 Rev 3 3 15 10 OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP These additional options may be purchased through your HTP distributor e Indirect Tank Sensor Part 7250P 325 Outdoor sensor Part 7250P 319 2 Stainless Steel Outside Termination Vent Kit V500 3 Stainless Steel Outside Termination Vent Kit V1000 2 PVC Concentric Vent Kit Part KGAVTO501CVT 3 PVC Concentric Vent Kit Part KGAVT0601 CVT 3 Polypro Vent Kit Part 8400P 001 3 Polypro Pipe 33 length Part 8400P 002 49 5 length Part 8400P 003 Alarm System Part 7350P 602 to monitor any failure Condensate Pump Part 7250P 320 Condensate Neutralizer Part 554200 Vision 1 Outdoor Sensing System Part 7250P 622 PART 3 PREPARE HEATER LOCATION CAUTION Carefully consider installation when determining heater location Please read the entire manual before attempting installation Failure to properly take factors such as heater venting piping condensate removal and wiring into account before installation could result in wasted time money and possible property damage and personal injury A BEFORE LOCATING THE HEATER WARNING Incorrect ambient conditions can lead to damage to the heating system and put saf
83. er Out 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 the tank manufacturer s instruction for specific information relating to expansion tank installation Size the expansion tank 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 the system NOTE The heater cannot be drained completely of water without purging the unit with an air pressure 15 psi 10 The safety relief valve is installed at the factory Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge 6 above the drain to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of safety relief valve H CIRCULATOR SIZING The heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator These minimum wa
84. ermister 3 Check thermister reading on supply thermister Replace switch if faulty TI Vent temperature limit exceeded 1 Push the red reset button on the vent temperature limit switch 2 Check module overheat switch Disconnect the wires plugged into the switch and measure continuity across the switch Check the flue temperature during operation using a combustion analyzer Replace the vent limit switch if faulty Replace module overheat switch if open Interrupted or shorted supply outlet thermister Check the electrical connection to the thermister on the outlet manifold If connection is okay replace thermister e fe 99 Interrupted or shorted return inlet thermister Check the electrical connection to the thermister on the outlet manifold If connection is okay replace thermister 41 M Supply outlet temperature exceeds 230 F Check circulation pump operation Assure that there is adequate flow through the heater by accessing the status menu and assuring that there is less than a 50 F rise from the return thermister to the supply thermister TI O Return inlet temperature exceeds 230 F 1 Check circulation pump operation 2 Assure that there is adequate flow through the heater by accessing the status menu and assuring that there is less than a 50 F rise from the return thermis
85. ersion from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada 2R3 Also Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada LAW 5N6 Code for the installation of Heat Producing Appliances latest version from American Insurance Association 85 John Street New York NY 11038 LP 171 Rev 3 3 15 The latest version of the National Electrical Code NFPA 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 WARNING 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 6 As PRECAUTIONS ee BERE eet non 6 B IMPROPER COMBUSTION a de ee e rte i c cd e ee 7 pc ERE 7 D WHEN SERVICING THE HEATER e eed ba eed C e ede d E CE d c 7 E HEATER SYSTEM oi rm tte te te si
86. etter manual 3 way valvo zone valve alr separator aquastat diaphra expansion tank py raj 21 2 s i E hose heater drain circulator w Integral check valve Se pressure reducing valve PRLE an pressure bypass 150 mixing valve P temperature pressure gauge spring loaded check valve 3 way Motorized mixing valve 4 way motorized mixing valve purging valve zh pressure relie valve C backflow preventer DHW temperature sensor Super Stor Ultra Outdoor temperature Indirect DHW Tank sensor heat exchanger radiant manitoid witn valve actuators Figure 5 radiant manifold LP 171 Rev 3 3 15 22 Standard MC Series Heater Drawing 1A zoning with valves Space heating mode LLLELLLELLELELULLLL PUMA zone valves ea seo note 6 i 4 1 2 make up water T D 2 Closely differential spaced 9 essure tees bypass valve L purging valves eese Heater 1 LI Super Stor Ultra indirect DHW Tank Figure 6 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed up
87. ettings Check ignition electrode Sand off any white oxide Clean and reposition Check ignition and ground wiring Check all control wiring and connections Check burner flame pattern stable and uniform Additional Items if Combustion or Performance is Poor e Clean heat exchanger and flue ways e Remove burner assembly and clean burner head using compressed air only Once the maintenance items are completed review service with the owner C COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS Before beginning this procedure you must on hand the following items e nylon stainless or brass brush not steel e Aliquid calcium and lime deposit remover e Gloves eye protection 1 Shut down the heater by using the following steps a Close the gas valve shut down the unit and wait for the unit to be cool to the touch b Disconnect the condensate hose from the outside connection not from the heater side so flow can be observed c Disconnect connections from the gas valve spark electrode and flame rectification probe and combustion blower d Remove the 4 screws on the aluminum 77 NPT connector on the gas valve e Disconnect the wiring connected to the combustion blower motor f Remove the 4 10MM nuts from the burner plate assembly to access the coils g Pull the entire burner plate assembly with blower still attached towards you while removing or pushing aside any wiring to allow the removal of the assembly LP 171 Rev
88. face Board Function 17 0 0 Building Management 1 Enables Tekmar Modulating Control Consult with Tekmar to assure the Tekmar Control is compatible LP 171 Rev 3 3 15 64 18 1 Step Modulation Regulates the burner output 6 steps in one minute intervals This reduces short cycling 1 0 off Indirect heater set point flow 13 Ted Temperature default 119 to 180 20 1 Not applicable NOTE The maximum water temperature leaving the heater is limited to 185 F Table 11 Central Heating Curve Function Central heating demand is detected when the room thermostat closes When an outside sensor is also connected the supply temperature will depend on the factory default central heating curve To set your heat curve you will have to set the following parameters 1 Minimum outside design temperature Function 8 CENTRAL HEATING CURVE CENTRAL HEATING CURVE Factory Default Plot your Curve 212 203 4 194 FUNCTION 9 476 EMEN 158 HH Q DEFAULT RESET CURVE 149 131 122 104 95 1 4 FUNCTION 11 864 FF 68 SUPPLY OUTLET TEMPERATURE F c 2 FE lt c ul gt ri 2 gt A a D o 59 UNCTIQN 1 0 41 OH TAL ILL or 45 63 59 41 24 9
89. g heater operation and service circulator replacement condensate trap control replacement etc Failure to follow these instructions could result in property damage serious personal injury or death A OPERATING INSTRUCTIONS Remove heater cover If you smell gas STOP Follow listed safety instructions If you do not smell gas follow the next steps DANGER 1 Turn on all electric power to heater Water temperature over 125 degrees can cause severe 2 If desired adjust the temperature set point of the heater The factory default burns instantly or death from setting is 180 F If changes are necessary follow Adjusting the Set point in this scalds Children disabled and section elderly are at highest risk of being scalded See instruction 3 Set the thermostat to the desired setting manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available 4 f the heater fails to start refer to the Troubleshooting section in the back of this manual ADJUSTING THE SET POINT 1 Before changing the temperature from the factory setting of 180 degrees you must make sure that none of the thermostats are call ing for heat The controller will not memorize a program setting while in a heating cycle To adjust the heater temperature simply press in the key for three seconds until you see a flashing C then an alternate value of 180
