Huron Valley Sales ProPak Series Wiring diagram

–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.
Huron Valley Sales, Inc.
25700 Princeton St., Dearborn Heights, MI 48125
Bus: 313.278.5200 •Fax: [phone]
Installing, Operating & Maintaining
PROPAK HIGH EFFICIENCY
WATER HEATERS AND HEATING BOILERS
WARNING
If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
WARNING
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
LIT 91127 REV 6/1/06
ASME 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
New York Massachusetts SCAQMD CEC Listed
MEA 425-05-E Boilers:G1-06-06-24A Compliant Rule1146.2 California Energy
Heaters: G1-06-06-24B Commission

USING THIS MANUAL
2
DANGER
Indicates a condition or hazard which
will cause severe personal injury,
death or major property damage.
SPECIAL ATTENTION BOXES
Throughout this manual you will see these
special attention boxes similar to this one,
which are intended to supplement the
instructions and make special notice of
potential hazards. These categories mean, in
the judgement of Huron Valley Sales, Inc.:
WARNING
Indicates a condition or hazard which
may cause severe personal injury,
death or major property damage.
WARNINGS
•THE VENT SYSTEM MUST BE 2 PIPE SEALED COMBUSTION CATEGORY IV
ONLY, PVC SCH 40 OR CPVC SCH 40 OR 80 OR AL 29C STAINLESS VENTING
FOR ALL MODELS.
•THIS HEATER INSTALLATION MUST CONFORM TO THE LATEST EDITION OF
THE “NATIONAL FUEL GAS CODE” ANSI Z223.1 NEPA 54 AND OR CAN/CGA B149
INSTALLATION CODES. STATE AND LOCAL CODES MIGHT ALSO APPLY TO
INSTALLATION.
•WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION, THE
INSTALLATION MUST CONFORM TO THE STANDARDS FOR CONTROLS AND
SAFETY DEVICES FOR AUTOMATICALLY FIRED HEATERS, ANSI/ASME HEATER
AND PRESSURE VESSEL CODE, Section IV, ALONG WITH CSD1.
•THE HEATER, GAS PIPING, WATER PIPING, VENTING AND ELECTRICAL MUST
BE INSTALLED BY TRAINED & QUALIFIED PERSONNEL FAMILIAR WITH
INSTALLATION PRACTICES, LOCAL CODE, LICENSING REQUIREMENTS.
•IF THE INFORMATION IN THESE INSTRUCTIONS ARE 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.
CAUTION
Indicates a condition or hazard which
will or can cause minor personal
injury or property damage.
USING THIS MANUAL

TABLE OF CONTENTS
3
TABLE OF CONTENTS
Part 1 . . . . . . . . . . . . . . . . . . . . .4–7
GENERAL INFORMATION
AHow It Operates . . . . . . . . . . . . . . . . . . .4
BPROPAK Dimensions . . . . . . . . . . . . . .5
CPre-installation Requirements . . . . . . . .6
D Pressure Relief Valve . . . . . . . . . . . . . .7
Part 2 . . . . . . . . . . . . . . . . . . . . . . .8
ELECTRICAL
AElectrical Connection . . . . . . . . . . . . . . .8
BInternal Wiring Connection . . . . . . . . . .8
Part 3 . . . . . . . . . . . . . . . . . . . .9–12
GAS CONNECTION
AGas Connection . . . . . . . . . . . . . . . . . . .9
BGas Piping . . . . . . . . . . . . . . . . . . . . . . .9
CGas Table . . . . . . . . . . . . . . . . . . . . . . . .9
DGas Valve Set Up . . . . . . . . . . . . . . . .10
ESetting Maximum Load . . . . . . . . . .11-12
FSetting Minimum Load . . . . . . . . . . . . .12
GGas Conversion . . . . . . . . . . . . . . . . . .11
HGas Valve Replacement . . . . . . . . . . .11
Part 4 . . . . . . . . . . . . . . . . . . .12–17
VENTING
AApproved Venting Materials . . . . . . . . .12
BVenting the ProPak . . . . . . . . . . . . . . .13
CInlet Air Vent . . . . . . . . . . . . . . . . . . . .16
DVenting Runs Exceeding Maximum
Combined Length . . . . . . . . . . . . . . . .16
EHeater Removal from a
Common Vent System . . . . . . . . . . . . .16
FCondensate Requirements . . . . . . . . .17
Part 5 . . . . . . . . . . . . . . . . . . .17–21
PIPING
AHydronic Heating Boiler Piping . . .17-18
BFill & Purge Heating System . . . . . . . .18
C Removing Air from Heat Exchanger . .18
DWater Heating Piping . . . . . . . . . . .18-21
Part 6 . . . . . . . . . . . . . . . . . . .21–23
START UP PROCEDURES
AItems to be checked before
lighting the ProPak . . . . . . . . . . . . . . .21
BLighting Instructions . . . . . . . . . . . . . . .22
COperating Instructions . . . . . . . . . . . . .22
DAdjusting the Temperature
on the ProPak Display . . . . . . . . . .22-23
ESequence of Operation . . . . . . . . . . . .23
Part 7 . . . . . . . . . . . . . . . . . . .23–30
SERVICING
AServicing the ProPak . . . . . . . . . . . . . .23
BPlacing ProPak into Normal Operation 23
CSoft Lockout Codes . . . . . . . . . . . . . . .24
DHard Lockout Codes . . . . . . . . . . . .24-25
EFault Codes . . . . . . . . . . . . . . . . . .26-29
FTo Turn Off Gas to Appliance . . . . . . .29
GPump & Wiring Control . . . . . . . . . . . .29
HTemperature Sensor Reading
Instructions . . . . . . . . . . . . . . . . . . . . .30
IProPak Sensor Resistance Table . . . .30
Part 8 . . . . . . . . . . . . . . . . . . .31–41
MAINTENANCE & SPEC. INSTALLATION REQ.
AMaintenance Procedures . . . . . . . . . . .31
BAnnual Inspection . . . . . . . . . . . . . . . .31
CCondensate Cleaning Instructions . . . .32
DCombustion Chamber
Coil Cleaning Instructions . . . . . . . .32-33
EProPak Controls . . . . . . . . . . . . . . .33-34
FInstallation at High Altitudes . . . . . . . .34
GCoil Scaling Prevention Feature(E-6 error
codes) . . . . . . . . . . . . . . . . . . . . . . . . . .34
HWater Heater Operating Sample . .34-35
IHW 129 Parts Breakdown . . . . . . .36-37
JHW 199-599 Parts Breakdown . . . .38-39
KWiring Diagrams . . . . . . . . . . . . . . .40-41
LInstallation Requirements (Massachusetts) 42

