Delta PG PLUS-25 - Manuals

iv Table of Contents SECTION XI - START-UP PROCEDURES Final Checks Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51PERFORMANCE PLUS Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51If PERFORMANCE PLUS Does Not Start Correctly . . . ...

v Table of Contents Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61Check Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Thermost...

Product & Safety Information 1 Indicates the presence of a hazardoussituation which, if ignored, will resultin death, serious injury or substantialproperty damage. Indicates a potentially hazardous situ-ation which, if ignored, can result indeath, serious injury or s u b s t a n t i a lproperty ...

Product & Safety Information 2 Bacteria can develop in the domesticw a t e r system if certain minimum watert e m p e r a t u res are not maintained. Water temperature over 125ºF can causes e v e re burns instantly or death fro mscalds. • Children, disabled and elderly are athighest risk of bein...

3 Product & Safety Information Do not use this appliance if any parthas been under water. Immediately calla qualified service technician to inspectthe appliance and to replace any part ofthe control system which has beenunder water. WHAT TO DO IF YOU SMELL GAS - Do not try to light any appliance...

4 Product & Safety Information OPERATING RESTRICTIONS • Maximum working pressure for inner(domestic water) tank is 150 psig. • Maximum working pressure for outer(primary water) tank is 45 psig. • Inner tank has factory installedTemperature & Pressure Relief Valvewith an AGA rating of 100,000...

Pre-Installation Items 5 SECTION I - Pre-Installation Items Code Compliance This product must be installed in accor-dance to the following: • All applicable local, state, national andprovincial codes, ordinances, regula-tions and laws. • The National Fuel Gas Code NFPA54/ANSI Z332.1 - Latest edition...

Pre-Installation Items To provide serviceability to the unit it isrecommended that the following clear-ances be maintained: Top and vent hood area - 36 inches. Front and burner area - 24 inches. Rear and primary piping areas - 12inches. When installing the PERFORMANCEPLUS in a confined space, suffic...

Combustion Air and Venting 7 SECTION II - Combustion Air and Venting Combustion Air Contamination If the PERFORMANCE PLUS combus-tion air inlet is located in any area likelyto cause or contain contamination, or ifproducts, which would contaminate theair cannot be removed, the combustionair must be r...

8 Combustion Air and Venting Combustion Air Requirements The PERFORMANCE PLUS can use insideair if no contaminants are present in the area ofinstallation. If contaminants are likely to bepresent in the area of installation, outside airmust be piped directly to the unit as referencedin Section VI Ven...

9 Combustion Air and Venting - Combining spaces on the same story.Each opening shall have a minimumfree area of 1 sq. in./1000 Btu/hr of thetotal input rating of all gas utilizationequipment in the space, but not less than100 sq. inches. One opening shall com-mence within 12 inches of the top, andon...

10 Combustion Air and Venting Combination of Indoor and OutdoorCombustion Air Indoor Openings: Where used, openings con-necting the interior spaces shall comply withthe Indoor Combustion Air section on page 8. Outdoor Opening(s) Location. Outdoor open-ing(s) shall be located in accordance with theOu...

11 Combustion Air and Venting Removal of an Existing Boiler f rom aCommon Vent System F o r installations in which the PERFOR-MANCE PLUS is replacing an existingb o i l e r / hot water h e a t e r system, whichwas connected to a common vent systemwith other appliances, the following stepsshall be co...

12 Unit Preparation SECTION III - Unit Preparation Handling Instructions The PERFORMANCE PLUS is generally eas-ier to handle and maneuver once removed fromthe shipping carton and pallet. To remove the shipping carton and pallet: a. Remove the shipping straps and open the top of the shipping carton t...

Unit Preparation 13 Do not leave the unit unattended whilep ressurized. A cold water fill couldexpand and cause excessive pre s s u re ,resulting in severe personal injury, deathor substantial property damage. 7. Ensure constant gauge pressure has been maintained throughout the 10 minute test.Check ...

Domestic Piping SECTION IV - Domestic Piping General Piping Requirements • All plumbing must meet or exceed alllocal, state and national plumbing codes. • Use pipe dope or tape suitable forpotable water. • Use isolation valves to isolate systemcomponents. • Install unions for easy removal of thePERF...

Domestic Piping The installer must install discharge pipingonto the T&P relief valve. The dischargepiping must be: • Made of material serviceable for tem-peratures of 250ºF or greater. • Directed so that any hot water dis-charge flows away from all persons. • Directed to a suitable place of drai...

Domestic Piping 3. Solder the U-Tube Assembly onto the adapter. (See Fig. 5) 4. Once the adapter has suff i c i e n t l y cooled, re-insert the check valve assem-bly making sure of orientation andreconnect onto the mixing valve. If the installation of the PERFORMANCEPLUS requires domestic hot water ...

17 Domestic Piping TR/SMART Series Application For applications requiring large volumes ofdomestic hot water over an extended period,the installer may include a Triangle Tu b eTR/SMART Indirect Water Heater in conjunc-tion with the PERFORMANCE PLUS. (SeeFig. 10 page 19) The domestic system recircula...

