Installation Manual Retrofit Coil TOP PERFORMER

Indirect Fired Water Heater

PLEASE READ INSTRUCTIONS CAREFULLY BEFORE INSTALLING WATER HEATER RETROFIT COIL

The Company does not warrant the fitness or performance of the heater within that system, nor does it assume any consequential damage to general property or other components of the system.

This appliance is designed to heat water by circulating water from the boiler through the internal coil in the tank. We specifically do not warrant this tank for high temperature applications such as wood stoves or steam producing systems. Such use of this product will automatically void the warranty. The design anticipates the proper installation and care in use of the product. There is risk of property damage and personal injury inherent in the use of any hot water system. The Company cannot supervise the installation and therefore makes it a specific condition of the warranty that the customer will supervise the installation and use of this product to be sure they are performed in accordance with safe guidelines and proper local or national codes. Generalized instructions and procedures cannot anticipate all situations. For this reason, only qualified installers should perform the installation. A qualified installer is a person who has licensed training or a working knowledge of the applicable codes, regulations, tools, equipment and methods necessary for safe installation of a boiler system and residential water heater. If questions regarding installation arise, check with your local plumbing and electrical inspectors for proper procedures and codes. Local codes take a precedent over instructions in this manual.

P.O. Box 5431 · Salisbury, MA 01952-5431 · 978.462.6683

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INSTALLATION GUIDELINES A. REMOVING OLD HEAT EXCHANGER q Close Cold water supply valve to heater. q Close Boiler supply and return valves to heat exchanger. q You don’t need to drain tank. Instead you can cut and cap the old cold water

inlet pipe above the level of the tank. q Disconnect heat exchanger. q Remove all 8 nuts, bolts and washers from coil and discard. q Remove heat exchanger from tank.

B. PREPARING TANK FOR NEW COIL q Before installing new heat exchanger it is imperative that the edge of the steel

pipe is clean from rust and not damaged. A file may be used to dress up the surface.

q Check INSERT at tank opening (See diagram 1). If it is nylon, you MUST NOT use the plastic spacer. If the insert is copper, you MUST use the plastic spacer.

C. INSTALLING THE REMOVABLE HEAT EXCHANGER q If the insert is copper, place the plastic spacer on top of tank flange and align

holes in spacer with slotted holes in flange. q WARNING: IT IS CRITICAL TO USE THE SPACER CORRECTLY!

ONLY use the plastic spacer if the insert is copper DON’T use the plastic spacer if the insert is nylon

q Apply the included o-ring lubricant to o-ring. q Insert the o-ring into the groove on the plastic o-ring housing. q Insert heat exchanger and align holes in cover plate with slotted holes in

flange. q WARNING: Plastic o-ring housing must be properly installed. (See Figure

1). Failure to do this will void the warranty. q Insert and secure the bolts to the nuts one at a time in the following manner:

• Place the nut and washer behind the slotted flange opening. • Hold the nut and washer in place with one hand – insert the bolt with the

other. • Thread the bolt through the washer and into the nut and tighten. NOTE: Be sure to place bolts in all of the openings.

q Heat exchanger connections are 3/4" male threaded fittings. q Connect the supply line (from the boiler) to the “Hx In” fittings of the heat

exchanger. It is recommended to use a union. q Connect the return line (back to the boiler) to the “Hx Out” fittings on the flange

of the heat exchanger. It is recommended to use a union.

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D. WATER SUPPLY CONNECTIONS q All water supply fittings on this heater are brass – do not over tighten or strip

threads. q Do not apply heat directly to any inlet or outlet. q Cut and cap the old cold water inlet pipe above the level of the tank. q Connect the cold water supply to the fitting on the flange of the heat

exchanger. It is recommended to use a union. q Connect the hot water to the fitting on the flange of the heat exchanger. It is

recommended to use a union. q WARNING: Some local codes mandate the use of a backflow preventer or

check valve or reducing valve. An adequate expansion tank (or other adequate means) must be installed to prevent pressure build up or damage from thermal expansion when a check valve or backflow preventer or reducing valve is used. Failure to do so could result in tank leakage and therefore void the warranty.

E. FILLING THE HEATER q Check that the temperature-and-pressure relief valve has been properly

installed (mandatory requirement). q Completely close the drain valve. q Open the highest hot water faucet to allow air to escape from piping. q Open the valve to the cold water inlet and allow the heater and piping system

to completely fill, as indicated by a steady flow of water from the open faucet.

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FIGURE 1