HeatLink TWH070P User manual

TWH070P, TWH070XP
Tankless Water Heater Panels
Installation, Operation, and Maintenance Manual
®
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L6TWH000P
MECHANICAL
ROOM IN A BOX
™

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2
TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Table Of Contents
Warnings........................................................................................................................3
Tools Needed ...............................................................................................................3
Function.........................................................................................................................4
Unpacking.....................................................................................................................4
Panel Components ....................................................................................................5
Specications...............................................................................................................6
Dimensions...................................................................................................................7
Panel Component Specications .........................................................................7-9
Valve Adjustments .....................................................................................................9
Mounting.......................................................................................................................10
Piping Hookup ............................................................................................................11
Fill and Purge ..............................................................................................................12
Panel Wiring .................................................................................................................13
Panel Control Sequence...........................................................................................14
DHW Priority Switch Installation...........................................................................15
Troubleshooting .........................................................................................................16-17
Maintenance ................................................................................................................17
Schematics
Mechanical ...............................................................................................................18-25
Electrical Rough-in ................................................................................................26-27
Electrical Detail .......................................................................................................28-34

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Installation, Operation, and Maintenance
Warnings
The zone control panel is for indoor use only and must be installed by a qualied installer/service technician. This product
must be installed and operated in strict accordance with the terms set out in this manual and in accordance with the relevant
requirements of the Local Authority Having Jurisdiction. Failure to comply will result in a void of warranty, and may also result
in property damage, serious injury, or death.
Servicing
Prior to commencing installation of this panel it is necessary to read and understand all sections of this manual. The
symbols below are used throughout this document to ensure proper operation of the panel, and your safety. Please pay
attention to these symbols.
Disclaimer
HeatLink Group Inc. shall not be responsible for errors in its brochures or printed materials. HeatLink Group Inc. reserves
the right to alter its products at any time without notice, provided that alterations to products already on order shall not
require material changes in specications previously agreed upon HeatLink Group Inc. and the Purchaser. All trademarks
in this material are property of the respective companies. HeatLink and the HeatLink logotype are trademarks of HeatLink
Group Inc. All rights reserved.
Tools For Installation
• Level
• Screwdriver or power drill
• Flat head bit
• Phillips head bit # 2
• 2 adjustable wrenches (or 2×30mm wrenches and 2×40mm wrenches)
In order to avoid injury or death, switch o the power to the panel prior to
inspecting or making connections to the terminal strip.
Warning
Possible Hazard
Warning
Live Power
Warning
Hot Pipes
Warning
Treated Water

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Unpacking
Step 1 Examine carton for any damage that may have occurred during shipping. If damage is visible notify your courier and
supplier immediately.
Step 2 Open the carton by removing the staples.
Step 3 Remove the cardboard spacers from the carton, then remove the panel from the carton. Lift the panel by the base,
not the enclosure.
Step 4 There are 2 screws holding the enclosure in place during shipping. They are located at the top left & right of the panel
base. Remove these 2 screws.
Step 5 Remove the enclosure from the panel by sliding it upwards until it stops, then gently pulling outwards o.
Function
This panel can provide mixing, distribution, and zoning for a wide variety of hydronic heating applications.
The eectiveness of the system is dependant on the system being designed and installed correctly. Proper consideration
of factors such as BTU loads, outdoor design temperature, indoor design temperature, room set-point temperature(s),
dierential uid temperatures, head loss, ow rates, and transfer capacities of the heat emitters is critical.
Once these factors have been considered and the system requirements determined, these can then be evaluated and
compared to the zone control panel capabilities (refer to pages 5-9).
Note: This panel does not regulate or monitor the operating safety limit temperatures of the uid leaving the heat source.
Step 6 Verify the following items:
• (4) Mounting screws
• (4) ¾" MBSP x 1" FNPT adapters
• (6) ¾" rubber washers (2 spares)
• (2) 1" rubber washers (spares)
Screws
Top
Side View
Bottom

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Installation, Operation, and Maintenance
Panel Components
# Component
Part Number
TWH070 TWH070XP
1Primary Circulator PUMP1558 PUMP2699BR
2Secondary Circulator PUMP1558 PUMP1558
3Thermostatic Mixing Valve – –
4Power Box with 6' Power Cord PWRB7R2 PWRB7R2
5Thermometer 76940 76940
6Enclosure n/a n/a
7Accessory Pack ACCTWH ACCTWH
3
⁄
4
" Washer WHTWSH34 WHTWSH34
1" Washer NTRWSH1 NTRWSH1
8Flow Switch for DHW Priority
(optional, sold separately) FLWSWTCH FLWSWTCH
7
6
1
2
3
4
5
TWH070P
1
2
3
4
5
TWH070XP
8