GENERAL INFORMATION
4
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.
This appliance has built-in freeze protection, automatically activating the circulation pump when the internal
water temperature drops below 41!F. If the internal water temperature drops to 37!F, a burn cycle will be
initiated and will shut down as soon as the supply water temperature has reached 50!F.
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.
When multiple units are operated as a Cascade to handle a common load, the control contains the ability to
control all of the units as efficiently as one. Cascade operation is a factory-installed and programmed
option, requiring a field wiring connection between appliances for operation.
Looking at the controls on the front of the appliance,
1) POWER on/off switch
2) SETPOINT knob, temperature control (and fan speed control knob during service mode)
3) TEMPERATURE setpoint display
a. Temperature in °F, corresponding to the SETPOINT knob
b. Display will always read temperature setpoint unless there is a fault code displayed.
c. Cascade indicator light, found in the lower right hand corner of the Temperature display. This
dot will be flashing when this appliance is part of a properly-connected, commonly-controlled
group of ProPak products and reading temperature sensors.
d. Display code, not flashing indicates a Soft Lockout
e. When this display is flashing a code, the appliance is in a Hard Lockout and the reset must be
pushed to re-start the appliance.
4) Green indicating light labeled BURNER ON; when this is light is on, the burner is in operation.
5) RESET button, used as described in 3e above, as well as to view sensors in service mode.
6) SERVICE port, used for connecting a computer to the appliance to download the service fault his-
tory, as well as factory setting of control board parameters. There is a service button located just
below the service port that must be pressed with a pointed object to get to the service mode.

5
GENERAL INFORMATION
B. 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
Figure 1-1: ProPak
Dimensions

RECOMMENDED SERVICE 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. This bracket is shipped attached to the shipping skid
on which the HW 129 is mounted. Details are shown in Figure 1-3. Huron
Valley Sales recommends the use of a factory engineered and supplied
mounting rack for all ProPak installations. It can be installed in alcoves,
basements, utility rooms as well as standard equipment rooms. Choose a
location for your ProPak, centralized to the piping system, along with
consideration for Electrical (Part 2, Page 8), Gas Connection (Part 2, Page 9),
Venting (Part 4, Page 14), and Condensate Drain (Part 4, Section F, Page 17).
The ProPak must be level as installed, and the mounting surface must be
designed to support the weight (see previous page, Table 1-1 for weights).
Be sure the appliance is adequately secured to the mounting surface.
The front cover is secured by a threaded screw and two clasp style latches;
it can only be installed one way. When removing the front cover of the
ProPak unit, you must make sure all electric power to the appliance is
turned off. Then remove the screw at the bottom of the panel, undo the
latches and remove the cover (see Figure 1-4 on the next page).
If the ProPak is set up for liquefied petroleum (LP) gas, some geographic areas follow the Uniform Mechanical Code,
section 304.6, “Liquefied petroleum gas burning appliances shall not be installed in a pit, basement or similar location
where heavier-than-air gas might collect. Appliances so fueled shall not be installed in a below grade under-floor space
or basement unless such location is provided with an approved means for removal of unburned gas.”
6
GENERAL INFORMATION
(NOTE: The ProPak is rated at
zero clearance to combustibles.)
Figure 1-2: ProPak Clearances
Figure 1-3: ProPak Mounting Detail