18 Domestic Piping Fig. 7: PERFORMANCE PLUS With Recirculation 1. Mixing valve with check valve2. Flow check valve3. Shut off valve4. Backflow preventer or pressure reducing valve* 6. Thermal expansion tank 7. Circulator (controlled by aquastat)8. Domestic drain valve9. Vacuum breaker* Note: All shu...

21 Primary Piping For proper operation of the expansion tankand system, remove the factory installedautomatic air vent from the PERFOR-MANCE PLUS and plug the connection.(See Item 10, Fig. 46 page 68) DO NOT install automatic air vents on aclosed-type expansion tank system. Airmust remain in the sys...

22 Primary Piping System Piping - Radiant Heating with MixingVa l v e Connect the PERFORMANCE PLUS to thesystem piping as shown with a radiant sys-tem using a thermostatic mixing valve asshown in Fig. 14 page 25. The primary / sec-ondary piping ensures sufficient return tem-perature to the PERFORMAN...

23 Primary Piping Near Appliance Piping 1. Appliance Circulator2. Shut Off valve3. Expansion tank 4. Auto fill valve5. Tank fitting6. Automatic air vent 7. Air Separator8. Plug (by others) Fig. 11 : Near Appliance Primary Piping with a Diaphragm Type Expansion Tank Fig. 11A : Near Appliance Primary ...

25 Primary Piping Fig. 14: Primary Piping - Low Temperature Radiant System Note: Adjust system temperature valve to establish maximum sup-ply/return temperature differen-tial of 30ºF and a minimum130ºF return water temperatureto the PERFORMANCE PLUS 1. Circulator2. Shut Off valves3. Flow check valve...

27 Venting and Combustion Air Installation SECTION VI - Venting andCombustion Air Installation General Requirements - Installation must comply with localrequirements and with the NationalFuel Gas Code, NFPA 54/ ANSI Z223.1for U.S. installations and CSA B149.1or B149.2 for Canadian installations. - T...

28 Venting and Combustion Air Installation Category IV Vent Termination Clearances Maintain the following clearances to the venttermination: - At least 6 feet from adjacent walls - No closer than 5 feet below roof over-hangs - At least 7 feet above any public walk-ways - At least 3 feet above any fo...

29 Venting and Combustion Air Installation - Must maintain 4 feet of clearancebelow and horizontally from doors andwindows. See dimension A Fig. 17. If the venting application is a vertical director non-direct vent application: - The vent must terminate at least 3 feetabove the roof and at least 2 f...

31 Venting and Combustion Air Installation Venting Option - Direct Vent / Horizontal In this vent application the PERFORMANCEPLUS is vented horizontally through a wallusing only approved 3-inch stainless steel ventmaterial and using outside air for combustion. The installer should consider the follo...

32 Venting and Combustion Air Installation Excessive Horizontal Vent Runs If maintaining the 1/4 inch per foot pitchrequirement creates clearance problems withstructural obstacles, i.e. low ceilings, theinstaller may opt to installing the vent in amanner that pitches up to a high point from theunit ...

33 Venting and Combustion Air Installation The maximum equivalent length is thetotal length of the venting and the com-bustion air inlet combined. This includestermination fittings. F o r Delta PERFORMANCE PLUSapplications that may exceed the 100 feetmaximum allowable equivalent lengthfor the ventin...

34 Venting and Combustion Air Installation Fig. 21: Standard Horizontal Venting Installation Fig. 22: Horizontal - Direct Vent Combination Fig. 22A: Concentric Horizontal Vent Installation Fig. 22B : Concentric Horizontal - Vent Snorkel I n s t a l l a t i o n

35 Venting and Combustion Air Installation Fig. 24B: Vent Termination - Non- Combustible Wall Fig. 24A: Vent Termination Combustible Wall Fig. 23: Location of Air Inlet Termination

37 Gas Piping SECTION VII - Gas Piping Gas Supply Piping Connection The gas supply piping must be installedin accordance to all applicable local,state and national codes and utilityrequirements. 1. Remove the burner jacket hood. Refer to Figure 27 to pipe gas supply to the burner. a. Install a pipe ...

38 Gas Piping NATURAL GAS Pipe Sizing - Natural Gas 1. Refer to Table 3 for pipe length and diame- ter requirements. Based on rated PER-FORMANCE PLUS input (divide by 1,000to obtain cubic feet per hour). - Table 3 is based on Natural Gas with aspecific gravity of 0.60 and a pressuredrop through the ...

39 Gas Piping PROPANE GAS Pipe Sizing - Propane Gas 1. Contact the local propane gas supplier for recommended sizing of piping, tanks and100% lockup gas regulator. P ropane Gas Supply Pre s s u re Require m e n t s 1. Adjust the propane supply regulator pro- vided by the gas supplier for 13”w.c. max...

