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Delta Performance PG PLUS-25 Installation And Maintenance Manual

Gas fired combination heaters
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PG PLUS-25/30/35/40 & 45
Gas Fired
Combination Heaters
Category IV Vented Appliance
Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa-
NOTICE
tion in order to gain warranty coverage.
When receiving the Delta Performance unit, any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
If the information in this manual is not followed exactly, a fire or explosion may
WARNING
result causing pro p e rty damage, personal injury or d e a t h .
• 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
s u p p l i e r's instructions.
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
- Input from 100,000 to 199,000 Btu/hr -
FOR YOUR SAFETY
2005-7 PG PLUS Manual 1/2005

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Summary of Contents for Delta Performance PG PLUS-25

  • Page 1 NOTICE tion in order to gain warranty coverage. When receiving the Delta Performance unit, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Leave all documentation received with appliance with owner for future reference.

  • Page 2: Table Of Contents

    Table of Contents PRODUCT AND SAFETY INFORMATION Definitions........... 1 Product Warnings .
  • Page 3 Table of Contents U-Tube Assembly ..........15-16 Domestic Drain Valve.
  • Page 4 Table of Contents SECTION VII - GAS PIPING Gas Supply Piping Connection........37 Natural Gas Pipe Sizing -Natural Gas .
  • Page 5 Table of Contents SECTION XI - START-UP PROCEDURES Final Checks Before Start-up ........51 PERFORMANCE PLUS Start-up .
  • Page 6 Table of Contents Inspection of Ignition Electrode ......61 Check Ignition Wiring and Ground Wiring ....61 Check Control Wiring.

  • Page 7: Product And Safety Information

    Product & Safety Information The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product. DANGER Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage.

  • Page 8: Product Warnings

    Product & Safety Information WARNING Bacteria can develop in the domestic w a t e r system if certain minimum water t e m p e r a t u res are not maintained. DANGER Water temperature over 125ºF can cause s e v e re burns instantly or death fro m scalds.
  • Page 9 Product & Safety Information DANGER Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. DANGER WHAT TO DO IF YOU SMELL GAS - Do not try to light any appliance...

  • Page 10: Operating Restrictions

    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 installed Temperature & Pressure Relief Valve with an AGA rating of 100,000 Btu/hr for PG-25 and 200,000 Btu/hr for PG- 30/35/40/45.

  • Page 11: Section I - Pre-Installation Items

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

  • Page 12: Flooring And Foundation

    Pre-Installation Items BEST PRACTICES To provide serviceability to the unit it is recommended 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 - 12 inches.

  • Page 13: Section Ii - Combustion Air And Venting

    Combustion Air and Venting SECTION II - Combustion Air and Venting Combustion Air Contamination WARNING If the PERFORMANCE PLUS combus- tion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to an outside location.

  • Page 14: Combustion Air Requirements

    Combustion Air and Venting Combustion Air Requirements The PERFORMANCE PLUS can use inside air if no contaminants are present in the area of installation. If contaminants are likely to be present in the area of installation, outside air must be piped directly to the unit as referenced in Section VI Venting and Combustion Air Piping.
  • Page 15 Combustion Air and Venting Combining spaces on the same story. Each opening shall have a minimum free area of 1 sq. in./1000 Btu/hr of the total input rating of all gas utilization equipment in the space, but not less than 100 sq.

  • Page 16: Vent System

    Combustion Air and Venting Fig. 3: Equipment Located in Confined Spaces; All Air from Outdoors Through Ventilated Attic Equipment Located in Confined Fig. 4: Spaces; All Air from Outdoors Combination of Indoor and Outdoor Combustion Air Indoor Openings: Where used, openings con- necting the interior spaces shall comply with the Indoor Combustion Air section on page 8.

  • Page 17: Removal Of An Existing Boiler From A Common Vent System

    Combustion Air and Venting Removal of an Existing Boiler f rom a Common Vent System BEST PRACTICES F o r installations in which the PERFOR- MANCE PLUS is replacing an existing b o i l e r / hot water h e a t e r system, which was connected to a common vent system with other appliances, the following steps shall be conducted with each re m a i n i n g...