7
GENERAL INFORMATION / ELECTRICAL
NOTICE
Condensation removal: This is a condensing, high efficiency appliance, therefore
condensation removal must be addressed to avoid damage to surrounding area or
appliance. See Part (4), Section F for Condensate Requirements (pg. 17).
WARNING
D. PRESSURE RELIEF VALVE
This unit is supplied with a relief valve sized in accordance with ANSI/ASME Heater and Pressure Vessel
Code, Section IV. The relief valve is installed near the hot water outlet. If the valve supplied is replaced,
the pressure rating of the valve must not exceed the listed working pressure of this appliance, and must
be rated to the proper BTU/hr capacity of the water heater. Do not, under any circumstances, thread
a cap or plug into the relief valve! Explosion, serious injury or death may result! To prevent water
damage, the relief valve piping must be directed to the floor or an open drain, but not connected directly.
There must be a 6" space between the outlet of relief valve piping and drain or floor. Do not hook up to
drain system directly without an air gap. Protect from freezing. Place no other valve between the relief
valve and the unit. Do not install any reducing couplings or other restrictions in the discharge line. The
discharge line must allow complete drainage of the valve and line. Manually operate the relief valve at
least once a year.
Also, care must be exercised when choosing the location of this appliance, where leakage from the relief
valve, leakage from related piping, or leakage from the tank or connections, will not result in damage to
the surrounding areas, or to the lower floors of the building. 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.
WARNING
The ProPak is certified as an indoor appliance. Do not install the ProPak outdoors or
locate where it will be exposed to freezing temperature. This includes all related piping
and components. If the ProPak is subjected to flood water or submersed in water, the
ProPak must be replaced.
SERVICE
RESET
LO
TEMPERATURE
CH
OFF
ON
- +
INNOVATIVECONDENSING TECHNOLOGY
By Hamilton Engineering, Inc.
WARNING!
#1 Turn off power
to unit
#2 Remove bottom
screw(s)
WARNING!
Before removing screw and opening front cover,
main power supply must be disconnected (shut off).
HIGH VOLTAGE - RISK OF ELECTRICAL SHOCK!
14 15 16
L L
230 VAC
Power supply
ST-6
Fuse
To Ground
OFFOFF
OFF
Service Switch
ON
Junction Box
Junction Box
INNOVATIVECONDENSING TECHNOLOGY
By Hamilton Engineering, Inc.
Figure 1-4: How to Remove the Front Cover

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. For your convenience, we have
labeled all the points for electrical connections needed to operate the ProPak.
The electrical requirements are for standard 208–240 volts, 50/60 Hz 15 Amp service. This unit is wired with
#18 awg and internally fused for no more than 3.15 Amps. When the unit is first powered on, there is a self-
setting of the electronics for 50 Hz or 60 Hz. At every power up, the electronics will take a couple of seconds
to compare the pulses of the power to the pulses of the crystal, which is built into the electronics. Then all time-
related functions are correct no matter the power source.
The standard supplied pumps are all 208–240 volt, 60 cycle and are wired to terminals on the heater. In
50 cycle applications, other pumps may need to be supplied, depending on water conditions. With the 914
controller there is an ability to program in a pump delay of any time frame desired, or one with no time out
(continuous). The factory default is a 5 minute delay to turn off after completing a burn cycle.
B. INTERNAL WIRING CONNECTION
Terminal 9 in the electrical compartment must be
connected to the building ground system.
The Incoming 208–240 volt Power Supply is connected
to single phase terminals 8 and 10.
It is important that the electrical power is not turned on at this
time. Double check all connections and then turn the power
on. The display that is provided with the ProPak should now
be reading the Setpoint temperature. Note: See Start-Up
Procedures (Part 6, Page 21) to change the temperature
setting or run the heater.
8
ELECTRICAL
CAUTION
The incoming power shall be connected directly to the labeled, intended connection
points only. Failure to do so may result in an Electrical Short will result and the
Control board will have to be replaced!
DANGER
IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED!
IT IS VERY IMPORTANT THAT THE BUILDING GROUND IS INSPECTED BY A
QUALIFIED ELECTRICIAN PRIOR TO MAKING THIS CONNECTION!
To Pump
Service Switch
Fused switch or from
a maximum 15 amp
dedicated circuit
breaker
Optional Connection
ST-3
208 - 240 VAC
L NN
60 Hz
208 - 240 VAC
L
Pump
ST-6ST-5
Power Supply
Thermostat
Remote
-+
ST-4
0-10 VDC
Sensor
Outside
Temperature
-+
ST-2
Cascade
Connection
Sensor
External
Temperature
ST-1
VST-5
765 8 9 10
VST-6
Optional Connection Optional Connection Optional Connection Optional Connection
To Ground
11 12 13 16151465 7 8 1093 421
Junction Box
Figure 2-1: Internal Wiring
Connections

