Comfort Indirect Fired Water Heater

30
Technical Specifications Installation and Maintenance Guide Before proceeding with installation and operation, read entire manual care- fully. Failure to do so can cause injury or property damage. When receiving COMFORT Water Heaters, any claims for damage or shortage in shipment must be filed immediately against the transporta- tion company by the consignee. 2013-32 COMFORT IWH Manual 661A0100 rev C Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage. Retain and affix this manual near the water heater for future reference Installation and service should only be performed by a qualified installer or service technician. Indirect Fired Water Heater Comfort Date Revised 06/20/14 WARNING IMPORTANT Comfort manual _Comfort 55 9/8/14 10:29 AM Page 1

Transcript of Comfort Indirect Fired Water Heater

Page 1: Comfort Indirect Fired Water Heater

Technical SpecificationsInstallation and Maintenance Guide

• Before proceeding with installation and operation, read entire manual care-fully. Failure to do so can cause injury or property damage.

• When receiving COMFORT Water Heaters, any claims for damage orshortage in shipment must be filed immediately against the transporta-tion company by the consignee.

2013-32 COMFORT IWH Manual661A0100 rev C

• Warranty Registration Card must be filled out by the customer and mailedwithin thirty (30) days of installation in order to gain warranty coverage.

• Retain and affix this manual near the water heater for future reference• Installation and service should only be performed by a qualified installer or

service technician.

Indirect Fired Water HeaterComfort

Date Revised 06/20/14

WARNING

IMPORTANT

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Table of Contents

Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4Installation - Piping

Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . . . . .5Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Manual Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Vacuum Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Installation - Piping Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11Installation - Wiring

Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Installation - Wiring Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18Water Heater Start-Up

Filling the Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . .19Filling the Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . .19General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Adjusting the Water Heater Thermostat . . . . . . . . . . . . . . . . . . . . . .21

Water Heater MaintenanceMaintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Filling Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Draining Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-24Draining Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . . . .23-24Draining Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . . . .24

Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-26Water Heater Specifications

COMFORT Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

i

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1

Definitions

Following terms are used to bring attention to thepresence of various risk levels, or to importantinformation concerning product life.

Indicates presence of a hazard which willcause severe personal injury, death or sub-stantial property damage if ignored.

Indicates the presence of a hazard whichcan cause severe personal injury, death orsubstantial property damage if ignored.

Indicates the presence of a hazard whichwill or can cause minor personal injury ordamage if ignored.

Indicates special instructions on installa-tion, operation, or maintenance which areimportant but not related to personalinjury hazards.

Indicates recommendations made by ACV-Triangle Tube for the installers which willhelp to ensure optimum operation andlongevity of the equipment.

ACV-Triangle Tube reserves the right tomodify the technical specifications andcomponents of its products without priornotice.

Hot Water Can Scald!• Water temperatures over 125ºF can cause

severe burns instantly or death from scalding.• Children, disabled and elderly are at highest

risk of being scalded.• Never leave them unattended in or near show-

er, bathtub or sink.• Never allow small children to use a hot water

faucet or draw their own bath.• If anyone using hot water in the building fits

the above description or if local codes or statelaws require specific water temperatures at hotwater faucet, it is recommended:- to install a thermostatic mixing valve at this

appliance or at each water faucet.or

- to set the thermostat knob for the lowesttemperature which satisfies your hot waterneeds.

• Water drained from the system drain valvesmay be extremely hot. To avoid injury:– Make sure all connections are tight.– Direct water flow away from any person.

Protection must be taken against excessivetemperature and pressure!• Installation of a Temperature & Pressure

(T&P) relief valve is required.

To prevent damage to the inner tank, theInstaller must:• Always fill inner tank prior to outer tank

and always drain outer tank prior to innertank.

• Relieve primary system pressure below 15psig prior to draining inner tank.

WARNING

DANGER

DANGER

CAUTION

CAUTION

CAUTION

NOTICE

BEST PRACTICE

NOTICE

Product & Safety Information

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Pre-Installation

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Codes ComplianceWater heater installation must conform with theinstructions in this manual and where applicable:

• local, state, provincial, and national codes,laws, regulations and ordinances.