  • Page 18: Section Iii - Unit Preparation

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

  • Page 19: Completion Of Hydrostatic Test And Draining

    Unit Preparation WARNING Do not leave the unit unattended while p ressurized. A cold water fill could expand and cause excessive pre s s u re , resulting in severe personal injury, death or substantial property damage. 7. Ensure constant gauge pressure has been maintained throughout the 10 minute test.

  • Page 20: Section Iv - Domestic Piping

    The PERFORMANCE PLUS has a factory installed Temperature / Pressure Relief valve. Ensure the rating of the T&P relief valve is correctly sized as follows per AGA: Model AGA Rating PG PLUS-25 100,000 Btu/hr PG PLUS-30 200,000 Btu/hr PG PLUS-35 200,000 Btu/hr PG PLUS-40...

  • Page 21: Thermostatic Mixing Valve

    Domestic Piping The installer must install discharge piping onto the T&P relief valve. The discharge piping 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. •...

  • Page 22: U-Tube Assembly

    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 and reconnect onto the mixing valve. If the installation of the PERFORMANCE PLUS requires domestic hot water for a commercial dishwasher, the installer may...

  • Page 23: Tr/Smart Series Application

    Domestic Piping TR/SMART Series Application For applications requiring large volumes of domestic hot water over an extended period, the installer may include a Triangle Tu b e TR/SMART Indirect Water Heater in conjunc- tion with the PERFORMANCE PLUS. (See Fig. 10 page 19) The domestic system recirculation, if used, is directed to the TR/SMART Series Tank.
  • Page 24 Domestic Piping Fig. 7: PERFORMANCE PLUS With Recirculation Fig. 8: Multiple Units Installation With Recirculation 1. Mixing valve with check valve 2. Flow check valve 3. Shut off valve 4. Backflow preventer or pressure reducing valve* * Optional devices may be required by local Codes Note: All shut off valves shown in this figure must be closed when siphon draining...
  • Page 25 Domestic Piping Fig. 9 : PERFORMANCE PLUS with Storage Tank Fig. 10: PERFORMANCE PLUS with TR/SMART Indirect Water Heater 1. Mixing valve with check valve 2. Flow check valve 3. Shut off valve 4. Backflow preventer or pressure reducing valve* * Optional devices may be required by local Codes 6.

  • Page 26: Section V - Primary Piping

    Primary Piping SECTION V - Primary Piping General Piping Requirements Low Water Cutoff Device The PERFORMANCE PLUS is equipped with a factory installed pressure switch style Low Water Cut Off device. The minimum operating system pressure allowable with this device is 10 psig. Check local codes which require a low water cutoff device for compliance of this device.

  • Page 27: Circulator

    Primary Piping For proper operation of the expansion tank and system, remove the factory installed automatic air vent from the PERFOR- MANCE PLUS and plug the connection. (See Item 10, Fig. 46 page 68) CAUTION DO NOT install automatic air vents on a closed-type expansion tank system.

  • Page 28: System Piping - Multiple Units Installation

    Primary Piping System Piping - Radiant Heating with Mixing Va l v e Connect the PERFORMANCE PLUS to the system piping as shown with a radiant sys- tem using a thermostatic mixing valve as shown in Fig. 14 page 25. The primary / sec- ondary piping ensures sufficient return tem- perature to the PERFORMANCE PLUS.
  • Page 29 Primary Piping Fig. 11 : Near Appliance Primary Piping with a Diaphragm Type Expansion Tank Fig. 11B : Near Appliance Primary Piping with Diaphragm - Type Expansion Tank (Alternate Circulator Location) 1. Appliance Circulator 2. Shut Off valve 3. Expansion tank Near Appliance Piping Fig.
  • Page 30 Primary Piping Fig. 12: Primary piping - Zoning with Circulators Fig. 13: Primary Piping - Zoning with Zone Valves 1. Appliance circulator 2. Shut-off valves 3. Flow check valve 4. Zone valve • Size primary manifold for total flow of all circula- tors •...
  • Page 31 Primary Piping Fig. 14: Primary Piping - Low Temperature Radiant System Fig. 15: Primary Piping - Multi Temperature System 1. Circulator 2. Shut Off valves 3. Flow check valve 4. Zone valve Note: Adjust system temperature valve to establish maximum sup- ply/return temperature differen- tial of 30ºF and a minimum 130ºF return water temperature...
  • Page 32 Primary Piping...

