Ideal Heating MONARCH 30 Instruction Manual

INSTALLATION &
MAINTENANCE MANUAL
A1009091 - 661A0600_EN • A
CTMAN01
MONARCH 30 - 40 - 50 - 60 - 80 - 100
Low Lead Content
NSF/ANSI 372
• When receiving the MONARCH unit, any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.
• Customer must register unit within sixty (60) days of installation in order to gain warranty coverage.
See Warranty Card for details.
• Leave all documentation received with appliance with the owner for future reference.
• Installation and service should only be performed by a qualified installer or service technician.
• Installations and service should be performed by a licensed plumber or gas fitter in the Common-
wealth of Massachusetts.
NOTICE
This document is intended to be used
by a factory trained and qualified
heating contractor or service technician
only. Read all Instructions within this
document and within the relevant Boiler
Installation and Maintenance Manual
before proceeding. It is recommended
to follow the procedures in the steps
given. Skipping or missing procedural
steps could result in substantial property
damage, serious injury, or death.
• The heat transfer medium must be
water or other nontoxic fluid hav-
ing a toxicity rating or class of 1, as
listed in Clinical Toxicology of Com-
mercial Products, 5th edition.
• The pressure of the heat transfer
medium must be limited to a max-
imum of 30 psig by an approved
safety or relief valve.
CAUTION
WARNING

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A1009091 - 661A0600_EN • A
ii
TABLE OF CONTENTS
PRODUCT AND SAFETY INFORMATION............................................................................V
CHAPTER 1 - PRE-INSTALLATION ...................................................................................... 1
1.1. Codes Compliance.......................................................................................................................... 1
1.2. Codes Restrictions.......................................................................................................................... 1
1.3. Operating Restrictions....................................................................................................................2
1.4. Potable DHW Water Quality Requirements .................................................................................3
1.5. Closed Loop Boiler Heating Water Quality Requirements ..........................................................3
1.6. Glycol ...............................................................................................................................................3
1.7. Locating Water Heater....................................................................................................................4
1.8. Recommended Clearances............................................................................................................4
CHAPTER 2 - INSTALLATION - PIPING .............................................................................. 5
2.1. Temperature & Pressure (T&P) Relief Valve.................................................................................5
2.1.1 Standard Installation.............................................................................................................5
2.1.2 Commonwealth of Massachusetts Installation ..................................................................5
2.1.3 T&P Relief Valve Discharge Piping .......................................................................................5
2.2. Drain Valve.......................................................................................................................................6
2.2.1 Standard Installation.............................................................................................................6
2.3. Thermal Expansion .........................................................................................................................6
2.4. Water Hammer................................................................................................................................6
2.5. Vacuum Breaker..............................................................................................................................6
2.6. General Piping .................................................................................................................................6
2.7. Domestic Piping ..............................................................................................................................6
2.8. Thermostatic Mixing Valve.............................................................................................................7
2.9. Recirculation Piping ........................................................................................................................7
2.10. Multiple Water Heater Systems .....................................................................................................7
2.11. Boiler Piping.....................................................................................................................................8
CHAPTER 3 - INSTALLATION - WIRING ........................................................................... 14
3.1. Temperature Sensor and Drywell................................................................................................ 14
3.2. Thermostat (Aquastat)................................................................................................................. 14
CHAPTER 4 - WATER HEATER START-UP ....................................................................... 16
4.1. Filling the Coil (Boiler Water) ....................................................................................................... 16
4.2. Filling the Tank (Domestic Water) ............................................................................................... 16
4.3. Adjusting the Temperature .......................................................................................................... 17
4.3.1 Adjusting the Temperature Using a Thermostat .............................................................. 17