• in Canada - CAN / CGA B149.1 or B149.2Installation Code.

COMFORT water heaters are exempt from ASMESection VIII, Division 1 Code construction perInterpretation VIII-86-136. Check with local codesfor applicability.

COMFORT Series water heaters willabsorb less than 200,000 BTU/hr whendomestic water outlet temperature is 210ºFand boiler water supply temperature is240ºF. Listed outputs are based on ASMESection VIII Interpretation VIII-1-86-136.

Where recommendations in this manual differfrom local, or national codes, the local or nationalcodes take precedence.

Codes RestrictionsSingle wall heat exchanger in the COMFORTwater heater complies with National StandardPlumbing Code, provided that:

– boiler water (including additives) is practicallynon-toxic, having toxicity rating or class of 1,as listed in Clinical Toxicology of CommercialProducts, and

– boiler water pressure is limited to maximum30 psig by approved relief valve.

Single wall heat exchangers are permitted under theUniform Plumbing code - Paragraph L3.2. and L3.3if they satisfy all of the following requirements.

1. The heat transfer medium is potable water orcontains only substances which are recog-nized as safe by the U.S. Food and DrugAdministration.

2. The pressure of the heat transfer medium ismaintained less than the normal minimumoperating pressure of the potable water system

Exception: Steam complying with sec-tion #1 above.

3. The equipment is permanently labeled toindicate that only additives recognized assafe by the FDA shall be used in the heattransfer medium.

Other heat exchanger designs may be permittedwhere approved by the Administrative Authority.

NOTICE

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Pre-Installation

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Operating Restrictions• Maximum boiler water temperature is

194ºF.• Maximum working pressure for inner

(domestic water) tank is 125 psig.• Maximum working pressure for outer

(boiler water) tank is 43.5 psig.• Water quality limitations (based on E.P.A

National Secondary Drinking WaterRegulations):

- Chloride, less than 150 ppm or mg/l- pH value min. 6, max. 8 - Total hardness 3 - 7 grains/gallon or 50-120

ppm or mg/l.- Total Dissolved Solids (TDS), less than

120 ppm or mg/l.- Iron less than 0.3 ppm or mg/l.- Aluminum, less than 0.2 ppm or mg/l.- Copper, less than 1 ppm or mg/l.- Manganese, less than 0.05 ppm or mg/l.- Zinc, less than 5 ppm or mg/l.

In hard water areas (more than 7 grains ofhardness) soften the cold domestic supplywater to the appliance to prevent scaling.

Any water conditioning system must beinstalled and maintained in accordance withmanufacturer’s specifications.

Do not install the water heater on any appli-cation if the boiler piping contains non-oxy-gen barrier tubing or if the boiler piping isconsidered an “open system”. Exposing theouter tank of the water heater to oxygencontamination will lead to premature tankfailure and denial of the warranty.

NOTICE

NOTICE

BEST PRACTICE

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Locating Water Heater• This water heater is not intended for out-

door installations.• Keep distance between boiler and water

heater to a minimum to:– reduce piping heat loss– provide minimal friction loss

• Locate water heater so that any leakage fromthe tank or water connections will not causedamage to the area adjoining the water heateror to lower floors in the structure.– When such a location is unavoidable, asuitable drain pan with adequate drainage,should be placed under the water heater.

• The COMFORT Series Water Heaters aredesigned for vertical installation only.

Recommended Clearances• Water heater should be installed to allow

adequate clearance for servicing.• Zero clearance is permissible to any side of

the COMFORT Series water heater, butinformation labels may be hidden.

• Recommended top or vertical clearance is 12”minimum.

• Refer to boiler manual for boiler clearances.