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Specications
TWH070P TWH070XP
Listing cETLus
Conforms to CAN/CSA-C22 No.14, UL508
Dimensions 18.25"H x 16.25"W x 8"D
Nominal panel output 70,000 btu/hr 70,000 btu/hr
Primary nominal flow 4.0 US gpm @ 35°F ΔT 4.0 US gpm @ 35°F ΔT
Primary nominal pressure drop outside of panel 14 ft 24 ft
Secondary nominal flow 7 US gpm @ 20°F ΔT 7 US gpm @ 20°F ΔT
Secondary nominal pressure drop outside of panel 4 ft 4 ft
Max ambient temperature 120°F
Max water temperature 200°F
Min required flow for correct temp control 1.3 US gpm (5 L/min)
Power supply: pre-wired on system controller 110 V(ac)
Primary circulator Non-ferrous, Grundfos
UPS15-58CIL2
Non-ferrous, Grundfos
UPS26-99BFC
Secondary circulator Non-ferrous, Grundfos
UPS15-58CIL2
Non-ferrous, Grundfos
UPS15-58CIL2
Auxiliary terminal Yes
DHW priority Optional @ ~0.5 US gpm DHW flow
Temperature control method 1" 3-Way thermostatic
Temperature control range 100°F - 145°F
Valve Cv 3.0
Piping
3
⁄
4
" 304 Stainless steel tubing
Piping connections 1" FNPT
DHW priority switch connection
1
⁄
2
" FNPT (FLWSWTCH optional)
Backplate Galvanized steel
Enclosure Powder coated steel
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
20.0
12345678
US GPM
FT HD
TWH Series FT HD Outside of Panel

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Installation, Operation, and Maintenance
Power Box
This module provides the required power for all electronic
components on the panel, via the ON/OFF switch. Power box may
not be exactly as shown.
Specications:
• Requires 115V power source.
• Requires a maximum 15A circuit breaker.
Panel Component Specications
Dimensions
16.250”
2.936”
7.998”
3.570”
7.533”
1.563”
1.563”
3.602”
7.908”
18.250”

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Circulators
The circulators moves the heated uid through the hydronic system when there is a call for heat from the thermostat. Primary
pump on the TWH070XP is a UPS26-99BFC.
Specications:
• The following pump curves apply.
UPS15-58CIL2 Pump Curve
0
2
4
6
8
10
12
14
16
18
20
0246810121416
Flow (gpm)
Head (feet)
1st Speed 2nd Speed 3rd Speed
UPS26-99BFC Pump Curve
0
5
10
15
20
25
30
35
0 5 10 15 20 25 30 35
Flow (gpm)
Head (feet)
1st Speed 2nd Speed 3rd Speed

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Installation, Operation, and Maintenance
MIN M A X 7 1 2
MIX
3-Way Thermostatic Mixing Valve (TMV)
The TMV controls the temperature of the hydronic system via a
self regulating thermostat.
Setting the TMV
The indicator for the valve is located at the base of the knob on
the back. The mixed (desired) temperature is a function of the
TMV setting.
See the below chart to determine the proper setting for you
system. After allowing the system to run for a short period, verify
the setting and adjust if necessary.
Unit Mixed Fluid Temperature
Min. 1234567Max.
°F 81 90 100 111 120 127 136 145 152
°C 27 32 38 44 49 53 58 63 67
Thermometer (76940)
The pipe mounted thermometer reads the supply uid
temperature.
Specications:
• Temperature range of 32-210°F (0-100°C).
Indicator
on back
Flow Switch for DHW Priority (FLWSWTCH)
(optional, sold separately)
The electronic ow indicator provides DHW priority when the
DHW ow rate reaches a factor pre-set level (approx. 0.5 US
gpm). Must be piped in downstream of panel (see schematic on
page 15).
Mounted separately from the panel (see page 15).