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TABLE OF CONTENTS
CHAPTER 5 - WATER HEATER MAINTENANCE............................................................... 18
5.1. Maintenance Schedule .................................................................................................................18
5.1.1 Annual service by qualified service technician should include the following:................ 18
5.1.2 Homeowner monthly maintenance to include:................................................................. 18
5.2. Filling Water Heater.......................................................................................................................18
5.3. Draining Water Heater ..................................................................................................................18
5.3.1 Preparation for Draining the Tank...................................................................................... 19
5.3.2 Draining Tank (Domestic Water) . ...................................................................................... 19
5.3.3 Draining Coil (Boiler Water) . .............................................................................................. 19
CHAPTER 6 - REPLACEMENT PARTS ............................................................................. 20
CHAPTER 7 - WATER HEATER SPECIFICATIONS AND PERFORMANCES ....................22

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INDEX OF ILLUSTRATIONS AND TABLES
Fig. 1 - MONARCH Clearances - View from the Top ................................................................................4
Fig. 2 - Standard Installation - Domestic Piping - MONARCH Series ....................................................9
Fig. 3 - Optional Installation - Domestic Piping with Recirculation - MONARCH Series .......................9
Fig. 4 - Multiple MONARCH Series Water Heater System Domestic Piping - Parallel ........................10
Fig. 5 - MONARCH System Piping with Zone Circulators ......................................................................10
Fig. 6 - MONARCH System Piping with 3-Port Zone Valve (Domestic Priority) ...................................11
Fig. 7 - MONARCH System Piping with 2-Port Zone Valves (Domestic Priority)..................................11
Fig. 8 - MONARCH System Piping with Zone Valves (Non Domestic Priority) ....................................12
Fig. 9 - MONARCH System Piping with Zone Circulators...................................................................... 12
Fig. 10 - Multiple MONARCH Series Water Heater System Boiler Piping Reverse
Return Balanced Flow ................................................................................................................. 13
Fig. 11 - Multiple MONARCH Series Water Heater System Boiler Piping - Manifold............................13
Fig. 12 - MONARCH Tank Temperature Sensor Connected to Gallant Boiler Low Voltage Terminal........ 14
Fig. 13 - MONARCH Tank Temperature Sensor Connected to Exalt Boiler Low Voltage Terminal .... 15
Fig. 14 - MONARCH Assembly ................................................................................................................ 20
Fig. 15 - MONARCH Dimensions - Side View ......................................................................................... 22
Fig. 16 - MONARCH Dimensions - Top View .......................................................................................... 22
Table 1 - Boiler/Heating Water Quality .....................................................................................................2
Table 2 - T&P Valve Characteristics ..........................................................................................................5
Table 3 - Piping dimensions .......................................................................................................................7
Table 4 - MONARCH Water Heater Specifications................................................................................ 23
Table 5 - MONARCH Water Heater Performance at 180°F boiler water supply (135°F DHW outlet).......24

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A1009091 - 661A0600_EN • A v
SAFETY
PRODUCT AND SAFETY INFORMATION
This manual contains important information for the installation,
starting up and maintenance of the appliance.
This manual must be provided to the Homeowner, who will
keep it in a safe place for future reference.
Ideal North America accepts no liability for any
damage, injury, or loss of life resulting from incorrect
installation, alteration of any factory supplied
parts, or the use of parts or ttings not specied
by Ideal. If there is a conict or doubt about the
proper installation of the unit or any factory supplied
replacement parts please contact Ideal Technical
Support.
DEFINITIONS
The following terms are used throughout this manual
to bring attention to the presence of potential hazards
or to important information concerning the product.
Indicates the presence of a hazardous situa-
tion which, if ignored, will result in substantial
property damage, serious injury, or death.
Indicates a potentially hazardous situation
which, if ignored, can result in substantial
property damage, serious injury, or death.
Indicates a potentially hazardous situation
which, if ignored, can result in minor property
damage, or injury.
Indicates special instructions on installation,
operation or maintenance, which are import-
ant to the equipment but not related to person-
al injury hazards.
Indicates recommendations made by Ideal for the
installers, which will help to ensure optimum op-
eration and longevity of the equipment.
DANGER
WARNING
CAUTION
NOTICE
BEST PRACTICEBEST PRACTICE
IMPORTANT SAFETY INFORMATION FOR
THE HOMEOWNER AND THE INSTALLER DANGER
• Water temperatures over 125ºF can cause severe
burns instantly or death from scalding.
Hot Water Can Scald!
• Children, disabled and elderly are at highest risk of
being scalded.
• Never leave them unattended in or near shower,
bathtub or sink.
• Never allow small children to use a hot water faucet
or draw their own bath.
• If anyone using hot water in the building fits the
above description or if local codes or state laws
require specific water temperatures at hot water
faucet, it is recommended:
- To install a thermostatic mixing valve at this
appliance or at each water faucet.
or
- To set the thermostat knob for the lowest
temperature which satisfies your hot water needs.
• Water drained from the system drain valves may be
extremely hot. To avoid injury:
– Make sure all connections are tight.
– Direct water flow away from any person.
Bacteria can develop in the domestic water
system if certain minimum water tempera-
tures are not maintained. Failure to maintain
at least 140°F [60°C] domestic hot water tem-
perature (using the Antilegionella function
of your boiler, if any) can result in bacteria
development, which can result in serious in-
jury, or death.
WARNING
Water Temp. Time for 3rd degree
burn to occur
104 ° F Safe for bathing
120 ° F 5 minutes
125 ° F 2 minutes
130 ° F 10 seconds
140 ° F 3 seconds
148 ° F 2 seconds
155 ° F 1 second