Pre-Installation

4

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Installation - Piping

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Temperature & Pressure (T&P) Relief Valve

To reduce risk of excessive pressures and tem-peratures in the water heater, install tempera-ture and pressure protective equipmentrequired by local codes, but no less than a com-bination temperature and pressure relief valvecertified by a nationally recognized testing lab-oratory that maintains periodic inspection ofproduction of listed equipment or materials, asmeeting the requirements for Relief Valves andAutomatic Gas Shutoff Devices for Hot WaterSupply Systems, ANSI Z21.22. This valve mustbe marked with a maximum working pressureof the water heater.• Every COMFORT water heater must be pro-

tected with a T&P relief valve.• Determine T&P relief valve size by the follow-

ing specifications, unless they conflict withlocal codes:- COMFORT 45 and 55: 3/4”NPT with anAGA Rating of 100,000 BTU/hr and amaximum pressure rating of 125 psig.(Watts 40XL8-125210 or Apollo18C40236 or equivalent).

For proper operation of the T&P and to pre-vent the T&P from activating due to boilerwater temperature, use a T&P relief valvewith extended element. We recommendedan 8” minimum length to ensure elementsenses domestic water.

Installation• Install the T&P in the run (straight through leg)

of a tee located at the domestic hot water out-let. Use a long element T&P relief valve (Figs.1 or 2 page 9).

T&P Relief Valve Discharge PipingT&P relief valve discharge piping must be:- made of material serviceable for tempera-tures of 250ºF or greater.

- directed so that hot water flows away fromall persons.

- directed to a suitable place for disposal.- installed so as to allow complete drainingof the T&P relief valve and discharge line.

T&P relief valve discharge piping must not be:- excessively long. Using more than 2elbows or 15 feet of piping can reduce dis-charge capacity.

- directly connected to a drain. Terminatedischarge piping within 6” from drain.Refer to local codes.

- plugged, reduced or restricted.- subject to freezing.

Do not install any valve between T&P reliefvalve and tank connection or on T&P reliefvalve discharge piping. Do not plug T&Prelief valve or discharge piping. Improperplacement and piping of T&P relief valvecan cause severe personal injury, death orsubstantial property damage.

CAUTION

NOTICEWARNING

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Installation - Piping

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Drain ValveDrain valve and fittings are supplied by others.Standard Installation• Install a tee connection at the domestic cold

water inlet (Fig. 1 and 2 page 9).• Pipe the drain piping with drain valve from

the tee connection to:- a suitable place for disposalor- terminate within 12” of the floor

Manual Air Vent 1. A manual air vent is factory installed.2.Open manul air vent and once the tank is full and

air has stop escaping the manual air vent close.

Thermal ExpansionIf a backflow preventer, check valve or pressurereducing valve is piped on cold water supply pipingof water heater, install an expansion tank on coldwater supply line to prevent normal thermal expan-sion from repeatedly forcing open T&P relief valve.

T&P relief valve is not intended for constantduty, such as relief of pressure due torepeated normal system expansion. Correctthis condition by installing a properly sizedexpansion tank in domestic water system.Refer to expansion tank manufacturer’sinstallation instructions for proper sizing.

Water Hammer

Dishwashers, clothes washers and fast-closing pos-itive shut-off valves incorporated in the system allcontribute to creating water shock. Install a waterhammer arrester to prevent damage to pipes andappliances. See device manufacturer’s instructionsfor application and installation.

Water hammering within the domestic pip-ing system can cause premature failure ofthe inner tank of the water heater. This typeof failure is NOT covered under warranty.

Vacuum BreakerInstalling a vacuum breaker Watts N36-M1 or equiv-alent on the domestic cold water inlet will preventdamage to the inner tank if a negative pressure isdeveloped in the domestic supply line. See manu-facturer’s instructions for application and installationof the vacuum breaker.

CAUTION

NOTICE

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Installation - Piping

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General Piping• For domestic water piping diagrams, see page 9.• See pages 10 and 11 for boiler water piping.• See water heater specifications for domestic

and boiler piping connection sizes, page 25.• All plumbing must meet or exceed all local,

state and national plumbing codes.• The supplied sealant is suitable for potable

water systems. Use only the supplied sealanton all Comfort fittings/joints.

• Use isolation valves to isolate system components.

Domestic Piping• Union on domestic hot water outlet should be

piped at a higher elevation than domestic waterdrain valve. This will make draining the waterheater easier.