90. gnal is still present replace the igniter If the flame signal is not present after turning off the gas supply check the gas valve electrical connection If there is no power to the gas valve remove the valve and check for obstruction in the valve seat or replace the gas valve 5 Turn the gas on at the service valve after corrective action is taken Combustion fan speed out of tolerance The appliance will lock out if it F13 senses that the fan speed is not at 7096 the expected speed for more than 60 seconds 1 2 3 Check the combustion fan wiring Replace the combustion fan Replace the control board The control has been programmed by a technician or the factory After programming the control is left in a locked out mode Press the RESET key for at least 1 second to begin use of the control F31 Parameter Memory Call factory for further assistance Table 15 Resistance Tables OUTDOOR SENSOR 7250P 319 OUTSIDE TEMP RESISTANCE CF ohms 22 171800 13 129800 4 98930 5 76020 14 58880 23 45950 32 36130 41 28600 50 22800 59 18300 68 14770 77 12000 86 9804 95 8054 104 6652 113 5522 Table 16 HEATER SENSOR INDIRECT SENSOR 7250P 059 7250P 325 HEATER AND INDIRECT TEMPERATURE F RESISTANCE ohms 32 32550 41
91. h NFPA 720 latest edition Failure to comply with requirements for detectors and alarms could result in property damage severe personal injury or death DETERMINE THE LOCATION OF CONDENSATE PIPING This is a high efficiency heater and therefore produces condensate a by product of the combustion process A condensate collection system with an internal float switch monitors condensate level to prevent it from backing up into the combustion system There is a 32 Socket connection provided to connect the outlet of the collection system to a drain or condensate pump kit p n 554200 available from HTP If the heater condensate outlet is lower than the drain you must use a condensate removal pump NOTE The installer should fill the condensate trap with tap water prior to operating the heater NOTE The use of 72 PVC or CPVC pipe are acceptable materials for condensate piping Steel brass copper or other materials will be subject to corrosion or deterioration However use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement If pipe is used deburr and chamfer pipe to allow proper mating to the drainage assembly NOTE To allow for proper drainage on long horizontal runs a second line vent may be required and tubing siz
92. han one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS the following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required to be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PRO
93. hange the indirect circulator post purge time once the sensor is satisfied NOTE It is 6 0 Min recommended that circulator post purge time be set no greater than 5 minutes Range 0 to 60 minutes Outdoor temperature that you wish the central heating should be disabled warm weather shutoff 1 er Range 41 F to 122 F g Changes the minimum outside design temperature Range 49 F to 32 F See Table 12 to set outdoor reset curve Changes the design supply water temperature based on the minimum outside design temperature 9 180 F o o Range 77 F to 180 F 10 68 F Changes the maximum outside design temperature for central heating Range 95 F to 32 F Changes the design supply water temperature from the heater based on the maximum outside design temperature 11 95 F Range 32 F to 180 12 68 F Sets the lowest temperature on heater for central heating Range 32 F to 180 F Changes the central heating circulator post purge time once the thermostat is satisfied 13 0 Min Range 0 to 10 minutes Sets the maximum run time for the indirect water heater and the minimum run time for central heating 14 30 Min Range 0 60 minutes 15 0 Bus address 0 20 master 1 8 cascade slave Not currently used Interface Board Activation 16 0 0 not active 1 active WARNING Never change the default setting without the heater interface board installed Inter
94. have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas G CHECK THERMOSTAT CIRCUIT S 1 Disconnect the two external wires connected to the heater thermostat terminals low voltage terminal strip terminals 5 and 6 2 Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to heater low voltage terminal strip Allow the heater to cycle H CONDENSATE REMOVAL 1 This a high efficiency condensing heater there the unit has a condensation drain Condensate is nothing more than water vapor derived from combustion products similar to an automobile when it is initially started The condensation is slightly acidic typically with pH of 3 to 5 and must be piped with the correct materials Never pipe the condensate using steel copper brass or other materials that will be subject to corrosion Plastic PVC or CPVC pipe are the only approved materials A condensate filter if required by local authorities can be made up
95. he air Operating a previously submerged heater could result in property damage severe personal injury or death NOTE Heater damage due to flood or submersion is considered an Act of God and IS NOT covered under product warranty CAUTION This heater has wire function labels on all internal wiring Observe the position of each wire before removing it Wiring errors may cause improper and dangerous operation Verify proper operation after servicing CAUTION If overheating occurs or the gas supply fails to shut off do not turn off electrical power to the circulating pump This may aggravate the problem and increase the likelihood of heater damage Instead shut off the gas supply to the heater at the gas service valve LP 171 Rev 3 3 15 66 926 CONTROL BOARD ERROR CODES CODE DESCRIPTION DURATION CORRECTIVE ACTION FOU Outdoor sensor is open shorted or outdoor temperature is below 40 F Until Corrected 1 Disconnect the outdoor sensor from the wiring and measure its resistance Compare the measured resistance to the table in this manual to see if it corresponds to the temperature of the sensor If the resistance does not agree with the sensor replace the sensor 2 If the resistance is OK disconnect the sensor wiring from both the boiler and the sensor and check continuity using an ohmmeter Repair or replace as necessary The system sensor is open or short
96. i 9 27 45 6 81 99 OUTSIDE TEMPERATURE OUTSIDE TEMPERATURE F Table 12 Central Heating Curve Factory Default 2 Design supply water temperature at the minimum design outside temperature Function 9 3 Maximum outside design temperature Function 10 4 Design supply water temperature at the maximum outside temperature Function 11 NOTE The homeowner can adjust the heat curve down by adjusting the central heating temperature to a lower setting LP 171 Rev 3 3 15 65 PART 14 TROUBLESHOOTING A ERROR CODE An error code may occur in the installation of the heater This condition may lead to a lock out condition of the controller which will need to be manually reset through the These temporary codes will help the A eum T CONTROL PROGRAM REFERENCE CHART installer correct the problem before going into a lock out condition which will require a manual reset FUNCTION DEFAULT PROGRAMMED SETTING SETTING B HEATER ERROR 1 de No change allowed 1 When an error condition occurs the controller will display an error code on the 149 F No change allowed display module 3 160 F 4 36 F No change allowed 2 These error codes and several suggested corrective actions are included in Table 5 7 F 14 6 0 7 68 F 3 In the case of E00 E13 and E14 this error if uncorrected will go into a fault 8 condition
97. ica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 e Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website e Wear long sleeved loose fitting clothing gloves and eye protection e Apply enough water to the combustion chamber to prevent dust e Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid e Eye Irrigate immediately e Breathing Fresh Air B MAINTENANCE SCHEDULE FOR THE SERVICE TECHNICIAN The following maintenance should be performed annually by a qualified service technician General e Attend to any reported problems Inspect the interior of the heater jacket area clean and vacuum if necessary Clean the condensate trap and fill with fresh water Check for water gas flue and condensate leaks Verify flue vent piping and air inlet piping are in good condition properly supported and tightly sealed Check heater water pressure piping and expansion tank Check control s
98. iction 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 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 DA This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage This heater must be installed by qualified and licensed personnel The installer should be guided by the instructions furnished with the heater 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 v
99. inimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 PART 4 PREPARE HEATER WARNING UNCRATING HEATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee CAUTION COLD WEATHER HANDLING If the heater has been stored a very cold location BELOW 0 F before installation handle with care until the plastic components come to room temperature A REMOVE HEATER FROM BOX The heater is easy to handle Care must be taken to place it in a safe location prior to installation to prevent damage to the bottom mechanical connections WALL MOUNTING CONSIDERATIONS These heaters are wall mounted Use only the wall mounting instructions included in installation envelope WARNING The wall must be capable of carrying the weight of the heater and its related components The weights of the heaters are approximately 50 71 lbs 80 74 Ibs 99 84 Ibs MC 120 84 lbs Failure to comply with above could result substantial property damage severe personal injury death LP 171 Rev 3 3 15 15 WALL MOUNTING INSTRUCTIONS WARNING This heater is heavy and awkward to lift It is recommended and safer to install the heater with two people Use caution as to not drop the heater which could damage the h
100. is iit ERE 20 t ent eed eni Bet e uo d ete ences 21 PART 6 PIPING WITH OPTIONAL VISION 1 SYSTEM 22221 111 nnns ates atn sana ssa ssa sms 28 VISION 1 SYSTEM PIPING tette b e HERR e d E RR 28 B ZONING WITH ZONE VALVES USING VISION 1 28 C ZONING WITH CIRCULATORS USING 28 D PIPING DETAILS WITH THE VISION 1 5 29 PART 7 VENTING COMBUSTION AIR AND CONDENSATE 39 A GENERAL en eU e eb e ete ei b t e C RE t E e E tae ce edu 39 B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE 40 C REQUIREMENTS FOR INSTALLATION IN 40 D EXHAUST VENT AND INTAKE PIPE itr itrs dtes 41 E ROTATING THE FLUE ADAPTER te od aN se cee pe t tem e e tnb eee ne 44 F EXHAUST VENT AND INTAKE PIPE 6 45 G LONGER VENT RUNS etd i Ue e ERE GERE RR ee ns 45 H EXHAUST VENT AND INTAKE PIPE 46 I VENTING DRAWINGS cist ete tete t tete ce n e a dud e Pet o ete tc 46 lE DEC tuu cm 48 A GAS GONNEGCTION det edis 48 GAS PIPIN G ie ERREUR e UC CIE ete Rd 50 GHECK IN
101. is 46 feet which is well below the maximum of 85 feet Figure 25 Upsizing Vent Diameter c The exhaust vent and intake pipe are intended to penetrate the same wall or roof of the building d Effort should be made to keep a minimum difference in equivalent length between the exhaust vent and intake pipe 3 The minimum total equivalent length is 32 equivalent feet G LONGER VENT RUNS The maximum total equivalent length can be extended by increasing the diameter of both exhaust vent and intake pipe equally However the transitions should begin a minimum of 15 equivalent feet from the heater a Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe b Use a 3 x 2 reducing coupling to transition from the 2 connections to a 3 vent c The maximum equivalent length for the increased diameter vent pipes is 125 feet d If the transition occurs at a distance greater than 15 equivalent feet from the heater the maximum equivalent length will be reduced See Table 6 The standard vent pipe is 2 TRANSITION POINT FT TEL OF STANDARD 2 TEL OF OVERSIZED 2 3 OR MAXIMUM TEL OF ALL VENT FROM HEATER VENT PIPE FT 4 VENT PIPE FT PIPE FT 15 30 95 125 20 40 77 1 2 117 1 2 25 50 60 1 2 110 1 2 30 60 43 103 35 70 26 96 40 80 8 1 2 88 1 2 85 0 85 Table 6 LP 171 Rev 3 3 15 46 EXH
102. k the operation of the float switch in the cup The float should pivot freely in the cup and the back of the float should contact the stem of the switch when in the down position 4 Reinstall the condensate cup While doing so check the operation of the cup in place switch The switch should contact the protrusion on the plastic socket that the cup is secured into and trip when the cup is snapped into place 5 Check to be sure that the 2 pin condensate cup connector is securely plugged into the socket on the bottom of the heater 6 If FLU code is still present and the cause not found check continuity of wiring from the flue switch to the condensate cup connector pink wires and from the condensate cup connector through the condensate float switch and condensate cup in place switch These three devices are all wired in series with each other Repair any wiring or replace defective components if necessary DANGER Do not Jump Out any of the devices in this circuit These devices ensure product safety and must be in place and connected at all times of normal operation Table 14 926 Control Board FAULT Code Description Remedy mele 1 Check circulation pump operation High temperature switch 2 Assure that there is adequate flow through the heater by accessing the status menu and assuring that there limit exceeded 194 F is less than a 50 F rise from the return thermister to the supply th
103. licable state codes may apply the unit shall be installed with a CO detector per the requirements listed below 5 08 Modifications to NFPA 54 Chapter 10 1 Revise NFPA 54 section 10 5 4 2 by adding a second exception as follows Existing chimneys shall be permitted to have their use continued when a gas conversion burner is installed and shall be equipped with a manually reset device that will automatically shut off the gas to the burner in the event of a sustained 2 Revise 10 8 3 by adding the following additional requirements For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an al
104. ls 3 Connect the expansion tank to the air separator only if the separator is 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 CAUTION 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 its air cushion An automatic air vent would cause air to leave the system resulting in water logging the expansion tank DIAPHRAGM OR BLADDER EXPANSION TANK Always install an automatic air vent on top of the air separator to remove residual air from the system F CIRCULATORS CAUTION DO NOT use the heater circulator in any location other than the ones shown in this manual The heater circulator is selected to ensure adequate flow through the heater Failure to do so could result in unreliable performance and nuisance shutdowns from insufficient flow LP 171 Rev 3 3 15 18 SIZING SPACE HEAT SYSTEM PIPING 1 See Piping Details in this section In all diagrams the space heating system is isolated from the heating loop by the primary secondary connection 2 Size the piping and components in the space heating system using recognized design methods G HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND MULTIPLE HEATERS This heater may function in a clos
105. me Follow all fluid manufacturer instructions NOTE Heater failure due to improper water chemistry is not covered by warranty LP 171 Rev 3 3 15 58 FREEZE PROTECTION WHEN USED CAUTION NEVER use automotive or standard glycol antifreeze or ethylene glycol made for hydronic systems System water including additives must be non toxic having a toxicity rating or Class of 1 as listed in Clinical Toxicology of Commercial Products Use only freeze prevention fluids certified by fluid manufacturer as suitable for use with stainless steel heaters verified in fluid manufacturer literature Thoroughly clean and flush any system that has used glycol before installing the new heater Provide heater owner with a material safety data sheet MSDS on the fluid used 1 Determine freeze protection fluid quantity using total system water content following fluid manufacturer s instructions Remember to include expansion tank water content 2 NOTE Local codes may require back flow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level C FILL AND TEST WATER SYSTEM WARNING Ensure the heater is full of water before firing the burner Failure to do so will damage the hea
106. mperature before attempting to purge air from the heat exchanger purge valve The supplied tubing is rated to 120 F maximum The control system allows the installer to run the heater pump and indirect pump manually to assist in purging air from the system This feature in combination with the supplied purge hose and fitting on the heat exchanger will help to remove air from the heat exchanger and hydronic piping system To remove air from the system follow the steps listed on the following page CAUTION Open manual air vent BY HAND ONLY Use of tools such as wrenches or pliers can snap or crack the valve NOTE This damage IS NOT COVERED BY WARRANTY LP 171 Rev 3 3 15 59 1 Take the 5 16 flexible clear tube rated for maximum temperature of 120 provided with the heater and place it over the barbed nipple on the manual air vent TURN TO OPEN POSITION as shown in Fig 31 AS SHOWN 2 Fasten the tie wrap provided securely around the tube fastened to the barbed y et dae nipple on the manual air vent to keep the plastic tube from separating from the WHILE PURGING WHEN barbed nipple while purging the system 1 DONE PURGING RETURN AIR VENT TO CLOSED 3 Turn the manual air vent to the open position as shown in Fig 31 Air and water Im viet EMO Va should drain freely from the system TUBE 4 Close the manual air vent when ONLY water flows freely from the end of