PART 3. GAS CONNECTION
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. The entire piping system, gas meter
and regulator must be sized properly to prevent
pressure drop greater than 1" as stated in the
National Fuel Gas Code. This information is
listed on the rating plate.It is very
important that you are connected to
the type of gas as noted on the rating
plate, "LP#for liquefied petroleum, propane
gas or "Nat#for natural or city gas. All gas
connections must be approved by the local gas
supplier, or utility in addition to the governing authority, prior to turning the gas supply on. It is mandatory
that a drip leg be fabricated, as per the National Fuel Gas code.Once all the inspections have been
performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the
maximum inlet pressure, you must isolate the ProPak from the gas line. In order to do this, you must shut
the gas off using factory and field-installed gas cocks (following the lighting instructions in Part 6, Section
B, Page 22.) This will prevent high pressure. Failure to do so may damage the gas valve. In the event the
gas valve is exposed to a pressure greater than 14" water column, the gas valve must be replaced.
Never use an open flame (match, lighter, etc.) to check gas connections.
B. GAS PIPING
1. Run the gas supply line in accordance with all applicable codes.
2. Locate and install manual shut off valves in accordance with state and local requirements.
C. GAS TABLE
It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate
a leak is present. The gas piping must be sized for the proper flow and length of pipe, to avoid pressure drop.
Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a
pressure drop greater than 1" WC, the meter, regulator or gas line is undersized or in need of service. You
can attach a manometer to the incoming gas drip leg, by removing the cap and installing the manometer,
see Figures 3-2 and 3-3. The gas pressure must remain between 4" and 14" during stand-by (static) mode
and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of
10 feet from the ProPak. It is very important that the gas line is properly purged by the
gas supplier or utility. Failure to properly purge the lines or improper line sizing, will
result in ignition failure. This problem is especially noticeable in NEW LP installations and also in
empty tank situations. This can also occur when a utility company shuts off service to an area to provide
maintenance to their lines. This gas valve must not be replaced with a conventional gas valve under any
circumstances. As an additional safety feature, this gas valve is easily de-coupled from the fan inlet.D.
TABLE 3-1)NATURAL G
Refer to the following tables to size the supply piping to minimize pressure drop
between meter or regulator and unit.
9
GAS CONNECTION
WARNING
Failure to follow all precautions could result in fire, explosion or death!
Figure 3-1: ProPak 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. GAS VALVE SET UP
Measure the gas supply pressure at the pressure nipple [3] of the gas valve. The required gas supply
pressure needed for these appliances to work properly is greater than 4" and less than 14" WC. This
pressure range should be maintained during full gas load on the building where the appliance is installed.
(TABLE 3-3) COMBUSTION & FUEL RELATED ADJUSTMENTS TABLE
Please note:All adjustments must be made with the appliance door off, which will lower the CO2 reading 0.2%.
Set the level 0.2% lower than shown above for proper levels when the door is installed for proper operation.
10
GAS CONNECTION
Nominal (Internal Length of Pipe (Feet)
Iron Pipe (Diameter
Size (in.) (inches) 10 20 30 40 50 60 70 80 90 100 125 150 200
3/4 (0.824 363 249 200 171 152 138 127 118 111 104 93 84 72 } BTUs
1(1.049 684 470 377 323 286 259 239 222 208 197 174 158 135 } per hr.
1-1/4 (1.380 1,404 965 775 663 588 532 490 456 428 404 358 324 278 } x
1-1/2 (1.610 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 419 } 1,000
2(2.067 4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936 801 }
Nominal (Internal Length of Pipe (Feet)
Iron Pipe (Diameter
Size (in.) (inches) 10 20 30 40 50 60 70 80 90 100 125 150 200
3/4 (0.824 567 393 315 267 237 217 196 185 173 162 146 132 112 } BTUs
1(1.049 1,071 732 590 504 448 409 378 346 322 307 275 352 213 } per hr.
1-1/4 (1.380 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 440 } x
1-1/2 (1.610 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 675 } 1,000
2(2.067 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 1,260 }
1
2
3
1
2
3
4(Outlet
Pressure
Tapping)
DO NOT ADJUST
Figure 3-2: ProPak Models 129–399 Figure 3-3: ProPak Model 599

