Pioneer Metro Installation & Owner's Operation Manual page 8

Wetback installation
Wetback installation for the Smart Insert & LTD Smart Insert
The Smart Insert water heater comes fully assembled and is designed to be
fitted to the outside face of either the left or right hand side of the firebox.
Note: The hot water output of this water heating device is dependent on
correct installation and the proximity of the Smart Insert to the hot water
storage cylinder.
To fit the Smart booster proceed as follows
• The closer the Smart Insert is to the hot water storage cylinder, the
greater the hot water production will be, and generally distances over 3
metres are not recommended
• The return hot water connection copper pipe must be insulated and
have a minimum rise of 1 in 12 along its entire length. 1 in 12 is
minimum and the greater the rise the better the performance
• The return hot water pipe must be connected to the riser pipe
connection in the base of the hot water storage cylinder.
1. Remove the fascia (if fitted), then on the side of the firebox to which
the water heater is to be fitted, remove the angle cover plate from the
inside face of the outer cabinet. Also, remove the fire brick on the
wetback side from inside the fire box.
2. Having removed this cover plate the front face of the inner wrap is
exposed. Fold the front face of the inner wrap outwards so it is parallel
with the outer cabinet. This is needed to create access for the water
heater to fit between the firebox and the inner wrap.
3. Remove the two square knock out plates from the front face of the
inner wrap to provide clearance for the two connection pipes when the
return is folded back.
4. Remove the two 50mm diameter knock out plates from the outer
cabinet.
5. With a long handled 10mm set spanner, reach in between the inner
wrap and the firebox and loosen the nut on the rear Pozi drive screw
which will be used to secure the water heater. Then unscrew from the
inside and discard the 6mm nut as the screw will thread directly into
the water heater casting. Repeat for the two front bolts but retain the
nuts and washers.
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6. Remove the water heater from it's box, which also contains a tube of
fire cement. You will note a 6mm bolt and washer is fitted to one of the
casting ribs, remove this.
7. Smear a "liberal but even" amount of Pioneer fire cement over the
entire 'flat face' of the water heater in order to ensure full surface
contact with the outside face of the firebox.
8. Hold the hot water heater by the two copper pipes and slide the water
heater between the inner wrap and the firebox until the pipes are
vertical and in line with the two 50mm holes in the outer cabinet. The
pipes will be tight against the outer cabinet as you do this, but the
cabinet will flex enough to allow you to work the device until the pipes
pass through the 2 x 50mm holes in the outer cabinet.
9. Re-fit one of the bolts previously removed (stage 5) from inside the
firebox through one of the two slots provided in the front edge of the
water heater casting, and loosely attach the washer and nut to the
thread of the bolt.
10. Next pivot the water heater using the first bolt just refitted as a pivot
point, and refit the rear pozi drive screw from inside the firebox into the
rear tapped hole in the casting. Then refit the remaining front bolt and
attach the washer and nut.
11. Fully tighten all three fastenings, and check to ensure the casting has
pulled up evenly onto the side of the firebox. Excess fire cement should
be visible around the entire perimeter of the casting.
12. Bend the front returns of the inner wrap back into place so it folds
around the front of the water heater, then secure the inner wrap to the
casting by refitting the 6mm bolt and washer previously removed at
stage 6.
13. The water heater is now ready to have the copper pipe work attached
for connection to the hot water storage cylinder (brazed joints are
recommended)
14. Once all joints have been thoroughly checked and tested for leaks,
refit the angle cover plate removed at stage 1, then align and refit the
fascia. Both side bricks must be fitted inside the firebox.