107. ms Glycol mixtures should not exceed 5096 1 Glycol for hydronic applications includes inhibitors that prevent it from attacking metallic system components Make certain that the System fluid is checked for the correct glycol concentration and inhibitor level 2 The glycol solution should be tested at least once a year and as recommended by the glycol manufacturer 3 Anti freeze solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F to 180 F while water expands 3 with the same temperature rise Allowances must be made for this expansion in the system design 4 A 3096 mixture of glycol will result in 1596 BTU output loss and a 596 increase in head against system circulator 5 A 50 mixture of glycol will result in 30 BTU output loss and a 50 increase in head against system circulator CAUTION It is highly recommended that you carefully follow the glycol manufacturer s concentrations expansion requirements and maintenance recommendations pH additive breakdown inhibitor reduction etc You must carefully figure the additional system friction loss as well as the reduction in heat transfer coefficients LP 171 Rev 3 3 15 PIPING DETAILS 21 Piping symbol legend circulator w Isolation flanges gate valve globe valve valve swing check valve flow check valve TRV straight TRV angle circuit s
108. n Specification Wire 18 AWG maximum Length of wire run cannot exceed 100 feet PART 11 START UP PREPARATION WARNING Thoroughly clean and flush any system that has used glycol before installing the heater Provide the customer with a material safety data sheet MSDS on the fluid used A CHECK CONTROL WATER CHEMISTRY CAUTION Chemical imbalance of your water can cause severe damage to your heater 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 heater 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 To assure extended service life it is recommended to test water quality prior to installation Listed below are some guidelines WARNING Do not use petroleum based cleaning or sealing compounds in heater system Damage to elastomer seals and gaskets in system could occur resulting in substantial property damage Sodium less than 20 mGL Water pH between
109. n be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 27 Multiple MC Series Heaters Drawing 1F Preferred piping zoning with circulators Domestic water heating mode La L LI guum Figure 11 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all
110. nges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 25 Standard Series Heater Drawing 1D zoning with circulators Domestic water heating mode see note 6 CN gt lt T 1 make up water closely spaced tees see note 6 purging valves mixing valve MC SERIES Heater v Lo wassaensed Super Stor Ultra indirect DHW Tank Figure 9 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges Th
111. nies 14 B WALL MOUNTING 14 GC WALL MOUNTING INSTRUCTIONS cninn aaa eben ei 15 Di INSTALLATION S EEPS n ee ih Aan eb cea te E E EE a ede T 15 PART 5 HEATER 250 0 15 A GENERAL PIPING INFOBMATION dte eio UR Ie GR RR URBC REM GR RAE DR HR IESUS 15 B RELIEF VALVE ee rette ete deti hav n hs EX reece 16 C SEPARATE LOW WATER CUTOFF e bpm btt t uites fecit 17 D BACKFEOW PREVENTER 1 5 ih tbe e e E ee tbe i t eh e TE m ete ed e RC 17 E SYSTEM WATER PIPING METHODS ne iet e tte EE iR te e RM tase itp xh dg 17 LP 171 Rev 3 3 15 tee t e c cede de ht pe ates ae tede 17 G HYDRONIC PIPING WITH CIRCULATORS ZONE VALVES AND MULTIPLE 18 H CIRCULATOR SIZINQG nnn rette eh Avital dite ri d e ecd Sees 18 I ZONING WITH ZONE VALVE Ssi ex ttle avn eo GM De AL a ma iets fb doeet dt 19 J ZONING WITH CIRCULATORS ii oh tetas is eR e ei Te av pel dla ee re 19 K MULTIPLE HEATERS heist ikke A uei Pb died c eoi EUR 19 Lo FLE AND PURGE HEATING SYSTEM iie ed
112. o not install the heater outdoors Failure to install this heater indoors could result in substantial property damage severe personal injury or death 2 Check for nearby connections to e System water piping Venting connections Gas supply piping Electrical power Condensate drain 3 Check area around heater Remove any combustible materials gasoline and other flammable liquids LP 171 Rev 3 3 15 11 WARNING Failure to keep heater area clear and free of combustible materials liquids and vapors can result in substantial property damage severe personal injury or death 4 Gas control system components must be protected from dripping water during operation and service 5 If the heater is to replace an existing heater check for and correct any existing system problems such as e System leaks e Location that could cause the system and heater to freeze and leak e Incorrectly sized expansion tank 6 Clean and flush system when reinstalling a heater 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 heater model and serial number SYSTEM RETURN COMBUSTION AIR INLET CONNECTION 2 ELECTRICAL BOX CONTROL PANEL 2 SYSTEM SUPPLY 5 EXHAUST VENT CONNECTION GAS LINE CONNECTION SYSTEM RELIEF 6 CONDENSATE CUP DRAIN ASSEMBLY G E 4
113. odulating temperature control The control module also provides low water protection by sensing the water pressure Some codes jurisdictions may require additional external controls B RELIEF VALVE The relief valve must comply with the standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI 221 22 and or the standard Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves CAN1 4 4 as well as all local codes In addition the relief valve must be rated to the maximum BTU hr rating of the heater The American National Standard ANSI Z21 10 3 Canadian Standard CSA 4 3 do not require a combination temperature and pressure relief valve for this heater However a combination temperature and pressure relief valve may be required by local codes Connect discharge piping to safe disposal location See the following guidelines WARNING To avoid water damage or scalding due to relief valve operation e 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 e Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain making di
114. of level installation 2 Remove the heater cover Locate the 2 keyway slots over the screws Then lower the heater onto the smallest part of the keyway slot 3 Once the heater is mounted on the first 2 screws finish tightening the screws to the back panel Then install the 6 additional screws of the same size to the back panel holes This will provide additional strength and support to the heater PART 5 HEATER PIPING WARNING Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage serious injury or death CAUTION Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or heater Use only copper or brass fittings Teflon thread sealant must be used on all connections All piping and components connected to the heater must be approved for potable water systems Plumbing of this product should only be done by a qualified licensed plumber in accordance with all local plumbing codes The heater may be connected to a storage tank to supply domestic hot water HTP offers 60 80 119 175 gallon size storage tanks in either stainless steel or glass lined construction These storage tanks can be directly connected to the heater supply and return connection CAUTION The National Standard Plumbing Code the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat tran
115. ompany shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with a conventional gas valve under any circumstances WARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure and requires no field adjustment Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve and cause substantial property damage severe personal injury or death D GAS VALVE OFF SET ADJUSTMENT ADJUSTMENT PRESSURE TAP OUTLET THIS SCREW WITHOUT A ecto THROTTLE ADJUSTER FOR COMBUSTION SETT NOTE IF FOR ANY REASON THE TABLE THROTTLE NEEDS TO BE ADJUSTED IT IS VERY IMPORTANT THAT A COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE ADJUSTER TO THE TO INCREASE GAS OR THE TO DECREASE THE GAS SUPPLY THIS ADJUSTMENT COULD AFFECT CO CO LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHART IN COMBUSTION SETTINGS sEE PART 12 SECTION D PRESSURE TAP INLET GAS VALVE Figure 29 LP 171 N LP 171 Rev 3 3 15 52 DANGER Do not do gas conversion on this heater without an officially approved conversion kit and instructions supplied by HTP Failure to use a conversion kit when converting the heater to fire on Natural or LP gas will result in extremely dangerous burner