11
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
$If
the
measuring process takes more than 40 minutes, the appliance will return to the automatic mode. If so
required, press the Service button another time.
$When you are done setting the valve, press the Service button again to return to normal run mode.
Do not forget to place the knob, labeled with “Setpoint,” at the proper temperature value when done.
If necessary, turn the adjusting slot [2], which sets the high fire performance, either counterclockwise to
increase the CO2 percentage or clockwise to reduce the CO2 percentage, as shown in Figures 3-2 and 3-3.
Appropriate CO2 percentages are shown in Table 3-3 above.
F. SETTING THE MINIMUM LOAD
Set the minimum load once the maximum load has been set, turn the knob until the minimum RPM setting
has been reached. In order to set or adjust the minimum load, turn the screw [1] for the minimum setting (first
remove the protective cap). Turn the screw clockwise to increase or counter clockwise to decrease the CO2
percentage. On the HW 599, you only are allowed to set the gas valve at the right side; the left gas valve is
set by the manufacturer. See Section H for special instructions on replacing both gas valves in a model 599.
Please do not forget to replace the protective cap on the gas valve.
G. GAS CONVERSION
If the appliance is to be converted in the field for using Propane (LPG), the following steps must be taken:
$Turn screw [2] (Figures 3-2 ) two full turns (720°) clockwise on models HW129 - HW399. On model
HW599, turn screw [2] (Figure 3-3) on the left hand valve four full turns (1440°) clockwise.
$Run the appliance. If the burner does not ignite after four starting efforts, turn the screw [2] one half
turn back (180°) (counter clockwise).
$After conversion, follow the steps in Sections E and F for setting the maximum and minimum loads,
using the LP gas values shown in Table 3-3.
GAS CONNECTION
Natural Gas CO2Natural Gas CO ppm LP Gas CO2LP Gas CO ppm
LOW FIRE 8.5% Less than 10 9.6% Less than 15
HIGH FIRE 8.8% Less than 110 10.0% Less than 120
Model HW 129.8 / 129 HW 199 HW 399 HW 599
Minimum fan
revolutions (RPM) 1664 1653 1860 1653
Maximum fan
revolutions (RPM) 5200 5700 6200 5700

12
GAS CONNECTION / VENTING
H. ADJUSTING & SETTING THE FIRING RATE (GAS VALVE MAINTENANCE/REPLACEMENT)
1) When checking or replacing a gas valve, the CO2percentage 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
the right hand valve. An electronic manometer must be used, as it will be set to a scale of 0.01" WC.
The adjustment screw [2] (see Figure 3-3) normally used for setting maximum flow rate must be
turned counterclockwise until it begins to click when turned. The screw will not fall out, but will be
fully retracted at this point, this is for Natural gas, for LP gas, close the valve four full turns (1440°).
The digital manometer must now be connected to the outlet pressure tapping [4], and the appliance
fired. It must be placed in the service mode and held at the minimum firing rate (1710 rpm fan
speed). With the appliance firing at this rate, adjust the offset (minimum firing rate) screw [1] to a
pressure of “0” +/- .0.01" WC. Be sure the manometer has been zeroed out prior to making this
setting.
Once this operation is complete, you may follow the instructions for setting the minimum and max-
imum firing rate as shown in Sections G and H, for the right hand gas valve only.
setting (first remove the protective cap). Turn the screw clockwise to increase or counter clockwise to
decrease the CO2percentage. On the HW 599, you only are allowed to set the gas valve at the right
side; the left gas valve is set by the manufacturer. See Section E(2) for special instructions on replacing
both gas valves in a model 599.
Please do not forget to replace the protective cap on the gas valve.
PART 4. VENTING
A. APPROVED VENTING MATERIALS
Extending Exhaust Vent in Plastic Pipe Schedule 40 or 80 or Stainless Steel.
1. Non-Foam Core PVC Pipe
2. Non-Foam Core CPVC Pipe
3. Non-Foam Core ABS Pipe
4. AL 29C Stainless as manufactured by ProTech, Heat Fab, Metal Fab or others.
Vent Piping must conform to the following:
1. PVC Non Foam Core Pipe (Polyvinyl Chloride) to ASTM D-1784 Class 12454-B, Formerly
designated Type 1, Grade 1.
DANGER
It is extremely important to follow these venting instructions carefully. Failure to do
so can cause severe personal injury, death or substantial property damage.
WARNING
Failure to follow all precautions could result in fire, explosion or death!