• It is prohibited to carry out any modifications to the
appliance without prior written consent from Ideal.
• Faulty parts must only be replaced by genuine Ideal
factory parts.
• Failure to comply with these instructions can result in
minor property damage, or injury.
• Protection must be taken against excessive
temperature and pressure! Installation of the
Temperature & Pressure (T&P) relief valve, supplied
from the factory with the appliance, is required.
• Failure to comply with these instructions can result
in minor property damage, or injury.
• In case of any concern, please call your qualified
service technician.
• Make sure to reference the unit’s model number and
serial number from the rating label when inquiring
about service or troubleshooting.
• Ideal North America reserves the
right to change the technical
characteristics, components and
features of its products without prior
notice. Check for an updated version
of this manual at www.idealheatingna.com.
CAUTION
CAUTION
NOTICE
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SAFETY
PRODUCT AND SAFETY INFORMATION

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A1009091 - 661A0600_EN • A 1
CHAPTER 1
CHAPTER 1 - PRE- IN STA LL ATI ON
1.1. Codes Compliance
Water heater installation must conform with the in-
structions in this manual and where applicable:
• local, state, provincial, and national codes, laws,
regulations and ordinances.
• in Canada - CAN / CGA B149.1 or B149.2 Instal-
lation Code.
The MONARCH indirect-red water heaters are exempt
from the scope of ASME Section VIII, Division 1.
An indirect-red water heater’s input is, by denition,
the amount of heat that can be transferred to the tank.
This heat transfer is determined by size and capacity of
the tank’s heat exchanger.
This is supported by ASME’s interpretation VIII-1-86-136,
dated May 22, 1987, which specically states that an in-
direct-red water heater with a heat exchanger capac-
ity of less than 200,000 BTUH is not considered within
the scope of Section VIII, Division 1, even when its heat
source is a heating boiler with an input above 200,000
BTUH.
Where instructions in this manual dier from local, or
national codes, the local or national codes take prece-
dence.
1.2. Codes Restrictions
The single wall heat exchanger in the MONARCH wa-
ter heater complies with National Standard Plumbing
Code, provided that:
• Boiler water (including additives) is practically
non-toxic, having toxicity rating or class of 1, as
listed in Clinical Toxicology of Commercial
Products, 5th Edition and
• Boiler water pressure is limited to maximum
30 psig by approved relief valve.
Single wall heat exchangers are permitted under the
Uniform Plumbing code - Paragraph L3.2. and L3.3 if
they satisfy all of the following requirements.
1. The heat transfer medium is potable water or con-
tains only substances which are recognized as safe
by the U.S. Food and Drug Administration.
2. The pressure of the heat transfer medium is main-
tained less than the normal minimum operating
pressure of the potable water system
3. The equipment is permanently labeled to indicate
that only additives recognized as safe by the FDA
shall be used in the heat transfer medium.
Other heat exchanger designs may be permitted where
approved by the Administrative Authority.
MONARCH Series water heaters will absorb
less than 200,000 BTU/hr when domestic
water outlet temperature is 210ºF and boil-
er water supply temperature is 240ºF. List-
ed outputs are based on ASME Section VIII
Interpretation VIII-1-86-136.
The MONARCH water heater is for opera-
tion at outlet water temperature(s) not in
excess of 180° F
NOTICE