116. ondensate neutralizers are made up of lime crystals marble or phosphate chips Neutralizers can be installed in the field by the installer and purchased from HTP p n N1100 It is also very important not to expose the condensate line to freezing temperatures or any type of blockage Plastic tubing must be the only material used for the condensate line Steel brass copper or other materials will be subject to corrosion or deterioration A second vent may be necessary to prevent condensate line vacuum lock on a long horizontal run Also an increase in pipe size may be necessary to allow condensate to drain properly Support of the condensation line may be necessary to avoid blockage of the condensate flow Spark Ignition The burner flame is ignited by applying a high voltage to the system spark electrode This causes a spark from electrode to ground The Vision 1 Optional System By controlling the temperature delivered to the central heating circuits based on outside temperature the Vision 1 System allows the installer to take this highly efficient heater and make it even more efficient The Vision 1 System is also a two temperature system using one temperature for central heating and the other for use with an indirect water heater This allows the user to increase the temperature supplied to the indirect water heater to get a faster recovery by prioritizing the flow at a higher temperature than may be needed for the central heating circuits this r
117. oxic NSF food grade propylene glycol FDA rated as GRAS Generally Recognized As Safe into the system Consult the glycol manufacturer for specific instructions on concentration percentage as well as freeze and burst protection methods Check the volume and concentration of antifreeze to assure protection is adequate to protect the entire system from freezing When pumping allow air and remaining water to escape from purge valve When the stream coming out of the purge valve matches the color of the non toxic glycol the system is adequately filled Finally it is recommended to start the circulation pump and allow the system to circulate for at 30 minutes to completely blend any trapped water that might be in the system with the glycol PART 2 BEFORE YOU START A WHAT S IN THE BOX Also included with the heater e Temperature and Pressure Relief Valve Pressure and Temperature Gauge Intake PVC Tee with Screens Exhaust PVC Coupling with Screens Plastic hose and Instructions for Purging Heat Exchanger Installation Manual Warranty B HOW THE HEATER OPERATES Modulation Condensing Technology is an intelligent system that delivers highly efficient water heating while maximizing efficiency by measuring the data parameters of your system Stainless Steel Heat Exchanger The highly efficient and durable stainless steel heat exchanger is designed to extract the last bit of energy from flue gas before it is exhausted LP 171 Rev 3 3 15 Mo
118. provided in this manual Failure to properly install the vent system will result in property damage severe personal injury or death A GENERAL DANGER This heater is certified as a Category IV appliance and requires a special venting system The vent system will operate with a positive pressure in the pipe Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure Follow the venting instructions below carefully Failure to do so will result in substantial property damage severe personal injury or death 1 Installation should be made in accordance with the regulations of the Authority Having Jurisdiction local code authorities and utility companies which pertain to this type of water heating equipment 2 Install the venting system in accordance with these instructions and with the National Fuel Gas Code ANSI Z223 1 NFPA 54 CAN CGA B149 and or applicable provisions of local building codes 3 This water heater must be vented with materials components and systems listed and approved for Category IV appliances A DANGER Exhaust vent and intake pipes are to be piped separately This heater cannot share a common exhaust or intake with multiple appliances Failure to follow this instruction will result in
119. r death F PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the heater as described in the Venting section Do not terminate exhaust in locations that can allow contamination of intake air 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 Table 1 Contaminant Table WARNING You must pipe outside air to the heater air intake Ensure that the intake air will not contain any of the contaminants listed in Table 1 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 Contaminated air will damage th
120. rculators are based on 1 gpm per 10 000 btu hr with 20At I ZONING WITH ZONE VALVES 1 Connect heater to system as shown in 1A and 1B in Piping Details when zoning with zone valves The primary secondary piping shown ensures the heater loop will have sufficient flow It also avoids applying the high head of the heater circulator to the zone valves 2 Connect DHW domestic hot water piping to indirect storage water heater as shown 4 ZONING WITH CIRCULATORS 1 Connect heater to system when circulator zoning as shown in 1C and 1D in Piping Details when zoning with circulators The heater circulator cannot be used for a zone It must supply only the heater loop Install a separate circulator for each zone 2 Connect DHW domestic hot water piping to indirect storage water heater as shown K MULTIPLE HEATERS 1 Connect multiple heaters as shown in 1E and 1F in Piping Details 2 All piping shown is reverse return to assure balanced flow through the connected heaters 3 Each connected heater must have its own circulator pump to assure adequate flow 4 Connect DHW domestic hot water piping to indirect storage water heater as shown LP 171 Rev 3 3 15 20 L FILL AND PURGE HEATING SYSTEM Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain e Close the other side of the balance and purge valve or the shut off valve after the drain e Open first zone balance and purge or drain
121. roduct Serial Number s Comments Installers Phone Number Signed by Installer Signed by Customer IMPORTANT NOTES Customer Please only sign after the installer has reviewed the installation safety proper operation and maintenance of the system In the case that the system has any problems please call the installer If you are unable to make contact please contact your HTP Sales Hepresentative Distributor Dealer Please insert contact details LP 171 Rev 3 3 15
122. ry D MAINTENANCE SCHEDULE FOR THE OWNER CAUTION The following information provides detailed instruction for completing maintenance items In addition to this maintenance the heater should be serviced at the beginning of the heating season by a qualified service technician Periodically e Check area around the unit o Review Table 1 Contaminant Table p 13 If contaminates are found Remove contaminates immediately from area If contaminates have been the area for an extended period call a qualified service technician to inspect the unit for possible acid corrosion damage f contaminates cannot be removed immediately call a qualified service technician to re pipe the combustion air inlet piping and locate the intake away from contaminated areas o Do not store combustible materials gasoline or other flammable vapors or liquids near the unit If found remove these materials immediately e Check and remove any blockage from the combustion air inlet and ventilation openings o If removing debris does not allow the unit to operate correctly contact a qualified service technician to inspect the unit and the vent combustion air system e Check the temperature and pressure gauge o Ensure the pressure reading on the gauge does not exceed 25 psig Higher pressure readings may indicate a problem with the expansion tank o Ensure the temperature on the LED display panel does not exceed 180 F Higher temperature reading