• Install unions for easy removal of water heater.It is recommended to use dielectric unions orcouplings to protect hot and cold water fittingsfrom corrosion when connecting dissimilarmaterials such as copper and galvanized ironpipe.

• If copper pipe is used for domestic water con-nections, first solder pipe to a threaded adapterand then screw adapter into cold water inlet ontop of water heater. Inlet contains an internalplastic dip tube which can be damaged by heatfrom soldering.

Do not apply heat to the cold water inletwhen making sweat connections to waterheater. Sweat tubing to adapter before fit-ting adapter to cold water inlet of heater. Itis imperative that no heat be applied to thecold water inlet, as it contains a non metal-lic dip tube.

• When the water supply pressure is higher than70 psig, it is recommended to install a pressurereducing valve on cold water supply line toprevent water loss through T&P relief valve.

• If water heater will replace tankless coil inboiler, disconnect piping to coil. Allow waterto drain from coil. Do not plug tankless coil.

Plugging tankless coil inlet and outlet willresult in severe personal injury, death, orsubstantial property damage.

NOTICE

DANGER

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Thermostatic Mixing Valve• A mixing valve complying with ASSE 1017

must be installed on the domestic hot wateroutlet.

Recirculation Piping• It is recommended to return the recirculation

loop to the cold water inlet as shown Fig. 2,page 9.

• A stainless steel or bronze circulator is requiredon potable water systems.

• Install automatic mixing valve either at the hotwater outlet of water heater or each hot waterfaucet.

Boiler Piping• If plastic pipe is used for boiler water piping, it

must have a maximum oxygen diffusion rate of0.1 mg/liter-day for boiler and water heaterprotection.

The COMFORT IDWH must be installedon a closed type hydronic system. Failure toprovide such a system will result in prema-ture failure of the outer tank and annulmentof warranty.

• Boiler water (including additives) must bepractically non-toxic, having toxicity rating orclass of 1, as listed in Clinical Toxicology ofCommercial Products.If antifreeze is used in boiler system, localcodes may require a backflow preventer oncold water supply line. Use antifreeze specifi-cally intended for hydronic heating systems.Inhibited propylene glycol is recommended ata maximum 50/50 mixture.

Do not use automotive, ethylene glycol orpetroleum-based antifreeze. Do not use anyundiluted antifreeze. This can cause severepersonal injury, death or substantial propertydamage.

DANGER

NOTICE

8

Installation - Piping

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Cold Water Inlet 6 1

12" min.Heat Trap

Loop(Optional)

12" min. Heat Trap

Loop (Optional)

5 1

874

1 5

10M H

C

Installation - Piping

RecirculatingLoop

4

1 5

12" min.Heat Trap

Loop(Optional)

7

510

M H

C

Cold Water Inlet

6 11

8

92 3

Standard InstallationDomestic Piping withRecirculation COMFORT

9

1. Shut-off valve2. Recirculation Circulator3. Flow Check Valve4. T&P relief valve5. Unions6. Backflow preventer or pressure reducing valve(*)

7. Drain valve8. Thermal expansion tank (potable)9. Flow Check Valve (**)10. Thermostatic mixing valve (*) Optional device may be required by local codes(**) Not required if item 6 is present

Standard InstallationDomestic PipingCOMFORT Series

Fig. 1:

Fig. 2:

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Installation -Piping

10

41

3

2

2-Port Priority Valve

(normally open)

2-Port Priority Valve

(normally close)

1

6

5Cold water

inlet

1

2

41

3- Port Priority Valve

3 1

6Cold water

inlet 5

Fig. 4:

1. Shut-off valves2. Circulator3. Expansion tank

4. Drain valve5. Feed valve6. Air separator

Fig. 3: COMFORT System Piping with 3-Port Zone Valve(Domestic Priority)

COMFORT System Piping with 2-Port Zone Valves(Domestic Priority)

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Fig. 6:

Fig. 5:

1. Shut-off valves2. Circulator3. Flow check valve4. Expansion tank

5. Drain valve 6. Feed valve7. Air separator

COMFORT System Piping with Zone Valves(Non Domestic Priority)

COMFORT System Piping with Zone Circulators

11

Installation - Piping

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Installation - Wiring

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Wiring Requirements

Electrical shock hazard can cause severepersonal injury, death or substantial prop-erty damage. Disconnect power beforeinstalling and/or servicing.