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A1009091 - 661A0600_EN • A
2
CHAPTER 1
CHAPTER 1 - PRE-INSTALLATION
• Artificially softened boiler/heating wa-
ter from a salt based water softener is not
allowed on the heating side of the water
heater
• Distilled or RO water is not allowed on the
heating side of the water heater
NOTICE
Table 1 - Boiler/Heating Water Quality
Boiler water hardness Less than 7 grains/gallon
pH level Between 6.0 and 8.0
Chlorine Less than 120 ppm (mg/l)
Chlorides Less than 150 ppm (mg/lL)
Conductivity 100 to 300 µS/cm
TDS (Total Dissolved Solids) 50 to 300 ppm (mg/L)
Molybdate Corrosion Inhibitor 100 to 300 ppm
Glycol 50% maximum inhibited pro-
pylene glycol only non-toxic
1.3. Operating Restrictions
• Maximum domestic hot water temperature is 180ºF
(82°C) for commercial applications and 160ºF (71°C)
for residential applications.
• Maximum boiler water temperature is 210ºF (99° C).
• Maximum working pressure for tank (domestic wa-
ter) is 150 psig.
• Maximum working pressure for the coil (boiler wa-
ter) is 30 psig.
• Water quality limitations (based on E.P.A National
Secondary Drinking Water Regulations). See Table
2 on page 3.
In hard water areas (more than 7 grains of
hardness) use a water softener on the cold do-
mestic supply water to the appliance to prevent
scaling.
BEST PRACTICEBEST PRACTICE
• Any water conditioning system for pota-
ble domestic water must be installed and
maintained in accordance with manufac-
turer’s specifications.
• Do not install the water heater on any appli-
cation if the boiler piping contains non-ox-
ygen barrier tubing or if the boiler piping is
considered an “open system”. Exposing the
tank of the water heater to oxygen contam-
ination will lead to premature tank failure
and denial of the warranty.
NOTICE
The MONARCH Tank Indirect Water Heater requires
both the closed loop boiler heating water and the open
loop domestic water to meet certain criteria to ensure
the safe and reliable operation of the unit and to main-
tain the warranty. The guidelines laid out below must
be followed for all installations of the MONARCH Tank
Indirect Water Heater.
NOTICE
Failure to follow the instructions contained in
this section will void the Warranty.