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Mounting
Prior to mounting the panel, ensure the wall is capable
of supporting the weight of the panel.
Ensure that a 115V receptacle is within reach of the
6-foot cord and plug.
Step 1 Determine the locations and distance
between the wall studs. With a level at a
minimum height of 4' from the oor draw a
straight line on the wall and mark the stud
locations.
If the panel cannot be secured directly to the
studs, or suitable backing boards, plywood
may need to be installed behind the panel to
properly secure it in place.
Step 2 Screw two of the supplied mounting screws
into the wall studs (or backing plywood) 2"
from the top of desired height, and 10-½"
apart, leaving ¼" of screw out from the wall.
Step 3 Lift and place the panel onto the mounting
screws.
Step 4 Screw the two remaining mounting screws
into the holes at the bottom of the panel and
tighten the top two screws.
Step 5 Before replacing the enclosure, refer to pages
12-14 for ll and purge, and proper wiring
instructions.
10-½"
2" 1⁄4"
Wall Stud
min. 4'
from floor

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Installation, Operation, and Maintenance
A
B
C
D
E
F
Note: Use precautions when soldering or applying heat within 16" of the panel.
Do not overtighten brass nuts!
1
2
3
4
Primary Supply
Primary Return
Secondary Supply
Secondary Return
Piping Hookup
Step 1 Before making any connections, identify the
required connections to and from the panel.
Adapters are ¾" M BSPP x 1" FNPT, and must use
the supplied adapters and rubber washers.
Step 2 Connect all adapters.
1. Connect MNPT adapter Eto copper pipe or
tubing F.
2. Screw supplied M x FNPT adapter Donto E
using appropriate thread sealant.
3. Take assembly
D E F and place rubber
washer Con at surface of D.
4. Without disturbing rubber washer C, place
assembly against anged stainless steel pipe
B.
5. Slide nut
Aover adapter Dand rst nger
tighten nut. Then, using two 30mm wrenches,
tighten the nut taking care not to overtighten
the nut, as this will damage the rubber washer.
Step 3 See page 15 for instructions on connecting
the optional Flow Switch for DHW Priority
(FLWSWTCH).
312
4

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Fill And Purge
The following steps are recommended in order to ll the panel
with water and purge entrained air once piping is completed,
and before activation of the panel.
Note: Additional purging steps may be required for the rest of
the hydronic system.
Note: Isolation and drain valves are not included with the
panel, but are necessary to properly ll and purge the
panel, and to isolate the panel for service.
Step 1 Ensure the panel is not plugged in.
Step 2 Adjust the thermostatic mixing valve to a position of
“Max.“ (see page 9).
Step 3 Fully close valves A, B, C, D,and F.
Fully open valve E.
Step 4 Attach a purge hose (not included) to Eand a ll
hose (not included) to F. Open valve F.
Step 5 When exiting water from Eis free of bubbles, close
valve E, then valve F.
Step 6 Remove hoses from drain valves and full open valves
A, B, C, and D.
Step 7 Check for leaks at connections. If any leaks are found,
use a back-up wrench and carefully tighten until leak
stops. Do not overtighten.
Step 8 Readjust the setting of the thermostatic mixing valve
to provide a proper mixed uid temperature to the
hydronic system (see page 8).
The discharged system uid from the ll and purge
process is not for consumption or washing.
A B C D
E F

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Installation, Operation, and Maintenance
Panel Wiring
Note: Terminal headers are removable to make wiring connections easier.
Thermostat Wiring
• 24V low voltage power may be supplied to the thermostat. Wiring of thermostat
should be done by qualied electrician and should meet local codes and
jurisdictions. Wiring to the terminal strip requires 18 gauge 4 wire.
• Do not exceed 2VA per thermostat.
• Do not cross terminals Cand R– this will damage the Power Box.
WRC AUX
24 V
Factory Jumper
Do not remove.
Signal
WRC AUX
Factory Jumper
Do not remove.
24 V 24 V Signal
WRC AUX
Signal 24 V 24 V
Jumper to Dry Contact
Factory Jumper
Do not remove.
2-Wire Thermostat
(battery only or non-electric)
3-Wire Thermostat
(HeatLink thermostats)
4-Wire Thermostat
(with dry contact signal)
Other Terminals
Auxiliary Contacts The auxiliary contact set is dry, meaning no supply of power is present at the terminal. The
maximum allowable load is 2A. The auxiliary dry contact located on the terminal is to switch
another device (ie. the heat source) when there is a call for heat from any zone.
DHW Priority Contacts The wiring harness of the optional Flow Switch for DHW Priority (FLWSWITCH) plugs into these
contacts (see page 15).