13
2. CPVC (Chlorinated Polyvinyl Chloride) Class 23447-B, Formerly designated Type IV, Grade 1
conforming to ASTM D-1784.
3. ABS (Acrylonitrile-Butadiene-Styrene) Class 3-2-2-2-2 conforming to ASTM D3965.
4. AL-29C Stainless steel pressure sealed venting
The ProPak is a direct vent appliance. It is listed as a Category IV Condensing
Appliance. (ProPak Venting is rated at Zero Clearance to combustibles.)
Note: For concrete construction or to meet
certain fire codes, exhaust and inlet piping at
the wall penetration to the ProPak must be
CPVC Schedule 40 or 80 or stainless. The
balance from the penetrated wall to the out-
side may be PVC Schedule 40 or 80.
B. VENTING THE PROPAK
(TABLE 4-1)VENTING SPECIFICATIONS
(TABLE 4-2)EQUIVALENT FEET
The inlet and exhaust pipes on the top of the cabinet should be the diameter and material indicated in
the Venting Specifications Table above. It is very important that you plan the location properly to elimi-
nate long pipe runs and excessive fittings. Inlet pipe size must not be reduced. Do not combine the inlet
air with any other inlet pipe including an inlet to an additional similar appliance, unless you have pur-
chased an engineered 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.
The piping must also be properly supported as per Local and National Standard Plumbing Codes. It is
important that the piping must be clean and free from burrs, debris, ragged ends and particles of PVC (if
applicable).
VENTING
DANGER
It is extremely important to follow these venting instructions exactly. Failure to do so can
cause severe personal injury, death or substantial property damage.
Model Vent
Diameter
Standard
Vent Type
Optional
Vent Type
(adapter required)
Minimum combined
vent length
Maximum
combined length
HW 129 3"Plastic Stainless 6'+ (2) 90!elbows 200'
HW 199 3"Plastic Stainless 6'+ (2) 90!elbows 90'
HW 399 4"Plastic Stainless 6'+ (2) 90!elbows 200'
HW 599 5"Stainless Plastic (6")6'+ (2) 90!elbows 170'
Fittings or Piping Equivalent Feet
90 degree elbow = 5
45 degree elbow = 3
Coupling = 0
Air inlet elbow = 6
Exhaust coupling = 1
WARNING
This vent system will operate with a positive pressure in the vent pipe. Do not
connect vent connectors serving appliances by natural draft into any portion of
mechanical draft systems operating under positive pressure.

14
Exhaust piping should be sloped back to the connection on the ProPak, at least 1/4" per foot to remove
additional condensate that forms within the pipe. The total combined length of pipe (intake piping plus
exhaust piping added together) including elbow allowances intake and exhaust should not exceed the
length shown in the vent table. The minimum combined vent length should not be less than a
combined length of 6'plus two 90!elbows. Choose your vent termination locations carefully. You must
also make certain that exhaust gas does not re-circulate back into the intake pipe. You must place them
in an open area and follow the following guidelines:
1) Never vent into a walkway, patio area, alley or otherwise public area less than 7'from the ground.
(See detail below references Fig. A.10.8 in the National Fuel Gas Code 2002 "Exit Terminals of
Mechanical Draft and Direct-Venting Systems.#)
2) Never vent over or under a window or a doorway where the exhaust plume or condensation liquid
will cause obtrusive or dangerous conditions. (Refer to National Fuel Gas Code, CAN B149).
3) Never install a heat saver or similar product to capture waste heat from exhaust.
4) Always have a vent location at least 12" above maximum snow level.
5) Always have vent a minimum of 24" above ground level, away from shrubs and bushes.
6) Follow local gas codes in your region or refer to National Fuel Gas Code, Can B149.
7) Always have at least 36" distance from an inside corner of the outside walls.
8) Maintain at least 48" clearance to electric, gas meters, windows, exhaust fans, chimneys, inlets
or mechanical vents.
9) VERY IMPORTANT! The inlet air connection must be connected to outside air and should be
located no closer than 8" and no further than 24" to the exhaust.
10) Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the unit.
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
VENTING
Figure 4-1: Exit Terminals of Mechanical Draft and Direct-Vent Venting System
* REFERENCE: THE NATIONAL FUEL GAS CODE 2002 EDITION
*IMPORTANT NOTE
*HURON VALLEY SALES,
*INC. RECOMMENDS A
*MINIMUM CLEARANCE OF
*4 FEET WHERE THE
*EXHAUST PLUME CAUSED
*BY THE UNIT MAY
*OBSTRUCT VIEWS OR
*AFFECT THE COSMETIC
*LOOK OF THE BUILDING.
*IN CANADA, THERE IS A
*MINIMUM CLEARANCE OF
*10 FEET.
NOTICE
The following are code restrictions for the location of the flue gas vent terminal.
Compliance to these requirements doesn't insure a satisfactory installation; good
common sense must also be applied. It is important to make sure that exhaust gases are
not recirculated into the inlet air of the ProPak. If there is any doubt, contact the factory
BEFORE installing.