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A1009091 - 661A0600_EN • A 3
CHAPTER 1
CHAPTER 1 - PRE-INSTALLATION
1.4. Potable DHW Water Quality Require-
ments
The domestic water supplied to the water heater must
be potable water that is free from contaminants, sedi-
ment, corrosive chemicals, and debris. It is the respon-
sibility of the installer to ensure the water meets all the
guidelines laid out in this manual. Water quality that ex-
ceeds the guidelines and results in damage or failure of
the indirect tank is not covered by warranty.
If the domestic potable water quality is not within the
allowable levels laid out in the document the water
must be treated. Special attention should be taken in
regard to sediment, hard water, pH, and chlorides.
• If sediment in the water supply is 5 microns or
greater, a water sediment lter must be used.
• If there is hard water, a water softening system
should be used.
• If the chlorides or pH are out of range, a water
treatment company should be consulted to
correct all water quality issues. Any water treat-
ment/conditioning system must be installed
and maintained in accordance with the manu-
facturer’s specications.
Table 2- Drinking Water Quality
Chloride less than 150 ppm or mg/l
pH value min. 6, max. 8
Total hardness 3 - 7 grains/gallon or
50-120 ppm or mg/l.
Total Dissolved Solids (TDS) less than 120 ppm or mg/l.
Iron less than 0.3 ppm or mg/l.
Aluminum less than 0.2 ppm or mg/l.
Copper less than 1 ppm or mg/l.
Manganese less than 0.05 ppm or mg/l.
Zinc less than 5 ppm or mg/l.
Dissolved Carbon Dioxide (CO2) less than 15 ppm (mg/l.)
Sulfate less than 250 ppm (mg/l.)
Corrosivity Non-corrosive
Fluoride less than 2 ppm (mg/l.)
Foaming agents less than 0.5 ppm (mg/l.)
1.5. Closed Loop Boiler Heating Water Quali-
ty Requirements
To maintain efficient operation of the heat ex-
changer in the MONARCH Tank the following
instructions must be followed. Failure to follow
these instructions will result in poor operation
of the appliance, lead to potential failure of the
product, and will void the warranty.
CAUTION
During installation and during the annual maintenance,
the water quality must be checked and if found outside
of the requirements, must be corrected.
A micro bubble air elimination device is required to
be installed in all heating systems. An air scoop or an
automatic air vent are not an acceptable substitute for
a micro bubble air elimination device and may not be
used as a substitute in the installation. A few examples
of acceptable devices are:
• Taco 4900 Series
• Cale Discal
• Spirovent
If an automatic feed valve is installed in the heating sys-
tem, it may not be left open indenitely. A continuous
feed of fresh water could damage the system. It is re-
quired that after a short period of time, between one
to four weeks following the installation of MONARCH
Tank Indirect water heater into a heating system, the
automatic feed valve be closed and the water quality
be checked.
Plastic tubing such as PEX might be used in a heating
system for piping or underoor radiant heat. If oxygen
permeable tubing is used in the heating system with
the MONARCH Tank, it must be separated from the rest
of the heating system with a heat exchanger. Only ox-
ygen barrier tubing can be used in the heating system
side of a MONARCH Tank indirect water heater.
1.6. Glycol
Boiler water (including additives) must be practically
non-toxic, having toxicity rating or class of 1, as listed
in Clinical Toxicology of Commercial Products, 5th Edi-
tion. A maximum 50/50 mixture of inhibited propylene
glycol is allowed. Less than a 20% concentration of gly-
col is not permitted. Glycol will acidify because of ther-
mal degradation overtime and could cause damage to
components in the heating system.
This degradation is why heating system specic propyl-
ene glycol only must be used, these glycols contain ad-
ditives and inhibitors or are meant to work with specic
system inhibitors. The service technician must follow
the antifreeze manufacturer’s instruction. Antifreeze
at a minimum must be checked on an annual basis or
what is specied by the manufacturer of the antifreeze.

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A1009091 - 661A0600_EN • A
4
CHAPTER 1
CHAPTER 1 - PRE-INSTALLATION
1.7. Locating Water Heater
• This water heater is not intended for outdoor installations.
• Keep distance between boiler and water heater to
a minimum to:
– Reduce piping heat loss
– Provide minimal friction loss
• A water heater should always be located in an area
with a oor drain.
• Locate water heater so that any leakage from the
tank or water connections will not cause damage
to the area adjoining the water heater or to lower
oors in the structure.
– When such a location is unavoidable, a suitable
drain pan with adequate drainage, should be
placed under the water heater.
• The MONARCH Series Water Heaters are designed
for vertical installation only.
BEST PRACTICEBEST PRACTICE
1.8. Recommended Clearances
Water heater should be installed to allow adequate
clearance for servicing.
Zero clearance is permissible to any side of the MON-
ARCH Series water heater that has no connection, but
information labels must be visible for inspection.
The clearance required for any accessory or tting that
will be installed on either the heating and/or domestic
circuits must be taken into account.
• Recommended top or vertical clearance is
12” minimum.
• Refer to boiler manual for boiler clearances.
Fig. 1 - MONARCH Clearances - View from the Top
Water
Heater
12” Minimum
Wall
Antifreeze must be replaced at a minimum every 3-5
years or what is specied by the manufacturer of the
antifreeze.
When using antifreeze in the heating system circula-
tor sizing must be considered because of the increase
viscosity of the glycol mixture, a higher head circulator
may be required. The glycol will also lower the heat ca-
pacity and the BTU output will be reduced by approxi-
mately 16-20% when using a mixture of 50% propylene
glycol and 50% water. The reduced heating capacity at
a 50/50 mixture will vary depending on the brand and
makeup of the glycol. Glycol will reduce the eciency
and output of the indirect water heater because of this.
When adding other additives to the heating system gly-
col water mixture make sure they are compatible with
the brand of glycol that is being used. Not all glycol and
additives are compatible.
Do not use automotive, ethylene glycol or pe-
troleum-based antifreeze. Do not use any un-
diluted antifreeze. This can cause substantial
property damage, serious injury, or death.
DANGER