  • Page 33: General Requirements

    Venting and Combustion Air Installation SECTION VI - Venting and Combustion Air Installation General Requirements Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54/ ANSI Z223.1 for U.S. installations and CSA B149.1 or B149.2 for Canadian installations. The PERFORMANCE PLUS requires a special vent system designed for pres- surized venting and is rated as ANSI...

  • Page 34: Category Iv Vent Termination Clearance

    Venting and Combustion Air Installation Category IV Vent Termination Clearances Maintain the following clearances to the vent termination: 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 forced air intake (does not include the combustion...

  • Page 35: Multiple Vent Terminations

    Venting and Combustion Air Installation Must maintain 4 feet of clearance below and horizontally from doors and windows. See dimension A Fig. 17. If the venting application is a vertical direct or non-direct vent application: The vent must terminate at least 3 feet above the roof and at least 2 feet higher than any portion of the building within 10 feet.

  • Page 36: Venting Option - Direct Vent / Vertical

    Venting and Combustion Air Installation Venting Option - Direct Vent / Vertical In this vent application the PERFORMANCE PLUS is vented vertically through the roof or an unused chimney using the Triangle Tube Concentric Vertical Vent Kit. The installer should consider the following when choosing this vent option: a.

  • Page 37: Venting Option - Direct Vent / Horizontal

    Venting and Combustion Air Installation Venting Option - Direct Vent / Horizontal In this vent application the PERFORMANCE PLUS is vented horizontally through a wall using only approved 3-inch stainless steel vent material and using outside air for combustion. The installer should consider the following when choosing this vent option: a.

  • Page 38: Excessive Horizontal Vent Runs

    Once the venting method and location for the vent termination has been determined the installer must select the vent components required for the system. The maximum combined equivalent lengths for venting and combustion air inlet are as follows: Delta PERFORMANCE PLUS - 200 feet (100 feet each)

  • Page 39: Venting Option Diagrams

    This includes termination fittings. NOTICE F o r Delta PERFORMANCE PLUS applications that may exceed the 100 feet maximum allowable equivalent length for the venting system, contact Triangle...
  • Page 40 Venting and Combustion Air Installation Fig. 21: Standard Horizontal Venting Installation Fig. 22: Horizontal - Direct Vent Combination Fig. 22B : Concentric Horizontal - Vent Snorkel Fig. 22A: Concentric Horizontal Vent Installation I n s t a l l a t i o n...
  • Page 41 Venting and Combustion Air Installation Fig. 23: Location of Air Inlet Termination Fig. 24A: Vent Termination Combustible Fig. 24B: Vent Termination - Non- Wall Combustible Wall...
  • Page 42 Venting and Combustion Air Installation...

  • Page 43: Section Vii - Gas Piping

    Gas Piping SECTION VII - Gas Piping Gas Supply Piping Connection NOTICE The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. 1. Remove the burner jacket hood. Refer to Figure 27 to pipe gas supply to the burner.

  • Page 44: Natural Gas

    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 1,000 to obtain cubic feet per hour). Table 3 is based on Natural Gas with a specific gravity of 0.60 and a pressure drop through the gas piping of 0.30”w.c..

  • Page 45: Propane Gas

    Gas Piping PROPANE GAS Pipe Sizing - Propane Gas 1. Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator. P ropane Gas Supply Pre s s u re Require m e n t s 1.

  • Page 46: Section Viii - Internal Wiring

    Internal Wiring SECTION VIII - Internal Wiring WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe person- al injury or death.

  • Page 47: Internal Control Wiring Diagrams

    Internal Wiring Fig. 30: Factory Wiring Schematic...
  • Page 48 Internal Wiring Fig. 31: Factory Internal Wiring...