123. s may indicate a problem with the thermostat operating controls o Contact a qualified service technician if problem persists Monthly e Check vent piping o Visually inspect the flue gas vent piping for any signs of blockage leakage or deterioration Ensure that vent piping is properly supported as described in this manual Notify a qualified service technician immediately if any problems are found WARNING Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure causing substantial property damage severe personal injury or death e Check combustion air inlet piping o Visually inspect the air inlet piping for any signs of blockage Inspect the entire length of the intake to ensure piping is intact and all joints are properly sealed and supported Notify a qualified service technician if any problems are found e Check the pressure relief valve LP 171 Rev 3 3 15 70 o Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage o Ifthe pressure relief valve often weeps the expansion tank may not be operating properly Immediately contact a qualified service technician to inspect the unit and system e Check the condensate drain system o While the unit is running check the discharge end of the condensate drain tubing Ensure no clue gas is leaking from the condensate drain tubing by holding yo
124. scharge clearly visible e discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater e Do not pipe discharge to any location where freezing could occur e 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 e 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 e Test relief valve at least once annually to ensure the waterway is clear If valve does not operate turn the heater and call a plumber immediately e care whenever operating relief valve to avoid scalding injury or property damage e For heaters installed with only a pressure relief valve the separate storage vessel must have a temperature and pressure relief valve installed This relief valve shall comply with Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA4 4 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 WARNING Hot water outlet pipes can be hot to touch Insulation must be used for hot water pipes below 36 to protect children against injuries due to
125. se Clean out dirt Fill with water to level of outlet and re install NOTE Verify the flow of condensate making sure that the hose is properly connected during final inspection GAS Pressure Measure incoming gas pressure 3 5 to 14 W C Pressure Drop Measure drop in pressure on light off no more than 1 W C Check gas pipe for leaks Check piping for leaks Verify that all are properly supported COMBUSTION 2 Levels Check levels in Exhaust See Start up Procedures for ranges Record at high and low fire SAFETIES ECO Energy Cut Off Check continuity on Flue and Water ECO Replace if corroded Water Pressure Switch Check operation and for signs of leakage Replace if corroded Thermistors Check wiring Verify through ohms reading FINAL INSPECTION Check list Verify that you have completed entire check list WARNING FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH Homeowner Review what you have done with the homeowner Table 19 Continue annual maintenance beyond the 4 year as required LP 171 Rev 3 3 15 76 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth When installed in the Commonwealth of Massachusetts or where app
126. severe burns instantly or death from scalds Children disabled and elderly are 4 t 2 _ at highest risk of being scalded See instruction manual before lt setting temperature at water heater Feel water before bathing or n 1 t h ean d LTA showering Temperature limiting valves are available See chart TA below showing temperature burn rate Indirect Circulator P2 Program Function The Indirect Circulator Program Function will automatically start when the water heater sensor reads a call for heat The installer can also program the post purge function on the circulator The post purge circulator function ranges from 1 30 minutes Indirect Circulator P2 The Indirect Circulator connects to the heater terminal strip Run wire to the SuperStor Ultra Indirect circulating pump The purple wire is the neutral lead and the pink wire is the hot This will supply 120 volts directly to the water heater circulator Fault Code Alarm Output The Fault Code Alarm Output connects to the heater main control Route wire from the heater controller to an external relay or an audible alarm The red wire will be your hot lead supplying 120 volts The neutral connection will be connected to the neutral on the incoming power to the heater CAUTION Do not tie neutrals or hot wire leads to any other wires Go directly from the heater controller to the circulator LP 171 Rev 3 3 15 57 Connectio
127. sfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum The heat transfer fluid must be water or other non toxic fluid having a toxicity of Class 1 as listed in Clinical Toxicology of Commercial Products 5 Edition A GENERAL PIPING INFORMATION CAUTION The building piping system must meet or exceed the piping requirements in this manual CAUTION Use two wrenches when tightening water piping at heater Use one wrench to prevent the heater return or supply line from turning Failure to prevent piping connections from turning could cause damage to heater components LP 171 Rev 3 3 15 16 1 The water supply should be shut off while connecting the heater A manual control valve must be placed on the inlet connection to the heater Unions can be used on both the hot and cold water lines for future servicing and disconnection of the unit 2 Purge the water line to remove all debris and air Debris will damage the water heater 3 If the heater is to be used as a potable water source it must not be connected to a system that was previously used for non potable purposes 4 Ensure that the water filter on the heater is clean and installed 5 New plumbing typically has contamination in the lines Please flush the system before connection CAUTION The heater control module uses temperature sensors to provide both high limit protection and m
128. sible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 39 PART 7 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL The heater must be vented as detailed in this Venting Section Ensure exhaust vent and intake piping complies with these instructions regarding vent system Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured airtight and comply with all applicable code requirements as well as with the instructions
129. sistor is provided between Bus Lines and DO NOT REMOVE THIS RESISTOR DOING SO WILL EFFECT HEATER OPERATION AND VOID WARRANTY LP 171 Rev 3 3 15 55 SERIES INTERNAL CONNECTION DIAGRAM 120 VAC LINE lt lt LEKE lt x lt NEUTRAL POWER SWITCH DISPLAY BOARD pus ASSEMBLY 2 E INLET TEMPERATURE SENSOR X61 X64 X62 X2 PROTECTED BY AN INTERNAL 6 3 AMP FUSE 221 lt WATER TEMP mueEco FUSE m oce CORK BRN e ALARM RELAY lt lt cRI ORANGE gt SPARK CABLE TO SPARK ELECTRODE H lt FLAME RECTIFICATION PROBE BLOWER MOTOR 4 HOT OUTDOOR DHW TANK FNT gt GAS VALVE TT TERMINALS 926 CONTROL 5 3 X54 I NEUTRAL RS485 BUS RS485 BUS LP 171 CC 04 10 14 Figure 32 MC Series Internal Connection Diagram PART 10 FIELD WIRING VISION 1 OPTION Outdoor Sensor Function The user can program the desired supply temperature based on the heat transmitter baseboard radiant floor air handler that will be used in the installation Once the outdoor sensor light green wires is connected to the control board the water temperature of the heater will adjust to run the heater more efficiently and provide greater comfort to the living space Connection Specification Wire
130. sponsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 37 Series Heater with optional VISION 1 system Drawing 3F Multiple high temperature priority loads controlled with zone valves Nigh temperature loads MC SERIES 1 t OFF 7 P1 EA Figure 20 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required
131. stream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an alternative 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 23 Drawing 1B SEED COU HAY q make up water m D a 3 DE closoly ditotontial LL rossu 995 lt U valve purging valves I 3 Super Stor Ultra indirect DHW Tank Figure 7 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5
132. substantial property damage severe personal injury or death NOTE To avoid contamination often contained in indoor air it is best to pipe all intake combustion air directly to the outdoors NOTE If exhaust vent pipe system passes through an unheated space such as an alcove or attic the space must be heated or the pipe must be insulated The insulation must have an R value sufficient to prevent freezing of the condensate WARNING Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter Failure to do so could result in property damage severe personal injury or death A DANGER Due to the extreme flammability of most glues cements solvents and primers used to join plastic exhaust vent and intake pipes explosive solvent vapors must be cleared from all vent piping before start up Avoid using excess cement or primer as this may pool in the vent pipes Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance Failure to follow these instructions will result in substantial property damage severe personal injury or death It is the installers responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks LP 171 Rev 3 3 15 40 APPROVED M