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A1009091 - 661A0600_EN • A 5
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
2.1. Temperature & Pressure (T&P) Relief
Valve
To reduce risk of excessive pressures and
temperatures in the water heater, install tem-
perature and pressure protective equipment
required by local codes, but no less than a com-
bination temperature and pressure relief valve
certified by a nationally recognized testing lab-
oratory that maintains periodic inspection of
production of listed equipment or materials, as
meeting the requirements for Relief Valves and
Automatic Gas Shutoff Devices for Hot Water
Supply Systems, ANSI Z21.22. This valve must
be marked with a maximum working pressure
of the water heater.
• Every MONARCH water heater must be protected
with a T&P relief valve.
– Every MONARCH Tank water heater is supplied
with a combination temperature and pressure
relief valve. See specications in Table 3 below.
– Always verify that the combination tempera-
ture and pressure relief valve supplied with the
water heater complies with local codes.
Table 3 - T&P Valve Characteristics
MONARCH
30-40-50 60-80-100
Inlet thread 3/4” M NPT
Probe length 8”
CSA rating 105,000 BTU/hr 205,000 BTU/hr
Rating 75 Psi — 1,034,000
Rating 100 Psi — 1,327,00
Rating 125 Psi 500,000 1,619,000
Rating 150 Psi 500,000 1,912,000
2.1.1 Standard Installation
• Install T&P relief valve in the Temperature and Pressure
Relief Valve connection on the top of the water heat-
er (Refer to Fig. 2 on page 9).
CAUTION
2.1.2 Commonwealth of Massachusetts Installation
In the Commonwealth of Massachusetts and in
all jurisdictions requiring a vacuum breaker to be
installed on the domestic cold water inlet, follow
these requirements:
• The water heater shall be protected against loss
of water from siphoning due to loss of supply
pressure by a vacuum relief valve installed in
the cold water supply line at a level above the
top of the heater or tank.
• The vacuum relief valve shall be in accordance with
the Standard ANSI Z21.22 at the latest revision.
• Valves shall have minimum ½-inch diameter orice
and the air inlet opening on any vacuum valve shall
not be smaller than the nominal pipe size of the valve
• Valves shall be sized to have a cross sectional
area equal to a pipe, not less than one pipe di-
ameter smaller than the tank supply or drain,
whichever is larger.
2.1.3 T&P Relief Valve Discharge Piping
• T&P relief valve discharge piping must be:
– Made of material serviceable for temperatures
of 250ºF or greater.
– Directed so that hot water ows away from all
persons.
– Directed to a suitable place for disposal.
– Installed so as to allow complete draining of the
T&P relief valve and discharge line.
– tted with a discharge piping, within 6”of the oor
• T&P relief valve discharge piping must not be:
– Excessively long. Using more than 2 elbows or
15 feet of piping can reduce discharge capacity.
– Directly connected to a drain.Terminate discharge
piping within 6”from drain. Refer to local codes.
– Plugged, reduced, blocked, capped, threaded,
or restricted .
– Subject to freezing.
Do not install any valve between T&P relief
valve and tank connection or onT&P relief valve
discharge piping. Do not plug T&P relief valve
or discharge piping. Improper placement and
piping of T&P relief valve can cause substantial
property damage, serious injury, or death.
WARNING

