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Table of Contents
- 1 Table of Contents
- 2 Pre-Installation Checklist
- 3 Required Components and Accessories Checklist
- 4 ZPG - Series Piping Installation
- 5 ZPGLP -Series Piping Installation
- 6 ZPG - Series Wiring
- 7 ZPGLP - Series Wiring
- 8 Startup Procedure
- 9 Troubleshooting
- 10 Replacement Parts
- 11 General Safety Information
- 12 Product Warranty
- Download this manual
PLUG N' GO and PIPE N' GO
INDIRECT-FIRED WATER HEATERS
INSTALLER: LEAVE THIS MANUAL WITH THE OWNER
IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING
INSTRUCTIONS.
READ CAREFULLY THE PRODUCT INSTALLATION, OPERATING AND MAINTENANCE MANUAL.
FAILURE TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN THE MANUAL MAY RESULT IN
SERIOUS OR FATAL INJURY AND/OR PROPERTY DAMAGE, AND WILL VOID THE PRODUCT WARRANTY. THIS PRODUCT
MUST BE INSTALLED BY A QUALIFIED PROFESSIONAL. FOLLOW ALL APPLICABLE LOCAL AND STATE CODES AND
REGULATIONS. IN THE ABSENCE OF SUCH CODES, FOLLOW THE CURRENT EDITIONS OF THE NATIONAL PLUMBING
CODE AND NATIONAL ELECTRIC CODE, AS APPLICABLE.
THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY AND
OTHER HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO REDUCE THE RISK OF
PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
The heat transfer medium must be water or other nontoxic fluid having a toxicity rating or class of 1, as
listed in Clinical Toxicology of Commercial Products, 5th edition. The pressure of the heat transfer
medium must be limited to 30 PSIG by an approved safety or relief valve.
Part #: 9040-658 (9/06)
INSTALLATION, OPERATION
INSTRUCTIONS
MODELS COVERED:
PLUG N' GO PRO-41ZPG, PRO-80ZPG
PIPE N' GO TD-41ZPGLP, TD-80ZPGLP
& MAINTENANCE
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Summary of Contents for PurePro PLUG N’ GO PRO-41ZPG
- Page 1 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS PLUG N’ GO and PIPE N’ GO INDIRECT-FIRED WATER HEATERS MODELS COVERED: PLUG N’ GO PRO-41ZPG, PRO-80ZPG PIPE N’ GO TD-41ZPGLP, TD-80ZPGLP INSTALLER: LEAVE THIS MANUAL WITH THE OWNER IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS.
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Page 2: Table Of Contents
1. TABLE OF CONTENTS 2. Pre-Installation Checklist..........9. Troubleshooting ............3. Required Components and Accessories Checklist..10. Replacement Parts ............15 4. ZPG - Series Piping Installation ........11. General Safety Information.......... 5. ZPGLP -Series Piping Installation ......... 12. Product Warranty............6. -
Page 3: Required Components And Accessories Checklist
3. REQUIRED COMPONENTS AND ACCESSORIES CHECKLIST SHUTOFF VACUUM RELIEF THERMAL EXPANSION MODEL CIRCULATOR ZONE VALVE* VALVE BREAKER VALVE TANK DRAIN PRO-41ZPG Included Included Required Included PRO-80ZPG *If Circulator not used TD-41ZPGLP 5GPM@ 5ft 3/4" Full Port Included Required Included TD-80ZPGLP or 1"... -
Page 4: Zpg - Series Piping Installation
4. ZPG-SERIES WITH CIRCULATOR (PLUG N’ GO) PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Connect the cold water supply to the pipe labeled COLD 1. Plumb the BOILER SUPPLY line. The circulator and flow check WATER. are factory installed 2. - Page 5 PIPING MODELS WITH PRE-INSTALLED CIRCULATOR W/INTEGRAL FLOW CHECK Thermal Expansion Tank...
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Page 6: Zpglp -Series Piping Installation
5. ZPGLP-SERIES W/O CIRCULATOR (PIPE N’ GO) PIPING INSTALLATION DOMESTIC WATER PIPING BOILER PIPING 1. Connect the cold water supply to the pipe labeled COLD 1. Plumb the circulator or zone valve on the BOILER SUPPLY line. WATER If using a separate circulator, the pump flange can be mounted directly to the threaded pipe marked BOILER SUPPLY. - Page 7 PIPING USING SEPARATE CIRCULATOR PUMP (RECOMMENDED) Thermal Expansion Tank PIPING USING ZONE VALVE WITH EXISTING HEATING SYSTEM CIRCULATOR Thermal Expansion Tank...