  • Page 49: Section Ix - External Wiring

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

  • Page 50: External Control Wiring Diagrams

    External Wiring 4 Wire Zone Valve 3 Wire Zone Valve *Use isolation relay on 3-wire zone valve with non-isolated end switch. Transformer and the PERFORMANCE PLUS control can burn out if isolation relay is not used. Fig. 33: Multiple Zone Field Wiring Using Zone Valves...
  • Page 51 External Wiring Fig. 34: Field wiring with zone circulators.
  • Page 52 External Wiring Fig. 35: Typical Zone Relay Panel Wiring Fig. 36: Storage Tank Recirculation Wiring...

  • Page 53: Section X - Start-Up Preparation

    Start-Up Preparations SECTION X - Start Up Preparation Check System Domestic Chemistry WARNING Do not use petroleum-base cleaning or sealing compounds in the primary sys- tem. Damage to seals and gaskets in the system components could occur, result- ing in substantial property damage. NOTICE System water including additives must be practically non-toxic, having a toxicity...

  • Page 54: Use Of Antifreeze In The Primary System

    Start-Up Preparations NOTICE System water including additives must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Pro d u c t s . Use of Antifreeze in the Primary System WARNING NEVER use automotive or ethylene gly- col antifreeze or undiluted antifreeze in...

  • Page 55: Check Low Water Cut-Off Device

    Table 3 : Pressure Switch Setting PG PLUS Natural Gas Model (inch w.c.) PG PLUS-25 1.84 " w.c. (yellow) 1.84" w.c. (yellow) PG PLUS-30 2.7" w.c. (red) PG PLUS-35 2.7 " w.c. (red) PG PLUS-40 2.7 " w.c. (red) PG PLUS-45 2.7 "...

  • Page 56: Verify Correct Pressure Switch

    The air shutter is located inside the com- bustion air inlet adapter located in the top /left jacket panel area. See Fig. 37. Table 4 : Air Shutter Settings Model Natural Gas PG PLUS-25 PG PLUS-30 PG PLUS-35 PG PLUS-40 PG PLUS-45 NR- Air shutter not required.

  • Page 57: Section Xi - Start-Up Procedures

    Start-Up Procedures SECTION XI - Start-Up Procedures Final Checks Before Start-up Verify the PERFORMANCE PLUS  and the primary and domestic systems are full of water and all system compo- nents are correctly set for operation. Verify Start-up Preparation items outlined ...

  • Page 58: Start-Up / Operating Instructions

    Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING The following instructions must be followed exactly, a fire or WARNING explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an electron- ic ignition system. Do not attempt to light the burner by hand.
  • Page 59 Start-Up Procedures WARNING Venting system must be sealed gas-tight to prevent flue gas spillage and potential carbon monoxide emissions, which will result in severe personal injury or death. Check Gas Piping  1. Check around the unit for gas odor fol- lowing the procedure outlined in this manual on Page 49.

  • Page 60: Section Xii - Temperature Limits

    Temperature Limits SECTION XII - Temperature Limits DANGER Studies have indicated that dangerous bacteria can form in the potable water distribution system if certain minimum water temperatures are not maintained. For prevention of this, it is recommend- ed that the Secondary Thermostat be set as shown in Figure 38 and maintained at 130ºF to 140ºF.

  • Page 61: Setting The Thermostatic Mixing Valve

    Temperature Limits Setting the Thermostatic Mixing Valve  NOTICE The thermostatic mixing valve controls the outlet hot water temperature deliv- ered to the faucets. WARNING POTENTIAL SCALD HAZARD The mixing valve must be installed on the PERFORMANCE PLUS. Removal of the mixing valve will create a potential scald hazard resulting in severe personal injury or death.

  • Page 62: Section Xiii - Check-Out Procedures

    Check-Out Procedures SECTION XIII- Check-Out Pro c e d u re s NOTICE Perform the following check-out proce- dures as outlined and check off items as completed. When procedures are com- pleted, the installer should complete the installation record on page 57. Check-out Procedures Both inner and outer tanks filled with ...

  • Page 63: Section Xiv - Installation Record

    Installation Record SECTION XIV - Installation Record...

  • Page 64: Sections Xv - Maintenance Schedule

    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 combustion chamber;...

  • Page 65: Section Xvi - Maintenance Procedures

    Maintenance Procedures SECTION XVI - Maintenance Procedures MAINTENANCE PROCEDURES WARNING The PERFORMANCE PLUS should be inspected and serviced annually, prefer- ably at the start of the heating season, by a qualified service technician. In addi- tion, the maintenance and care of the unit as outlined on page 58 and further explained on pages 59 through 62 should be performed to assure maximum effi-...