133. t over public walkways driveways or parking lots Condensate could drip and freeze resulting in a slip hazard or damage to vehicles and machinery 9 Due to potential moisture build up sidewall venting may not be the preferred venting option To save time and cost carefully consider venting installation and location 10 Horizontal lengths of exhaust vent must slope back towards the heater not less than 1 4 per foot to allow condensate to drain from the vent pipe 11 The exhaust vent must terminate where vapors cannot make accidental contact with people or pets or damage shrubs or plants 12 In vacant chimney applications install and seal a rain cap over existing chimney openings 13 All piping must be fully supported Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form 14 Do not use the heater to support any piping 15 A screened straight coupling is provided with the heater for use as an outside exhaust termination 16 A screened inlet air tee is provided with the heater to be used as an outside intake termination The following information on Table 7 lists optional intake air exhaust vent terminations available from HTP DESCRIPTION STOCK CODE 2 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0501CVT 3 PVC CONCENTRIC VENT TERMINATION KIT KGAVT0601CVT 2 STAINLESS STEEL VENT TERMINATION KIT V500 3 STAINLESS STEEL VENT TERMINATION KIT V1000 4
134. t vented appliance is approved for zero clearance to combustible construction e The flue products coming from the exhaust vent will create a large plume when the boiler is in operation Avoid venting in areas that will affect neighboring buildings or be considered objectionable DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe DO NOT locate the exhaust vent or intake pipe terminals under a porch balcony or veranda Avoid terminating exhaust vents near shrubs air conditioners or other objects that will obstruct the exhaust stream DO NOT vent over a public walkway Condensate could drip or freeze and create a nuisance or hazard NOTE Due to potential moisture build up sidewall venting may not be the preferred venting option Carefully consider venting installation and location to save time and cost LP 171 Rev 3 3 15 42 WARNING The building owner is responsible for keeping the exhaust and intake terminations free of snow ice or other potential blockages as well as scheduling routine maintenance Failure to keep the vent piping terminations clear and properly maintain the heater could result in property damage severe personal injury or death WARNING For each floor containing bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms as well as in the room that houses the heater Detectors and alarms shall comply wit
135. ter Such damage IS NOT covered by warranty and could result in property damage severe personal injury or death 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and heater drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a Typical cold water fill pressure for a residential system is 12 psi b Pressure will rise when heater is turned on and system water temperature increases Operating pressure must never exceed 25 psig 4 At initial fill and during heater startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further WARNING Eliminate all system leaks Continual fresh make up water will reduce heater life Minerals can build up in the heat exchanger reducing heat transfer overheating heat exchanger causing heat exchanger failure and possibly resulting in property damage severe personal injury or death 5 The system may have residual substances that could affect water chemistry After the system has been filled and leak tested verify water pH and chlorine concentrations are acceptable D AIR PURGING PROCEDURE FOR HEAT EXCHANGER CAUTION It is important that you purge the system of air to avoid damage to the heater Make sure that this procedure is followed before firing the heater WARNING The heater must be room te
136. ter to the supply thermister LP 171 Rev 3 3 15 67 No flame detected heater will make three attempts at ignition before the control goes into this lockout condition See spark electrode detail 1 Watch the igniter through the observation window provided 2 If there is no spark check the spark electrode for the proper gap by holding two quarters together and sliding them through the gap Remove any corrosion from the spark electrode and flame rectifier probe If there is a spark but no flame check the gas supply to the heater If there is a flame check the flame sensor Check any flue blockage or condensate blocks Loss of flame signal The heater will relight 4 times F10 before the control goes into this lockout condition Will reset in 1 hour Monitor the gas pressure to the unit while in operation Assure that the flame is stable when lit Check to see if the green light on the display module is out while the heater is running If the green light doesn t come on or goes off during operation check the flame signal on the status menu If the signal reads less than 1 microampere clean the flame rectifier probe If the flame rectifier probe continues to read low replace it False flame signal The heater will lock out if it senses a flame signal when there should be none present Turn the gas off to the unit at the service valve If the flame si
137. ter volumes are listed in Table 3 below MINIMUM BOILER FLOW RATES MODEL MINIMUM FLOW GPM MC 50 3 3 MC 80 5 3 MC 99 7 8 120 8 Table 3 Minimum Heat Exchanger Water Volumes In addition the heat exchanger has pressure drop which must be considered in your system design Refer to the graph in Figure 4 for pressure drop through the heat exchanger for recommended pump selection at a 20At design LP 171 Rev 3 3 15 19 chart below represents various system temperatures and their respective flows and friction loss through the heater which will aid circulator selection Friction in Feat of Head Flow in Gallons per Minute 1 CONTENDER 9 CONTENDER MCA 8 CONTENDER 4 CONTENDER MC120 BL GOSSET ears osese sro wcwrwcuo ono war UP 171 F Rew 10 30 06 NOTE The recommended circulators are based on 1 gpm per 10 000 btu hr with 20 At The chart below represents various system temperatures and respective flows and friction loss which will aid circulator selection SYSTEM TEMPERATURE RISE CHART 20 At 25 At _ 30 A At Flow Friction Flow Friction Flow Model Feet GPM Feet GPM Feet 50 80 7 8 47 64 29 53 Reno Imi oo Io IL Mc i20 10 12 7 96 5 N R Not recommended Figure 4 Pressure Drop Graph and Temperature Rise Chart LP 171 F NOTE The recommended ci
138. the hose 5 Follow the guidelines in Section E in this section to purge each individual zone in the system 6 Remove any electrical connections to the Thermostat terminals and DHW Re sensor terminals of the heater This will prevent the heater from the firing when the 2 POSITION power is applied 7 Apply power to the heater making sure that the thermostat terminals are not connected The display will show you the temperature of the water and or air in the heat exchanger Figure 33 WARNING Do not open purge valve if displayed temperature is greater than 90 F 8 Press the and keys on the display simultaneously and hold for 1 second The display will begin alternating between SEP and CH and the heater pump will come on If you press the key the heater pump will shut off the display will begin alternating between SEP and DH and the DHW pump will come on Using the and keys in this manner you can toggle between running each pump in the system as required to help bleed out all entrapped air Some good indicators that air is removed include the absence of gurgling noises in the pipes and the pump operation becomes very quiet Pressing and together at any time will return the heater control to normal operation NOTE IF THE INSTALLER DOES NOT CANCEL THIS FUNCTION BY PRESSING AND TOGETHER THE PUMPS WILL RUN FOR A MAXIMUM OF 20 MINUTES AND SHUT OFF AUTOMATICALLY 9 While the pump is running as described