15
Figure 4-2: Sidewall Vent with Down Elbow (Intake) & Up Elbow (Exhaust)
**IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust
must be pitched a minimum of a 1/4" per foot back to the heater (to allow drainage of condensate).
All stainless venting must be sealed at each joint per manufacturer's instructions.
Figure 4-3: Vertical Vent with Double Elbow
(Intake) & Coupling (Exhaust)
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported and the exhaust must be pitched a minimum of
a 1/4" per foot back to the heater (to allow drainage of
condensate). All stainless venting must be sealed at each
joint per manufacturer's instructions.
DIAGRAM FOR VERTICAL VENTING
DIAGRAMS FOR SIDEWALL VENTING
VENTING
VENTING FOR MULTIPLE
UNITS, with vents all on same
horizontal plane, spaced at
least 8 inches apart, and at level
of highest unit.
OR
Front Elevation
(Multiple Vents)
8"
2
"
Front Elevation
8"
All horizontal runs must
be supported every 24"
Exterior wall
Intake
EVO
Exhaust
18" Minimum
12"above maximum
snow level or 24"
whichever is greater
Right Side View
SHOWN OFFSET
FOR CLARITY
18” minimum
24” maximum

16
VENTING
ProPak can be found in Figures 4-2 and 4-3 of this section, on page 15. Use these layouts as
guidelines: certain site conditions such as multiple roof lines/pitches may require venting modifi-
cations (consult Huron Valley Sales, Inc.).
RECOMMENDED VENTING CLEARANCES PER THE NATIONAL FUEL GAS CODE*
C. INLET AIR VENT
You may use the same material as used for exhaust or any material that is the same diameter that pro-
vides a pressure tight connection. THIS IS ONLY FOR INLET AIR, NOT FOR EXHAUST PIPING!
The air inlet must be a minimum of 12" vertically above the maximum snow level. It is very important that
there are no other vents, chimneys or air inlets in any direction for at least 48".
All venting must be properly supported. The ProPak is not intended to support any
venting whatsoever. All piping, glue, solvents, cleaners, fittings and components, must conform to
ASTM (American Society for Testing and Materials), and ANSI (American National Standards Institute).
D. VENTING RUNS THAT EXCEED MAXIMUM COMBINED LENGTH
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 [phone].
VENT CALCULATION EXAMPLE: Installation requires the following material for both inlet and exhaust
piping for the ProPak HW 199 (maximum combined equivalent length is 90 feet).
Required: 6 Pcs. 90!elbow (6 x 5 = 30 equivalent feet) = 30 equivalent feet
Required: 20'of Plastic PVC Pipe (20 x 1 = 20 equivalent feet)= 20 equivalent feet
Required: Inlet air in vertical termination (1 + 1 - 90!elbows) = 11 equivalent feet (includes inlet screen)
Required: Exhaust coupling = 1 equivalent foot
Total Friction Loss in equivalent feet = 62 equivalent feet
This venting layout is OK!
E. HEATER REMOVAL FROM AN EXISTING COMMON VENT SYSTEM
At the time of removal of an existing heater, the following steps shall be followed with each appliance
that remains connected to the common venting system placed in operation, while the other appliances
that remain connected to common venting system are not operating.
1. Seal any unused openings in the common venting system.The ProPak venting is NOT to be
combined with this older venting system!
CAUTION
Flue Gas will condense as it exits the vent termination. This condensate can freeze on
exterior building surfaces which may cause discoloration of these surfaces.
Consideration should be given to the plume of condensation that exits the exhaust which
may affect the cosmetic appearance of the building.
DANGER
The ProPak is not intended to be common vented with any other existing appli-
ance! Multiple ProPak products may be common vented, only if using an engi-
neered system from Huron Valley Sales, Inc.

17
VENTING
2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is
blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.
3. If practical, close all building doors, windows and all doors between the space in which the appli-
ance remains connected to the common venting system and other spaces in the building. Turn
on clothes dryers and any appliances not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate
a summer exhaust fan. Close all fireplace dampers.
4. Place the appliance being inspected in operation. Follow the lighting instructions. Adjust the
thermostat so the appliance will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the
flame of a match or candle or smoke from a cigarette.
6. After it has been determined that each appliance remaining connected to common venting
system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the common venting system,
the common venting system should be resized to approach
the minimum size as determined using the appropriate tables
in Appendix G in the National Fuel Gas Code, ANSI Z 223.1
F. CONDENSATE REQUIREMENTS
This is a condensing high efficiency appliance, therefore this unit has
a condensate removal system. Condensate is nothing more than
water vapor derived from the combustion products, similar to an
automobile when it is initially started. This condensate does have a
low pH and should be treated with a Condensate Neutralizer Filter.
This filter contains either lime or marble rocks, which will neutralize
the condensate. The outlet of the filter is sized for 1.5” PVC pipe. It
is very important that the condensate line is sloped away from and
down to a suitable inside drain. 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. Plastic tubing
or PVC pipe should be the only materials used for the condensate
line. Steel, brass, copper or others will be subject to corrosion and
deterioration. A second vent may be necessary to prevent condensate line vacuum lock if a long
horizontal run is used. The ProPak appliance has an automatic safety device that will shut it down in the
event of a condensate drain blockage. Please test annually.
Maximum volume of condensate produced is 11 gallons per hour per 1,000,000 BTU of gas burned.
PART 5. PIPING
A. HYDRONIC HEATING BOILER PIPING
The ProPak is designed to function in a closed loop (minimum) 12 PSI System. Never let the ProPak
operate without a minimum of 10 PSI water pressure, this assures that the ProPak heat exchanger can
be completely purged of air, failure to do so could cause damage. It is important to note that the ProPak
Boiler is flow dependent for proper efficiency and life expectancy; therefore, primary-secondary piping or
use of a low loss header design is always recommended, as shown in the Figure 5-1. Each ProPak
Heating Boiler System should have an Air Eliminator, in addition to the heat exchanger mounted air vent,
which will remove air from the Hydronic System. Always follow good piping practices. Observe minimum
Figure 4-4: Condensate
Drain Detail