  • Page 66: Check Combustion/Ventilation Air Operating

    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 or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers.

  • Page 67: Check Boiler Relief Valve

    Maintenance Procedures Check Boiler Relief Valve Inspect the relief valve and lift the lever to verify flow at least annually or as recom- mended on the warning tag of the valve. WARNING B e f o re manually operating the pre s s u re relief valve ensure the discharge piping is d i rected to a suitable place of disposal to avoid a potential scald hazard.

  • Page 68: Check Burner Flame

    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 covers the entire burner surface, shut the unit down and allow it to cool thoroughly. Close the manual gas valve on the gas sup- ply line and disconnect the gas piping to remove the burner assembly from the unit.

  • Page 69: Section Xvii - Replacement Parts

    Replacement Parts SECTION XVII - Replacement Parts Replacement Parts WARNING Replacement parts can be ordered and purchased through a local Triangle Tube distributor. When ordering parts, spec- ify the Model Number and Serial Number. Include a description of the part and a replacement part number. Using modified or other manufacturer parts will not be covered by warranty and may damage or cause improper...

  • Page 70: Replacement Parts

    HMJKT40B HMJKT25TOP Jacket, Top cover HMJKT40TOP Jacket, Top cover HMHOO06 PGRKIT20 Fig. 40: Jacket Components Description PG PLUS-25/ 30/35 PG PLUS-40/45 Complete Jacket Set Complete Jacket Set Jacket, Front Jacket, Front Jacket, Left side Jacket, Left side Jacket, Right side...
  • Page 71 Replacement Parts Fig. 41: Control Panel Components Item Part No. Description Operating Thermostat PGRKIT21 Primary or Secondary Manual Reset Hight Limit PGRKIT 22 Pre-set at 205ºF HMCS01 Control Panel Auto Reset High Limit PGRKIT23 Pre-Set at 194ºF Temperature / Pressure HMGAU01 Gauge...
  • Page 72 PGRKIT 19 Domestic Priority & Circulator 120 V-24 V 40VA PGRKIT18 Transformer Description Pressure Relief Valve 30 psi Air Vent Thermostatic Mixing valve 3/4" Snap sets Male / Female Temperature/Pressure Relief Valve (PG PLUS-30/35/40/45 only) Temperature/Pressure Relief Valve (PG PLUS-25 only)

  • Page 73: Replacement Parts

    PGRKIT17 PGRKIT16 Description Gas valve replacement kit PG PLUS-25 Blower / motor replacement kit PG PLUS-30 Blower / motor replacement kit PG PLUS-35 Blower / motor replacement kit PG PLUS-40 Blower / motor replacement kit PG PLUS-45 Blower / motor replacement kit...

  • Page 74: Specifications

    Specifications Fig. 44: Side View Fig. 46: Top View Primary circuit, ø 1” NPT Primary circuit drain valve connection, ø 1/2” NPT Domestic temperature/pressure relief valve (150 psi), ø 3/4” NPT Primary circuit & pressure relief valve (30 psi), ø 1” Domestic cold water inlet, ø...

  • Page 75: Specifications

    Specifications Type PG PLUS-25 Input Nat. Gas Btu/hr Inner Tank Capacity Outer Tank Capacity Dimensions Inches Vent outlet size TP Valve (domestic) ø Domestic water ø Primary connection ø Drain ø Empty weight Heat exchanger surface Sq. Ft. Table 7: PERFORMANCE PLUS Data Model 10 Min.
  • Page 76 Additional quality water heating equipment available Phase III Indirect Fired Water Heaters TTP Brazed Plate Heat Exchangers Maxi-flo Pool and Spa Heat Exchangers from Triangle Tube/Phase III Exclusive “Tank-in-Tank” design Stainless steel construction Available in 8 sizes and 2 models Limited LIFETIME residential warranty 15 year limited commercial warranty Self cleaning/self descaling design...

This manual is also suitable for:

Pg plus-30Pg plus-35Pg plus-40Pg plus-45

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