139. the device and thermostat instructions for details LP 171 Rev 3 3 15 120 Figure 30 53 FIELD WIRING WITH ZONE CIRCULATORS H 120 N VAL HGH VOLTAGE TRANSFORMER Thermostat POWER Clreuatce X ADCITIONAL ZONES Thermostat Zone 2 120 VAC HIGH VOLTAGE 24 VAC TRANSFORMER POWER ROOM THERMOSTAT TONE VALVE Cireviator t Use isolation relay on 3 wire zone valve with non isolated end switch Transformer and control can burn out of isolation relay is not used ADCIIONAL ZONES Low Voltage LP 171 03 Rev 12 4 07 LP 171 01 Rev 12 4 07 THERMOSTAT THERMOSTAT THERMOSTAT ZONE TONE 2 ZONES 2e Low voboge Wing 180v MO 7 LOW VOLTAGE 1 TONE 2 ZONE3 CIRCULATOR CRCLLATIOR C amp CULATOR TYPICAL ZONE RELAY PANEL WIRING SECONDARY SYSTEM CIRCULATOR WIRING LP 171 02 Rev 12 4 07 LP 171 04 Rev 12 4 07 LP 171 Rev 3 3 15 54 SERIES Field Wiring Diagram THERMOSTAT THERMOSTAT INDIRECT SENSOR INDIRECT SENSOR OUTDOOR SENSOR OUTDOOR SENSOR BUS LINE COMMON BUS LINE A BUS LINE B GREEN TO GROUND BUS GREEN TO GROUND BUS GREEN TO GROUND BUS SWITCH BUS TERMINATION RESISTOR REVOVE IF NOT FIRST OR LAST BOILER IN CASCADE SYSTEM GRN BLUE CONTRACTOR FIELD CONNECTIONS THIS LOCATION CONTRACTOR FIELD CONNECTIONS THIS LOCATION THERMOSTAT SENSOR DHW SENSOR OUT
140. ull port ball valves Purge valves can be used with the circulator flanges as an alternative 7 Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately 8 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 35 Series Heater with optional VISION 1 system Drawing 3D zoning with circulators Space heating mode 3 fully reset supply temperatures medium temperature manifold station E RE air handler higher temp optional high limit safety low temperature manifold station soe note 6 3 way manually set mixing valve SERIES T T 7 1 H i t r Qutdoor ELE J temperature Sensor Vision 1 system thermal trap w drain plug Figure 18 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstr
141. ur fingers near the opening o notice flue gas leaking from the opening this indicates a dry condensate drain trap Fill the condensate trap assembly with water If problem persists regularly contact a qualified service technician to inspect the unit and condensate line o service technician must ensure the condensate drain line is not blocked by pouring water through the plug port on the condensate drain assembly The water should flow out of the end of the drain line If water does not appear at the end of the drain line the qualified service technician must clean the condensate line o Tofillthe condensate drain assembly remove the cup from the assembly Slowly pour water into the cup until water appears at the end of the drain line Stop filling and replace the cup WARNING You must ensure that the condensate cup is securely fastened before restarting heater Do a final check to ensure proper condensate flow Every 6 Months e Check heater piping and gas supply piping for corrosion or signs of potential leakage o Remove the heater cover and perform a gas leak inspection following Gas Valve Operating Instructions p 2 in this manual If gas or odor leak is detected immediately shut down the unit following To Turn Off Gas To Appliance procedures on p 2 Call a qualified service technician o Visually inspect for leaks around the internal heater water connections and around the heat exchanger Visually insp
142. ure is set above the factory setting of 119 F 9 Install a minimum of 12 diameters of straight pipe upstream of all circulators 10 Winterization When winterizing the unit put a drain valve on both the supply and return between the union and the shut off connection LP 171 Rev 3 3 15 33 Series Heater with optional VISION 1 system Drawing 3B Zoning with circulators Domestic water heating mode MC SERIES Heater III DHW temperature sensor Vision 1 system ey ee eee eee eee ee oom LJ LJ M Outdoor temperature ser sor Vision 1 system thermal trap Super Stor Ultra 4 Indirect DHW Tank w drain Figure 16 NOTES 1 This drawing is meant to demonstrate system piping concept only Installer is responsible for all equipment and detailing required by local codes 2 All closely spaced tees shall be within 4 pipe diameters center to center spacing 3 A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting an indirect water heater is 1 5 The minimum pipe size for connecting the unit is 1 25 6 Circulators are shown with isolation flanges The alternative is standard flanges with full port ball valves Purge valves can be used with the circulator flanges as an altern
143. urning the gas on all gas connections must be approved by the local gas supplier or utility in addition to the governing authority A gas conversion kit comes with the heater Follow the included instructions VERY carefully Failure to follow gas conversion instructions could result in property damage serious injury or death DRIP LEG Do not remove the adaptor in Figure 28 It is mandatory that this fitting is used for connection to a field fabricated drip leg per the National Fuel Gas Code You must Figure 28 LP 171 BB ensure that the entire gas line to the connection at the heater is no smaller than 34 WARNING Do not attempt to support the weight of gas piping with the heater or its accessories The gas valve and blower will not support the weight of the piping Failure to follow this warning could result in substantial property damage severe personal injury or death Once all inspections have been performed the piping must be leak tested If the leak test requirement is a higher test pressure than the maximum gas inlet pressure you must isolate the heater from the gas line to continue leak testing To do this you must turn off the factory and field installed gas cocks This will minimize the possibility of damaging the gas valve Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure greater than PSI 14 water column the gas valve must be replaced Never
144. 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 s instruction prior to opening valves manually so as not to damage the valve e 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 e Repeat this procedure for additional zones one at time CAUTION For installations that incorporate standing iron radiation and systems with manual vents at the highest points Follow the above section and starting with the nearest manual vent open until water flows out Then close vent Repeat procedure working your way toward furthest air vent It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present Annual cleaning of the strainer may be necessary 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 positioned for automatic operation WARNING Use only inhibited propylene glycol solutions specially formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic syste
145. vert the If necessary convert the heater to the proper heater gas type Locate the stickers in the appropriate locations on the heater ___ 2 HighFire ___ 2 Low Fire Verify combustion settings after gas E PPM eee Lowie Mail in the conversion registration Notes Table 18 MAINTENANCE REPORT CAUTION In unusually dirty or dusty conditions care must be taken to keep heater cabinet door in place at all times Failure to do so VOIDS WARRANTY WARNING Allowing the heater to operate with a dirty combustion chamber will hurt operation Failure to clean the heat exchanger as needed by the installation location could result in heater failure property damage personal injury or death Such product failures ARE NOT covered under warranty The heater requires minimal periodic maintenance under normal conditions However in unusually dirty or dusty conditions periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous con
146. y analyzed by water treatment company o Ifthe pH differs from above consult local water treatment company for treatment needed e Hardness less than 7 grains o Consult local water treatment companies for unusually hard water areas above 7 grains hardness e Chlorine concentration less than 100 ppm o Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm Donot connect the heater to directly heat swimming pool or spa water o Do not fill heater or operate with water containing chlorine in excess of 100 ppm e NOTE It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup To clean the heat exchanger follow the maintenance procedure in Part 15 Section B of this manual Hardness 7 grains Chloride levels 100 ppm pH levels 6 8 TDS 2000 ppm Sodium 20 mGL G WINTERIZING CAUTION NEVER use any toxic chemical including automotive standard glycol antifreeze or ethylene glycol made for hydronic non potable Systems These chemicals can attack gaskets and seals in heaters are poisonous if consumed and can cause injury or death CAUTION Consider piping and installation when determining heater location To winterize the heater drain the entire system Then apply air pressure to the drain valve and allow air and water to escape from the purge valve see piping instructions Once you have evacuated as much water as possible pump non t

MC Series Gas-Fired Circulating Heater

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