41 Internal Wiring Fig. 30: Factory Wiring Schematic

43 External Wiring SECTION IX - External Wiring Installation Compliance All field wiring made during installation mustcomply with: - National Electrical Code NFPA 70 andany other national, state, provincial orlocal codes or requirements. - In Canada, CSA C22.1 CanadianElectrical Code Part 1, and any...

External Wiring 44 4 Wire Zone Valve Fig. 33: Multiple Zone Field Wiring Using Zone Valves 3 Wire Zone Valve *Use isolation relay on 3-wirezone valve with non-isolatedend switch. Transformer andthe PERFORMANCE PLUScontrol can burn out if isolationrelay is not used.

46 External Wiring Fig. 35: Typical Zone Relay Panel Wiring Fig. 36: Storage Tank Recirculation Wiring

47 Start-Up Preparations SECTION X - Start Up Preparation Check System and Domestic Wa t e rChemistry Do not use petroleum-base cleaning orsealing compounds in the primary sys-tem. Damage to seals and gaskets in thesystem components could occur, result-ing in substantial property damage. System wate...

48 Start-Up Preparations System water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Pro d u c t s . Use of Antifreeze in the Primary System NEVER use automotive or ethylene gly-col antifreeze or undiluted antifr...

49 Start-Up Preparations 3. Fill the outer tank to correct system pressure. Correct pressure will varywith each application. Typical residential system fill pressure is12 psi. System pressure will increasewhen system temperature incre a s e s .Operating pressure of the system shouldnever exceed 25 p...

50 Start-Up Preparations Verify Correct Pressure Switch 1. Remove the burner hood and verify the burner pressure switch setting. 2. Check and compare the color of the out- line on the pressure switch label to Table 3page 49. The PERFORMANCE PLUS is equipped with an air pressure switch,which provides...

52 Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE 1. STOP! Read the safety information above. 2. Set the secondary thermostat to the lowest setting. 3. Turn manual shutoff valve on the gas supply line clockwise to “Close” 4. Set the unit’...

53 Start-Up Procedures Venting system must be sealed gas-tightto prevent flue gas spillage and potentialcarbon monoxide emissions, which willresult in severe personal injury or death.  Check Gas Piping 1. Check around the unit for gas odor fol- lowing the procedure outlined in thismanual on Page 49...

54 Temperature Limits SECTION XII - Temperature Limits Studies have indicated that dangerousbacteria can form in the potable waterdistribution system if certain minimumwater temperatures are not maintained.For prevention of this, it is recommend-ed that the Secondary Thermostat be setas shown in Fig...

55 Temperature Limits  Setting the Thermostatic Mixing Valve The thermostatic mixing valve controlsthe outlet hot water temperature deliv-ered to the faucets. POTENTIAL SCALD HAZARD Themixing valve must be installed on thePERFORMANCE PLUS. Removal ofthe mixing valve will create a potentialscald haz...

57 Installation Record SECTION XIV - Installation Record

58 Maintenance Schedule SECTION XV - Maintenance Schedule Service Technician At least on an annual basis the following main-tenance should be performed by a qualified ser-vice technician: General • Attend to any reported problems. • Inspect the interior of the combustionchamber; clean and vacuum if ...

59 Maintenance Procedures SECTION XVI - Maintenance Procedures MAINTENANCE PROCEDURES The PERFORMANCE PLUS should beinspected and serviced annually, prefer-ably at the start of the heating season, bya qualified service technician. In addi-tion, the maintenance and care of theunit as outlined on page...

60 Maintenance Procedures Check Combustion/ Ventilation A i r O p e n i n g s Verify that all combustion air and ventila-tion openings to the mechanical room orbuilding are open and unobstructed. Checkthe operation and wiring of any automaticventilation dampers. Check and verify the vent discharge a...

62 Maintenance Procedures Check Burner Flame Inspect the burner flame through the obser-vation port on the burner mounting plate. If flame pattern is not fully blue and coversthe entire burner surface, shut the unitdown and allow it to cool thoroughly. Close the manual gas valve on the gas sup-ply l...

63 Replacement Parts SECTION XVII - Replacement Parts Replacement Parts Replacement parts can be ordered andpurchased through a local Triangle Tubedistributor. When ordering parts, spec-ify the Model Number and SerialNumber. Include a description of thepart and a replacement part number.Using modifi...

Specifications 68 Fig. 45: Rear View Fig. 44: Side View 1. Primary circuit, ø 1” NPT 2. Primary circuit drain valve connection, ø 1/2” NPT 3. Domestic temperature/pressure relief valve (150psi), ø 3/4” NPT 4. Primary circuit & pressure relief valve (30 psi), ø 1”NPT 5. Domestic cold water inlet,...

Specifications 69 Table 7: PERFORMANCE PLUS Data Table 6: Dimensional Data T y p e PG PLUS-25 PG PLUS-30 PG PLUS-35 PG PLUS-40 PG PLUS-45 Input Nat. Gas Btu/hr 100,000 120,000 140,000 165,000 199,000 Inner Tank Capacity Gal 17 17 17 22 22 Outer Tank Capacity Gal 20 20 20 18 18 Dimensions Inches A 59...