1. All wiring must be a minimum of 18 gaugeand installed in accordance with:• U.S.A. - National Electrical Code and any

other national, state or local code require-ments having jurisdiction.

• Canada - C.S.A. C22.1 Canadian ElectricalCode Part 1 and any other national, provin-cial and local code requirements havingjurisdiction.

2. If original wire supplied with appliance mustbe replaced, Type 90ºC or its equivalent mustbe used.

3. Refer to control component instructionspacked with boiler for application information.

4. An optional service switch may be installed inwater heater electrical circuit. This switchwould only shut off the water heater, not thehome heating system. Do not shut off waterheater if there is a chance of freezing.

5. All electrical contacts shown do not havepower applied - off the shelf condition. Seepages 13 thru 18.

Circulators• Priority relay must be sized for total amp draw

of all circulators.Zone Valves• Transformer must be sized for maximum load

of all zone valves.Connection• For easy wiring between water heater ther-

mostats P and 1 connections and boiler con-trols see Installation Wiring section pages 13through 18.

WARNING

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P and 1 Connections

Optima Zone Panel SZC5 with Zone Pumps WiringFig. 7:

13

Installation - Wiring

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P and 1 Connections

Optima Zone Panel SCZ5 with Zone Valves WiringFig. 8:

14

Installation - Wiring

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15

H N

High Voltage 120

V.A.C.

24 V.A.C.

Room Thermostat

Zone 1

Additional zones Additional zones may be added as shown above

Transformer (Power)

Zone Valve

Zone Valve

1 2 P

Water HeaterThermostatWater

Heater Zone

*Isolation Relay

Boiler Thermostat Terminals

* Use isolation relay on 3-wire zone valves with non-isolated end switches. Transformer and boiler control can burn out if isolation relay is not used

Priority Relay

H N

High Voltage 120

V.A.C.

24 V.A.C.

Room Thermostat

Zone 1

Additional zones Additional zones may be added as shown above

Transformer (Power)

Zone Valve

Zone Valve

1 2 P

Water HeaterThermostat

Water Heater Zone

Boiler Thermostat Terminals

High Voltage Low Voltage

Priority Relay

Typical 3-wire Zone Valve Zoning,with Domestic Priority

Typical 4-wire Zone Valve Zoning,with Domestic Priority

Fig. 9: Fig. 10:

Installation - Wiring

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Installation - Wiring

H N

High Voltage 120

V.A.C.

24 V.A.C.

Room Thermostat

Room Thermostat

Zone 1

Zone 2

Additional zones Additional zones may be added as shown above

Transformer (Power)

Zone Valve

Zone Valve

Zone Valve

1 2 P

Water HeaterThermostatWater

Heater Zone

*Isolation Relay

Boiler Thermostat Terminals

* Use isolation relay on 3-wire zone valves with non-isolated end switches. Transformer and boiler control can burn out if isolation relay is not used

16

Typical 3-wire Zone Valve Zoning,without Domestic Priority

H N

High Voltage 120

V.A.C.

24 V.A.C.

Room Thermostat

Room Thermostat

Zone 1

Zone 2

Additional zones Additional zones may be added as shown above

Transformer (Power)

Zone Valve

Zone Valve

Zone Valve

1 2 P

Water HeaterThermostat

Water Heater Zone

Boiler Thermostat Terminals

High Voltage Low Voltage

Typical 4-wire Zone Valve Zoning,without Domestic Priority

Fig. 11: Fig. 12:

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2

T T

1 4 3 5 6

Circulator Zone 1

Thermostat zone 1 Honeywell

R845A Relay

120 H

VAC N

2

T T

1 4 3 6

Circulator Zone 2

Thermostat zone 2

5

2

T T

1 4 3 6

Water Heater

Circulator

Water HeaterThermostat

5

1 2

P

Boiler Thermostat Terminals

Priority Relay

17

Typical Circulator Zoningwith Domestic Priority

2

T T

1 4 3 5 6

Circulator Zone 1

Thermostat zone 1 Honeywell

R845A Relay

120 H

VAC N

2

T T

1 4 3 6

Circulator Zone 2

Thermostat zone 2

5

2

T T

1 4 3 6

Water Heater

Circulator

Water HeaterThermostat

5

1 2

P

High Voltage Low Voltage

Boiler Thermostat Terminals

Typical Circulator Zoningwithout Domestic Priority

Fig. 13: Fig. 14:

Installation - Wiring

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Installation - Wiring

18

T T

1 4 3 5 6

Circulator Zone 1

Thermostat zone 1 Honeywell

R845A Circulator

Relay

120 H

VAC N

2

T T

1 4 3 6

Circulator Zone 2

Circulator Zone 3

Thermostat zone 2

Thermostat zone 3

5

2

T T

1 4 3 6 5

High Voltage Low Voltage

To Boiler 24 VAC Thermostat Leads

2

ON PRIORITY

ZONING CIRCULATOR

CIRC ON

PR1 LIVE NEUT

T T

2

1 P

Water HeaterThermostat

Priority Zone Circulator

Note: Maximum of 4 total circulatorzone when wiring 1 zone for priority.

Fig. 15: Priority Zone Circulator Wiring

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19

Filling the Inner (Domestic Water) Tank

• Never use water heater unless inner andouter tanks are completely filled with water.

• Inner tank must be completely filled andpressurized before pressurizing outer tank.

1. Close domestic water drain valve.

2. Open domestic water isolation valves forwater heater.

3. Vent air from inner (domestic water) tank byopening nearest hot water faucet. Filldomestic water tank completely by allowingwater to run until there is a constant flow ofwater.

4. Close hot water faucet.

Filling the Outer (Boiler Water) Tank

• Never use water heater unless inner andouter tanks are completely filled with water.

• Inner tank must be completely filled andpressurized before pressurizing outer tank.

1. Close boiler water drain valve at boiler wateroutlet of water heater.

2. Open water heater’s boiler water isolationvalves.

3. Allow air to escape from outer (boiler water)tank by opening manual air vent located ontop of water heater.

4. Follow instructions furnished with boiler tofill with water.

5. When tank is full and air stops escaping,close the manual air vent.

6. If antifreeze is used in boiler water, checkconcentration. Boiler water (including addi-tives) must be practically non-toxic, havingtoxicity rating or class of 1, as listed inClinical Toxicology of Commercial Products.

Do not use automotive, ethylene glycol orpetroleum-based antifreeze. Do not use anyundiluted antifreeze. This can cause severepersonal injury, death or substantial propertydamage.

CAUTION CAUTION

WARNING

Water Heater Start-Up

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Water Heater Start-Up

20

HOT WATER CAN SCALD!• Water temperatures over 125ºF can causesevere burns instantly, or death from scalds.

• Feel water before bathing or showering.• Consumer Product Safety Commission andsome states recommend temperatures set-tings of 130ºF or less. Setting thermostathigher than 130ºF will increase risk of scaldinjury and cause severe personal injury ordeath.

• Water heated to a temperature suitable forclothes washing, dish washing and other san-itizing needs will scald and cause permanentinjury.

• Children and elderly, infirm, or physicallyhandicapped persons are more likely to beinjured by hot water. Never leave themunattended in or near a bathtub. If anyoneusing hot water in the building fits thisdescription, or if state laws or local codesrequire certain water temperatures at hotwater faucets, take special precautions.- Install an automatic mixing valve atwater heater or at each hot water faucet,bath and shower outlet. Selection andinstallation must comply with valvemanufacturer’s recommendation andinstructions.- Use the lowest practical temperature set-ting.- Check water temperature after anyadjustment. You must follow“Adjusting the Water HeaterThermostat” procedures.

General Notes• Household water usage patterns will affect

water temperature at any faucet or shower.Occasionally check temperature at each pointof use, then adjust thermostat accordingly.Always recheck temperature after adjustingthermostat.

