Table of Contents
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Installing, Operating & Maintaining
PROPAK HIGH EFFICIENCY
WATER HEATERS AND HEATING BOILERS
If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
– Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your
building.
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
New York
MEA 425-05-E
These appliances MUST be installed by a properly licensed installer in the State and City in which it is
being installed in. All start up adjustments and subsequent service work must be done by a similarly
licensed contractor or a factory trained service individual. Failure to comply could result in loss of
warranty and or severe personal injury, death and or substantial property damage. These Instructions
are required to be kept with the appliance on the left side, in the pocket provided
WARNING
ASME
Massachusetts
Boilers:G1-06-06-24A
Heaters: G1-06-06-24B
WARNING
Huron Valley Sales, Inc.
25700 Princeton St., Dearborn Heights, MI 48125
Bus: 313.278.5200 • Fax: 313.278.0275
ANSI STD Z21-13/Z21.13A
Certified to CSA 4.9-2004
ANSI STD Z21.10.3/Z21.10.3.b
Certified to CSA 4.1-2004, add.A,B
SCAQMD
Compliant Rule1146.2
CEC Listed
California Energy
Commission
LIT 91127 REV 6/1/06
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Table of Contents
Summary of Contents for Huron Valley Sales ProPak Series
- Page 1 These Instructions are required to be kept with the appliance on the left side, in the pocket provided Huron Valley Sales, Inc. 25700 Princeton St., Dearborn Heights, MI 48125 Bus: 313.278.5200 •...
- Page 2 These categories mean, in the judgement of Huron Valley Sales, Inc.: WARNING CAUTION Indicates a condition or hazard which Indicates a condition or hazard which...
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Page 3: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Removing Air from Heat Exchanger . .18 Part 1 .....4–7 Water Heating Piping ...18-21 GENERAL INFORMATION Part 6 . -
Page 4: Part 1
GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES The ProPak product line is an extremely high efficiency water heating product, requiring special venting and condensate removal precautions. Failure to follow all of the instructions contained in this manual may cause premature product failure that may not be covered under warranty. -
Page 5: Propak Dimensions
GENERAL INFORMATION B. PROPAK DIMENSIONS Figure 1-1: ProPak Dimensions (TABLE 1-1) ProPak INFORMATION *At 97% thermal efficiency with 86!F incoming water to heat exchanger **At 95% thermal efficiency with 140!F incoming water to heat exchanger... -
Page 6: Pre-Installation Requirements
GENERAL INFORMATION RECOMMENDED SERVICE CLEARANCES (NOTE: The ProPak is rated at zero clearance to combustibles.) Figure 1-2: ProPak Clearances C. PRE-INSTALLATION REQUIREMENTS The ProPak is designed to be wall mounted or hung from an approved or company-provided rack. The HW 129 comes with a factory-mounted bracket on the back that attaches to a bracket to be mounted to the surface the appliance will hang from. -
Page 7: Pressure Relief Valve
A water heating appliance should always be located in an area with a floor drain or installed in a drain pan suitable for water heating appliances. Under no circumstances, shall Huron Valley Sales, Inc. be held liable for any such water damage whatsoever. -
Page 8: Part 2
ELECTRICAL PART 2. ELECTRICAL A. ELECTRICAL CONNECTION The electrical connection for the ProPak is on the bottom of the unit. There is a 1/2” knockout location for an electrical connection for the heater's incoming power connection. All electrical wiring must be performed by a qualified licensed electrician in accordance with National Electrical Code ANSI/NEPA to and/or the Canadian Electrical Code, Part 1 CSA C22.1, or to the applicable codes and standards. -
Page 9: Part 3
GAS CONNECTION PART 3. GAS CONNECTION WARNING Failure to follow all precautions could result in fire, explosion or death! A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" water column (1/2 PSI) (3.44 kPa), and a minimum of 4" water column. -
Page 10: Gas Valve Set Up
GAS CONNECTION ( TABLE 3-1 ) NATURAL GAS SUPPLY PIPING (Based on 0.60 specific gravity for natural gas at 0.5" WC pressure drop; DOE standard is 1100 BTU per cubic foot of natural gas.) ( TABLE 3-2 ) PROPANE SUPPLY PIPING (Based on 11" WC supply pressure.) D. -
Page 11: E Setting Maximum Load
GAS CONNECTION E. SETTING THE MAXIMUM LOAD $ Press the service button with a pointed object and set the temperature knob on the maximum fan speed as shown by model in the table below (display will indicate 1st three digits only) (TABLE 3-4) FAN SPEEDS TABLE - based on version F Control Board Natural Gas LP Gas... -
Page 12: F Setting Minimum Load
GAS CONNECTION / VENTING H. ADJUSTING & SETTING THE FIRING RATE (GAS VALVE MAINTENANCE/REPLACEMENT) 1) When checking or replacing a gas valve, the CO percentage in the flue gas is the preferred measuring method to insure proper combustion and firing rate, CO is used as the alternate. 2) Gas valve replacement for the HW 599: The left hand gas valve (which is normally factory-set and sealed and must not be adjusted) must be set up to factory specifications before any combustion related adjustments can be performed on... -
Page 13: Venting The Propak
Common Venting System from Huron Valley Sales, Inc. The joints must be prop- erly cleaned, primed and cemented if plastic, and sealed per the manufacturer's instructions if stainless. - Page 14 11) The vent intake and exhaust must be properly cleaned and glued if plastic, and sealed per the manufacturer’s directions if stainless for a pressure tight joint. Several methods for venting the *IMPORTANT NOTE *HURON VALLEY SALES, *INC. RECOMMENDS A *MINIMUM CLEARANCE OF...