18
PIPING
1" clearance to combustibles around all uninsulat-
ed hot water pipes, or when openings around
pipes are not protected by non-combustible mat-
erials. On an ProPak installed above radiation
level, some state and local codes require a low
water cut off device at the time of installation by
the installer. A water flow switch is provided as
standard and will take the place of a low water cut-
off. If the ProPak supplies hot water to heating
coils in air handler units, flow control valves or
other devices must be installed to prevent gravity
circulation of boiler water in the coils during the
cooling cycle.
Basic piping connection steps are listed below. A
drawing, specific to your application can be
obtained from your distributor or 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.
3) Connect system supply to the pipe leaving the ProPak containing the Relief Valve.
4) Install Drain Valve on system supply. Note: the ProPak can not be drained of water without purging
the unit with air pressure, 15 PSI minimum. The system's air vent must be closed during this
process.
B. FILL & PURGE HEATING SYSTEM
1) Attach hose to balance and purge hose connector and run to drain.
2) Close the other side of the balance and purge valve.
3) Open first zone balance and purge valve, so as to let the water flow out of the hose. If zone valves
are used, open zone valves one at a time, manually. (NOTE: please check manufacturer’s
instructions prior to opening valves manually, so as not to damage the valve.)
4) Manually operate fill valve regulator. When water runs out of hose, connected to the balance and
purge valve, in steady stream (with no air bubbles), close balance and purge valve to stop the
water from flowing. Disconnect hose and connect to next zone to be purged.
5) Repeat procedure for additional zones (one at a time).
Upon completion, make sure that the fill valve is in automatic position and each zone balance and purge
valve is in the open position and zone valves are positioned for automatic operation.
NOTE: Installations that incorporate Standing Iron Radiation and systems with manual vents high points:
Follow the above procedure, then starting with nearest manual air vent, open vent until water flows out;
close vent. Repeat procedure, working your way toward furthest air vent. It may be necessary to install
basket strainer in an older hydronic system where larger amounts of sediment may be present. Annual
cleaning of the strainer may be necessary.
C. REMOVING AIR FROM THE HEAT EXCHANGER
The ProPak has an automatic air vent on the top of the appliance and the air vent cap must be loosened
to allow trapped air to escape when the appliance is initially filled an put into operation. If this air vent
should start to leak, there are two possible solutions:
a. Close the cap – the air vent is not needed anymore after the heat exchanger has been purged
of air. This air vent MUST be operable if the appliance is drained and refilled.
b. Replace the air vent – When replacing the Air Vent, the water must be shut off and pressure
released first.
D. WATER HEATING PIPING
Figure 5-1: Boiler Piping
In From Zone
Out To Zone
Install Drain
Valve Here
Relief Valve
Location

(TABLE 5-2)HW 199: PRESSURE DROP VS. FLOW
Standard pump supplied is PMP 30205.
Approximate design !T is 22.5°F.
(TABLE 5-1)HW 129: PRESSURE DROP VS. FLOW
Standard pump supplied is PMP 30205.
Approximate design !T is 28°F.
19
PIPING
Quantity of Units Piping Required
1 1"
2 1-1/2"
3 2"
4 2"
Quantity of Units Piping Required
1 1-1/2"
2 2"
3 2"
4 2-1/2"
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 5-4)HW 599: PRESSURE DROP VS. FLOW
Standard pump supplied is PMP 30215.
Approximate design !T is 30.5°F.
(TABLE 5-3)HW 399: PRESSURE DROP VS. FLOW
Standard pump supplied is PMP 30211.
Approximate design !T is 23.5°F.
20
PIPING
Quantity of Units Piping Required
1 2"
2 2-1/2"
3 2-1/2"
4 2-1/2"
Quantity of Units Piping Required
1 2"
2 2-1/2"
3 3"
4 3"