• When hot water is used in repeated small quan-tities, a “stacking” effect can develop in thewater heater. The upper layer of water in tankcan be hotter than lower layer.

• Lowering the thermostat setting or installingautomatic mixing valves as indicated in theseinstructions will reduce water temperature levels.Consult your installer or service technician.

At no time should boiler limit control be setabove 210ºF. This can cause severe person-al injury, death or substantial propertydamage if ignored.

WARNING

DANGER

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Adjusting the Water Heater ThermostatWater heater thermostat is factory set to itslowest temperature. This may or may not besuitable for your needs.

Turn thermostat knob clockwise toward5 increase water temperature.Turn thermostat knob counter-clockwisetoward 1 to decrease water temperature.

Studies have indicated that dangerous bac-teria, including legionella, pneumophila, canform in the potable water distribution sys-tem if certain minimum water temperaturesare not maintained. Contact your localhealth department for more information.

• Check water temperature at a hot water faucetimmediately after first heating cycle. Furthertemperature adjustment may be necessary aswater heating system is used. Recheck watertemperature at faucet after adjustment.

• When adjusting thermostat, be sure boiler limitcontrol is set a minimum of 20ºF higher.

WARNING

21

Water Heater Start-Up

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Water Heater Maintenance

22

Maintenance ScheduleAnnual service by qualified service technicianshould include the following:

Any procedure required by local codes.Check air vent operation.Verify system pressure. Manual air ventingprocedure may require adding water to bringsystem up to pressure, typically 12 psig.Manually operate T&P relief valve at leastonce a year. This will release some hot water.

Before operating T&P relief valve, makesure no one is in front of or around T&Prelief valve discharge piping. Hot dischargewater can cause severe personal injury orsubstantial property damage.

Move operating lever to open position for afew seconds and then move it back, allowing itto snap closed. After T&P relief valve is oper-ated, if it continues to release water, close coldwater inlet to water heater immediately.Follow draining instructions, to relieve pres-sure from the inner tank and replace T&P reliefvalve. If T&P relief valve weeps periodically,it may be due to thermal expansion seeThermal Expansion, page 6. Do not plug T&Prelief valve or discharge piping.

Plugging T&P relief valve or discharge pip-ing can cause excessive pressure in waterheater, resulting in severe personal injury,death, or substantial property damage.Follow instructions on circulator to oil it, ifrequired.Check mixing valve, valves, pipes and fit-tings for leaks.Check function of field-installed controlsand valves. See component manufacturer’sinstructions.

Review homeowner’s maintenance responsi-bilities and their frequencies, including anynot listed in the following section.

Homeowner monthly maintenance to include:Check for air

• Manual air vent - open and close briefly torelease any air. Visually check valves, pipes and fittings forleaks. Call qualified service technician torepair leaks.

Filling Water HeaterSee “Filling the Inner (Domestic Water) Tank and“Filling the Outer (Boiler Water) Tank” on page 19.Draining Water HeaterDrain water heater if it will be shut off and exposedto freezing temperatures. Freezing water willexpand and damage water heater.

• If boiler water contains sufficientantifreeze, then only the domestic waterneeds to be drained.

Close boiler water isolation valves andrelieve system pressure to below 15 psig inouter tank before draining inner tank toprevent damage to inner tank.• If boiler water does not contain sufficient

antifreeze, then the boiler water anddomestic water must be drained.

If antifreeze is used in boiler water, check concen-tration. Boiler water (including additives) must bepractically non-toxic, having toxicity rating orclass of 1, as listed in Clinical Toxicology ofCommercial Products. A maximum 50/50 mixtureof inhibited propylene glycol is recommended.Follow antifreeze manufacturer’s instruction.

WARNING

WARNING

DANGER

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23

Do not use automotive, ethylene glycol orpetroleum-based antifreeze. Do not useany undiluted antifreeze. This can causesevere personal injury, death or substantialproperty damage.

Water from opened drain valves, unionsand other connections may be extremelyhot. To avoid severe personal injury, deathor substantial property damage:- Tighten all drain hose connections.- Direct hot water away from all persons.