- Page 15 VENTING DIAGRAMS FOR SIDEWALL VENTING VENTING FOR MULTIPLE UNITS, with vents all on same horizontal plane, spaced at Exterior wall All horizontal runs must least 8 inches apart, and at level be supported every 24" of highest unit. Exhaust 8" SHOWN OFFSET 18"...
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Page 16: Inlet Air Vent
If the combined venting length of a heater’s exhaust/inlet air system exceeds the Maximum Combined Length called out in Table 4-1, Page 13, contact Huron Valley Sales, Inc. for an engineered venting cal- culation. Do not proceed without calling Huron Valley Sales, Inc. at (313) 278-5200. -
Page 17: Condensate Requirements
A condensate neutralizer and a condensate pump kit are available from Huron Valley Sales, Inc. It is also very important that the condensate line is not exposed to freezing temperatures, or any other type of blockage. -
Page 18: Fill & Purge Heating System
Huron Valley Sales, Inc., which will guide you through proper installation of the ProPak. 1) Pipe properly, in accordance with generally accepted piping principals or Huron Valley Sales spe- cific documents. 2) Connect system return to the pipe leaving the ProPak closest to the back. - Page 19 PIPING Appliance maximum pipe & fittings for is as follows: 20’ straight copper pipe (2) full port ball values, (2) tees, (1) branch (1) lime flow (6) 90˚ Elbows and (2) unions. ( TABLE 5-1 ) HW 129: PRESSURE DROP VS. FLOW Standard pump supplied is PMP 30205.
- Page 20 PIPING ( TABLE 5-3 ) HW 399: PRESSURE DROP VS. FLOW Standard pump supplied is PMP 30211. Quantity of Units Piping Required Approximate design T is 23.5°F. 2" 2-1/2" 2-1/2" 2-1/2" ( TABLE 5-4 ) HW 599: PRESSURE DROP VS. FLOW Standard pump supplied is PMP 30215.
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Page 21: Part 6
Upon completion of piping, fill and properly purge of all air. Open all valves and start circulating pump. Consult Huron Valley Sales, Inc. for specific piping diagrams for your application at (313) 278-5200. PART 6. START-UP PROCEDURES Figure 5-2: Heater Piping A. -
Page 22: B Lighting Instructions
START-UP PROCEDURES WARNING If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. 2. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. -
Page 23: Sequence Of Operation
SERVICING E. SEQUENCE OF OPERATION 1. When power is first applied to the control, the control display will read the temperature Setpoint. The control will initially run through a self-diagnostic routine and then go into its operating mode. If there is no call for heat, the system will go into an idle state. 2. -
Page 24: C Soft Lockout Codes
SERVICING C. SOFT LOCKOUT CODES If the appliance is shut down for any reason other than the operating setpoint, a Soft Lockout Code is dis- played in the Temperature Display. If the Code is not flashing, the codes reference the following information: ( TABLE 7-1 ) FMT 914 SOFT LOCKOUT CODES Description Display Code... - Page 25 SERVICING IN MANY CASES, A “HARD LOCKOUT” WILL INDICATE THAT THERE IS SOMETHING WRONG WITH THE APPLIANCE, THAT SHOULD BE SERVICED OR REPAIRED. EXAMPLE: If there is a loss of flow due to an air bubble passing through the appliance (sensed via the water flow switch), the appliance will shut down and display a temporary fault (H1).
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Page 26: Fault Codes
SERVICING E. FAULT CODES The numbers given in Tables 7.3 and 7.4 match with those in the following table to give the reason for the fault. ( TABLE 7-5 ) CAUSES OF FAULTS Room thermostat incorrectly connected Pump not running or partially clogged Water pressure in the system too low (heat exchanger/radiator air bound) Fan speed control wiring not connected (unplugged) Fan blades are fouled - check for lint or dirt build-up on blades... - Page 27 SERVICING ( TABLE 7-5 continued ) CAUSES OF FAULTS Flow and return line on the boiler have been changed around Priority sensor (S3) not placed correctly, or is defective Cable harness connectors incorrectly mounted on the PCB Gas valve is defective Incorrect parameters or values outside the range of the program have been entered Gas valve not correctly adjusted at maximum load Venting system has too much resistance (possibly partially blocked)
- Page 28 Compare to Figure 7-1 on page 30. If it does not match, replace. Contact Huron Valley Sales for assistance at (313) 278-5200. Check the type of room thermostat and contact Huron Valley Sales for assistance at (313) 278-5200 Contact Huron Valley Sales for assistance at (313) 278-5200.