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Page 8: Zpg - Series Wiring
6. ZPG-SERIES WITH CIRCULATOR (PLUG N’ GO) WIRING ZPG models include a circulator with built-in priority zoning relay. The aquastat is pre-wired and controls the circulator. Line voltage must be supplied and a signal wire must be run to fire the boiler. LIVE NEUT LINE IN LINE OUT... - Page 9 CIRCULATOR RELAY BOX CIRCULATOR RELAY BOX LIVE NEUT LIVE NEUT Indirect Indirect Aquastat Aquastat REMOVE JUMPER BETWEEN 1 & 3 HEATING CIRCULATOR L1 L2 HONEYWELL L8148A OR SIMILAR W/PRIORITY HONEYWELL L8148J W/MILLIVOLT GAS VALVE CIRCULATOR RELAY BOX CIRCULATOR RELAY BOX LIVE NEUT LIVE NEUT Indirect...
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Page 10: Zpglp - Series Wiring
7. ZPGLP-SERIES W/O CIRCULATOR (PIPE N’ GO) WIRING Dial Control models utilize a standard dry-contact aquastat with capillary temperature senor. The dial control contains a make-and-break switch and is suitable for 24V or 120V, 25A Max. CAPILLARY TUBE SENSOR BULB SHAFT WIRE LEADS To wire Dial Control models, select the appropriate diagram from the following pages. - Page 11 ZONE VALVES - SCHEMATIC 3 AQUASTAT AQUASTAT AQUASTAT 3-WIRE ZONE VALVES PRIORITY W/CIRCULATORS - SCHEMATIC 4 Typical Multi-Zone Relay Thermostat Inputs Aquastat Priority or DHW Zone Zone Outputs Boiler Aquastat Circulator -11-...
- Page 12 BOILER CONTROL - SCHEMATIC 5 AQUASTAT HONEYWELL L8148E -12-...
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Page 13: Startup Procedure
8. STARTUP PROCEDURE FOR ALL MODELS 1. PURGE HEAT EXCHANGER: The heat exchanger should boiler should start momentarily. If not, check wiring and be free of large air pockets to allow the circulator to consult the troubleshooting section in this manual. operate properly. -
Page 14: Troubleshooting
9. TROUBLESHOOTING PROBLEM POSSIBLE CAUSES SOLUTION 1. No power to unit 1. Check circuit breaker, boiler emergency switch and boiler reset switch 2. Air in heat exchanger loop 2. Purge air. Ensure circulator is on Boiler Supply. Check air vents 3. -
Page 15: Replacement Parts
10. REPLACEMENT PARTS ZPG Series ZPGLP Series 41-Gallon 41-Gallon 2700-5007 2700-5007 Heat Exchanger w/Gasket and Nuts 80-Gallon 80-Gallon (Pump not included) 2700-5009 2700-500 Flange Gasket Only 2704-403 2704-403 Aquastat Well Assembly 2700-924 2700-924 Bottom Drain O-Ring 2500-178 2500-178 Dial Aquastat 2704-093 2704-093 Circulator Pump... -
Page 16: General Safety Information
11. GENERAL SAFETY INFORMATION SCALDING HAZARD. If the water temperature Chlorine Aggressive Water: The water quality is over 120°F, household members can suffer can significantly influence the life of this Product. serious or fatal scalding and painful and permanent injury. • The You should test for corrosive elements, acidity, total solids and other Consumer Products Safety Commission recommends an initial setting relevant contaminants, including chlorine and treat your water... -
Page 17: Product Warranty
Pure Pro™ Indirect-Fired Water Heater LIMITED PRODUCT WARRANTY Products covered: all Pure Pro™ brand indirect-fired water heaters Manufacturer more than 30 days after expiration of the applicable manufactured by AMTROL Inc. (the “Manufacturer”) and warranty time period described in this Warranty - see table distributed by the FW Webb Company (the “Distributor”). - Page 18 Notes -18-...
- Page 19 Notes -19-...
- Page 20 Part #: 9040-658 (9/06) -20-...
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