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Panel Control Sequence
1. When the power cord 1from the power module is plugged in, and the Power switch located on the front of the module
is placed in the on position the red LED will be lit, indicating that the panel is powered with 110V.
2. The factory setting for the BYPASS switches 2are to remain in the OFF position. Only switch the front 3-way switch to
“Heat Source Pump Bypass“ or Radiant Pump Bypass switch to ON if the red and green LED’s on the power module do not
light up during a call for heat. Please refer to the troubleshooting section of the manual for further details.
3. When a thermostat calls for heat, its internal 24V contacts close, the auxiliary terminals close, and both circulators 3
turn on.
4. As the circulators move uid through the panel the thermostatic mixing valve adjusts the uid temperature based on the
user settings (page 8).
5. When the requirements of the thermostat are met, the internal contacts of the thermostat open, the auxiliary contacts
open, and the circulators stop.
6. Both the primary and secondary circulators are activated once every 24 hours, for 15 minutes, to ensure that potable
water in the piping is not stagnant.
Note: If the FLWSWTCH optional DHW priority ow switch 4is installed and the DHW ow is above the factory setting for
this device, the primary pump stops. When the DHW ow drops below the factory setting the primary pump resumes
and the panel returns to normal operation.
1
2
3
4

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Installation, Operation, and Maintenance
Flow Switch for DHW Priority (FLWSWTCH) Installation (optional, sold separately)
Installation Notes:
• Makes sure the cable to the ow switch isn't under tension.
• Clean the pipe system in which the ow switch is to be installed and remove any magnetic
particles, e.g. welding residue.
• The straight in- and outlet pipe (in front of and behind the ow switch) has to be at least
2-
1
⁄
2
" (65 mm).
• The ow switch should be installed in an“upright standing position” in horizontal pipework.
• The switch should only be installed in a vertical position, deviation max. 45°.
• Make sure that ther are no external magnetic elds or large ferromagnetic
bodies in the immediate vicinity of the ow switch, since these can impair
device functioning.
• Screw on the union plastic nut with a maximum torque of 8 Nm.
• To prevent overheating when soldering near the ow switch, the ow switch
(body with paddle system) and the o-ring must be removed from the pipe
section.
max. 45°
Step 1 DHW connectors are
1
⁄
2
” FNPT. Using appropriate thread sealant and
ttings, connect the water heater output to the input on the ow
switch; and house hot water system to output on ow switch.
The straight in- and outlet pipe (in front of and behind the ow
switch) has to be at least 2-
1
⁄
2
" (65 mm).
Observe ow direction when making connections.
Be sure to connect the DHW priority downstream from the panel
(see schematic below).
Terminal Header
of Wiring Harness
DHW Supply
to House
Thermostat
Heat
Source
Heating Load
FLWSWTCH
DHW Priority Switch
FS
Min. 2-1⁄2" (65 mm)Min. 2-1⁄2" (65 mm)
Step 2 Turn the panel o. Plu
g
the terminal header of the wirin
g
harness into the DHW priorit
y
contacts of the power box.

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TWH – Tankless Water Heater Panels
Installation, Operation, and Maintenance
Troubleshooting
Problem Check / Verify Possible Cause
Low Temperature Within Room Misplacement of thermostat location within
room.
Make sure thermostat is not being influenced
by an additional heat source, such as lighting
or air duct.
Low temperature setting of the thermostat. Adjust the temperature setting on thermostat.
The system fails to turn on if the thermostat is
set to high setting
Thermostat may be out of calibration or
defective. Replace thermostat.
The electronic actuator fails to open during a
call for heat
The electronic actuator may be improperly
seated or may be defective. Replace if
necessary.
Low supply mixed fluid temperature. Adjust the thermostatic mixing valve to the
appropriate setting.
Wiring from heat source to panel. Check that the wiring is done properly. Consult
qualified electrician prior to alteration of wiring
between heat source and panel.
Output of heat source is unable to meet
demand of heating system.
Compare output of heat source to the
requirements of the heating system.
The red and green LED’s on the power module
do not light up during a call for heat.
The zone valve controller may be defective
or there is no power being supplied to the
panel or the power module is not on. If this
is so, switch the power module to by-pass
mode. When the front three-way switch is
placed in the “Heat Source Pump Bypass”
position, the green LED will be lit, indicating
that the panel is powered with 110V, and the
Primary pump will run. When the side “Bypass
Radiant Pump” switch is placed in the “ON”
position, the yellow LED will be lit, indicating
that the panel is powered with 110V, and the
Secondary pump will run. This will provide
constant circulation so long as there is still
110V power to the panel.
Circulator is not on during a call for heat. (Use
a stethoscope or similar device to verify)
The power box or circulator may be defective.
When zone valves are installed outside the
panel a qualified electrician should verify 24V
power is supplied to the thermostats and
actuator.
The 24V transformer may have failed. If this
so, switch the power module to Bypass mode.
This will provide constant circulation so long
as there is still 110V power to the panel. Prior
to Bypass mode selection, any zone valves
must be opened manually to avoid dead-
heading of the circulator.
High Temperature Within Room Check current setting of the thermostat. Adjust the temperature setting on thermostat
to a lower setting.
High supply mixed fluid temperature. Adjust the Thermostatic Mixing Valve to the
appropriate settings.
Installed electronic actuators remain open
after the thermostat is satisfied.
An obstruction inside the zone valve is not
allowing the actuator to fully close or the
thermostat is still calling for heat.
Bypass switch(es) may be on. Check that the front three-way switch on the
power box is in the “ON” position and the side
“Bypass Radiant Pump” switch is in the “OFF”
position.