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Page 29: To Turn Off Gas To Appliance
Replace the part; it cannot be repaired Check the wiring Check the entire system, including the pump for blockage and scaling For descaling, see the special instructions. Contact Huron Valley Sales for assistance at (313) 278-5200 F. TO TURN OFF GAS TO THE APPLIANCE 1) Set the thermostat to lowest setting. -
Page 30: Temperature Sensor Reading Instructions
SERVICING H. TEMPERATURE SENSOR READING INSTRUCTIONS Figure 7-1: Temperature Sensor Reading Instructions I. PROPAK SENSOR RESISTANCE TABLE Temperature Resistance Temperature Resistance (!F) (Ohm) (!C) (Ohm) 32550 32550 25340 25340 19870 19870 15700 15700 12490 12490 10000 10000 8059 8059 6535 6535 5330 5330... -
Page 31: Part 8
Open the Condensate Drain Cleanout and remove any dirt. Flush and replace. d. If the inspection is being carried out by a Huron Valley Sales Certified Technician, connect your computer and check the service page for error messages, starts and failed / successful starting efforts. -
Page 32: C Condensate Cleaning Instructions
MAINTENANCE DANGER IT IS EXTREMELY IMPORTANT TO MAKE SURE THE EXHAUST VENT IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH. C. CONDENSATE TRAP CLEANING INSTRUCTIONS The condensate trap should be cleaned at least once every year. 1) Turn off the power to the ProPak. -
Page 33: Propak Controls
MAINTENANCE 3) Re-connect the molex plugs. 4) Re-set thermostats. 5) Replace the clean-out cap. 6) Turn the ProPak back on** and monitor the condensate drain until flow has been established. 7) Re-connect the condensate hose to the outside connection. **NOTE: When firing up the boiler for the first few times you may experience some fluttering of the gas burner that may result in a flame lockout. -
Page 34: Installation At High Altitudes
MAINTENANCE history. It is also used for the factory setting of control board parameters. Located just below the service port, there is a service button that must be pressed with a sharp object to enter service mode. The appliance’s primary controller (FMT 914) operates all functions of needed control and safety. It contains sophisticated logic that allows it to operate at very precise temperatures while minimizing burner on/off cycling. -
Page 35: Water Heater Operating Sample
MAINTENANCE H. WATER HEATER OPERATING SAMPLE All of the following parameters are controlled by either a storage tank temperature sensor or the inlet temperature sensor: • Setpoint = Target Temperature (120!F) Low fire only above this point • Offset = Off Setpoint (3) = 123!F off •... -
Page 36: Hw 129 Parts Breakdown
MAINTENANCE I. PROPAK ( HW 129 ) PARTS BREAKDOWN... - Page 37 MAINTENANCE I. PROPAK ( HW 129 ) PARTS BREAKDOWN Number Part Description Part Number on drawing Front panel JKR 74076 Air inlet pipe MSC 74053 Pressure switch PRS 74326 Flue gas collector MSC 74081 Seal ring 60 mm GKT 74022 Seal plug 12 mm GKT 74050 Seal ring flue gas collector - heat exchanger...
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Page 38: Jhw 199-599 Parts Breakdown
MAINTENANCE J. PROPAK ( HW 199, 399, 599 ) PARTS BREAKDOWN... - Page 39 MAINTENANCE J. PROPAK ( HW 199, 399, 599 ) PARTS BREAKDOWN Part No. Part No Part No No. on Part Description drawing Side panel JKR 74071 JKR 74071 JKR 74072 Front panel JKR 74073 JKR 74073 JKR 74074 " " "...
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Page 40: K Wiring Diagrams
STANDARD INTERNAL WIRING DIAGRAM Model 599 only Outlet sensor Burner Inlet sensor Outl e t se nsor 3-way C lose Gas valve-1 Gas valve-2 3-way Open Pump P1 L Inlet sensor Tank Sensor 3-way N Fan Speed Pump P1 L Control Power M od el 59 9 on l y... - Page 41 INTERNAL WIRING DIAGRAM with OPTIONAL HEATING WIRING HARNESS Outl e t se nsor 3-way C lose 3-way Open Pump P1 L Inlet sensor Tank Sensor 3-way N Pump P1 L M od el 59 9 on l y fa n Gas valve-1 Gas valve-2 Pump L...
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Page 42: Installation Requirements
INSTALLATION REQUIREMENTS Requirements for installation – Commonwealth of Massachusetts For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or struc- ture 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 fin- ished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:... - Page 43 NOTES...
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