Draining Inner (Domestic Water) Tank

There are 3 methods typically used in thedraining of the inner tank. The first methodoutlined as Option 1 is to siphon the waterout. This method is typically the easiest toperform, but may be lengthly in time to com-plete. The second method, shown as Option 2,uses compressed air. This method is morecomplicated however it is generally quickerin draining the tank. The final method,Option 3, use a pump to drain the tank. Aswith Option 2, Option 3 is generally morecomplicated, but is quicker in draining thetank.

Prior to draining the inner tank, ensure thefollowing is completed:1. Wiring at the water heater is disconnected.2. The DHW system supply isolation valveis closed.

3. The outer (boiler water) tank pressure isless than 15 psig.

Reference domestic piping diagrams Figs. 1and 2 on page 9.

Draining Inner Tank - Option 11. Connect a hose to the domestic water drain

valve at the cold water inlet. The hose shouldextend to a drain at floor level to allow siphon-ing of the domestic inner tank.

2. Open a hot water faucet at the highest pointabove the water heater.

3. Open the domestic water drain valve to startthe siphoning of the domestic inner tank.

4. When draining is complete, close the hotwater faucet and the domestic drain valve.

Draining Inner Tank - Option 21. Connect a hose to the domestic water drain

valve at the cold water inlet. Direct the hose toa proper drain/suitable place for drainage.

2. Close the isolation valve on the DHW systemhot outlet of the water heater.

3. On the hot water outlet piping between thewater heater and the isolation valve install ashrader (air tank) valve or some other fitting ormeans that allows connection of an air hosefrom a compressor.

4. Open the domestic water drain valve on thecold water inlet.

5. Apply compressed air at a maximum regulatedpressure of 40 psig.

WARNING

BEST PRACTICE

NOTICEWARNING

Water Heater Maintenance

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6. When draining is complete, remove the airhose and fittings needed to connect the airhose.

7. Close the domestic water drain valve on thecold water inlet and open the isolation valve onthe hot water outlet.

Draining Inner Tank - Option 31. Connect the suction side of the pump to the

domestic water drain valve using a hose and/orpiping fittings.

2. Connect a hose to the discharge side of thepump. Direct the hose to a proper drain or asuitable place for drainage.

3. Open a hot water faucet at the highest pointabove the water heater.

4. Open the domestic water drain valve and startthe pump to begin draining the inner tank.

5. When draining is complete stop the pump,close the hot water faucet and close the domes-tic drain valve. Remove the pump and allhoses and fittings.

Draining Outer (Boiler Water) Tank1. Disconnect wiring connection at water heater.2. Close boiler water isolation valves between

boiler and water heater.3. Connect hose to boiler water drain valve at

water heater. Open and drain water to a safeplace.

4. To speed draining procedure, open manualair vent on top of tank.

5. When draining is complete, close drain valveand close manual air vent.

24

Water Heater Maintenance

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2

7

2

Aquastat Assembly

6

3

1

4

COMFORT

Replacement Parts

25

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Comfort

Item Part # Models Description1 P3KITAV02 All Air vent, manual

2 P3KITTH04 All Aquastat Assembly ( Knob, Cover &Aquastat - 160ºF)

3 P3KITBTM05 All Bottom cap4 P3KITTOP05 All Top cap5 P3DW06 All Drywell (Not Shown)

6P3WKITDT01 COMFORT 45

Dip tubeP3WKITDT02 COMFORT 55

7 P3KNB02 All Knob

Replacement Parts

26

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27

Water Heater Specifications

E

Cold WaterInlet

Hot Water Outlet

Thermostat& Cover

Air Vent

Top View C

A B

D

BoilerReturn

BoilerSupply

MODEL COMFORT 45 COMFORT 55Capacity Gal.

Domestic 28 35Boiler 17 20

Heating surface Sq. Ft. 13 16Head loss boiler side Ft. 3/4 1-1/4Piping connections Inches

Domestic ø 3/4 3/4Boiler ø 1 1-1/4

Dimensions InchesDiameterA 47-1/2 58B 37 47-3/4C 8-1/2 8-1/2D 20-5/8 20-5/8E 14-3/16 14-3/16

Left Side View

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