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Installation, Operation, and Maintenance
Maintenance
Yearly maintenance should be done on the panel prior to each heating season to ensure the ecient and accurate operation
of the panel.
Complete the following check list:
• Raise all thermostats to cause a call for heat within the system. Verify that the circulator starts, via a stethoscope or
similar device.
• Conrm that the Auxiliary Contacts close.
• If applicable, verify that each zone valve opens during the call for heat – the actuator should be warm to the touch, the
LED will light up (on 5620x models) and the white indicator should rise from the top of the actuator.
• Return all thermostats to a desirable setting.
You are now ready for another heating season with HeatLink.
Troubleshooting (continued)
Temporarily create a “permanent” heat demand:
(closed when
pump running)
Install Jumper
between W & R
With switch in‘ON’
position, red ‘POWER’
light will be on.
With jumper between
W & R, green and yellow
lights will be on and
pumps will run.

18
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Heat Source:
Panel(s):
Heat Load(s):
Schematic #:
Date:
Notes:
Drawings are for HeatLink suggested system layout only! User must determine if system layout will work for their particular application. Air vents, expansion tanks, pressure relief valves, etc. for heat source as per local codes. Use isolation ball valves for all circuits and components. Local codes, regulations, and authorities have final jurisdiction.
Rough-in wiring see:
Wiring detail see:
TWH070P/
TWH070XP
Panel
Check
Valve in
Primary
Pump T
Thermostat
Cold Water
Supply
T
SCH-TWH-M002
DHW Supply
to House
2013-03-18
SCH-MRIB-R001
SCH-TWH-E001
Tankless Water Heater TWH Series Radiant Floor Heating – Single Zone
Optional
DHW Priority Switch
180
FS Radiant Heating
Manifold

19
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1-866-661-5332
Heat Source:
Panel(s):
Heat Load(s):
Schematic #:
Date:
Notes:
Drawings are for HeatLink suggested system layout only! User must determine if system layout will work for their particular application. Air vents, expansion tanks, pressure relief valves, etc. for heat source as per local codes. Use isolation ball valves for all circuits and components. Local codes, regulations, and authorities have final jurisdiction.
Rough-in wiring see:
Wiring detail see:
TWH070P/
TWH070XP
Panel
Check
Valve in
Primary
Pump T
Thermostat
Cold Water
Supply
T
SCH-TWH-M003
DHW Supply
to House
2013-03-18
SCH-MRIB-R001
SCH-TWH-E003
Optional
DHW Priority Switch
180
FS
Storage Tank
R1
Check Valve in Pump
P3
Tankless Water Heater with Storage Tank TWH Series Radiant Heating – Single Zone
Radiant Heating
Manifold

20
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1-866-661-5332
Heat Source:
Panel(s):
Heat Load(s):
Schematic #:
Date:
Notes:
Drawings are for HeatLink suggested system layout only! User must determine if system layout will work for their particular application. Air vents, expansion tanks, pressure relief valves, etc. for heat source as per local codes. Use isolation ball valves for all circuits and components. Local codes, regulations, and authorities have final jurisdiction.
Rough-in wiring see:
Wiring detail see:
TWH070P/
TWH070XP
Panel
Check
Valve in
Primary
Pump T
Thermostat
Cold Water
Supply
T
SCH-TWH-M004
DHW Supply
to House
2013-03-18
SCH-MRIB-R001
SCH-TWH-E004
Tankless Water Heater with High Flow Resistance TWH Series Radiant Floor Heating – Single Zone
Optional
DHW Priority Switch
180
FS Radiant Heating
Manifold
R1
P3
In Series Pump