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A1009091 - 661A0600_EN • A
6
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
2.2. Drain Valve
A drain valve is supplied with the unit (draining of the
domestic tank). For information on draining the tank,
see page 18.
2.2.1 Standard Installation
• Install drain valve on drain connection (Refer to Fig.
2 on page 9).
• Pipe the drain piping with drain valve from the tee
connection to:
– a suitable place for disposal
or
– terminate within 12”of the oor.
2.3. Thermal Expansion
If a backow preventer, check valve or pressure reduc-
ing valve is piped on cold water supply piping of water
heater, install a potable water expansion tank on cold
water supply line to prevent normal thermal expansion
from repeatedly forcing open T&P relief valve.
T&P relief valve is not intended for constant duty,
such as relief of pressure due to repeated nor-
mal system expansion. Correct this condition by
installing a properly sized expansion tank in do-
mestic water system.
Refer to expansion tank manufacturer’s instal-
lation instructions for proper sizing.
2.4. Water Hammer
Dishwashers, clothes washers and fast-closing positive
shut-o valves incorporated in the system all contribute
to creating water shock. Install a water hammer arrester
to prevent damage to pipes and appliances. See device
manufacturer’s instructions for application and installation.
Water hammering within the domestic piping
system can cause premature failure of the tank
of the water heater. This type of failure is NOT
covered under warranty.
CAUTION
NOTICE
2.5. Vacuum Breaker
Installing a vacuum breaker (Watts N36-M1 or equiva-
lent) on the domestic cold water inlet will prevent dam-
age to the tank if a negative pressure is developed in the
domestic supply line. See manufacturer’s instructions
for application and installation of the vacuum breaker.
2.6. General Piping
• For domestic water piping diagram, refer to Fig. 2
on page 9 and Fig. 3 on page 9.
• For Boiler water piping, refer to Fig. 6 on page 11
thru Fig. 9 on page 12.
• For Multiple water heater domestic and boiler pip-
ing, refer to Fig. 4 on page 10 and Fig. 5 on page
10., and Fig. 10 on page 13 and Fig. 11 on page
13.
• See Table 4 on page 7 for domestic and boiler
piping connection sizes .
• All plumbing must meet or exceed all local, state
and national plumbing codes.
• Use pipe dope or tape suitable for potable water
systems.
• Use isolation valves to isolate system components.
2.7. Domestic Piping
• Union on domestic hot water outlet should be piped
at a higher elevation than domestic water drain valve.
This will make draining the water heater easier.
• Install unions for easy removal of water heater. It
is recommended to use dielectric unions or cou-
plings to protect hot and cold water ttings from
corrosion when connecting dissimilar materials
such as copper and galvanized iron pipe.
• If copper pipe is used for domestic water connec-
tions, rst solder or press pipe to a threaded adapter
and then screw adapter into cold water inlet on top
of water heater. Inlet connection contains an internal
plastic dip tube which can be damaged by heat from
soldering.
Do not apply heat to the cold water inlet when
making sweat connections to water heater.
Sweat tubing to adapter before fitting adapter
to cold water inlet of heater. It is imperative that
no heat be applied to the cold water inlet, as it
contains a non metallic dip tube.
NOTICE

7
A1009091 - 661A0600_EN • A 7
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
• When the water supply pressure is higher than 70
psig, it is recommended to install a pressure reduc-
ing valve on cold water supply line to prevent wa-
ter loss through T&P relief valve.
• If the water heater will replace a tankless coil in the
boiler, disconnect the piping to coil and allow the
water to drain from coil. Do not plug the tankless coil.
Plugging tankless coil inlet and outlet will re-
sult in substantial property damage, serious
injury, or death.
2.8. Thermostatic Mixing Valve
• It is recommended to install an optional mixing
valve on the domestic hot water outlet.
• Mixing valve must comply with ASSE 1017
2.9. Recirculation Piping
• A stainless steel or bronze circulator is required on
potable water systems.
• Install automatic mixing valve either at the hot wa-
ter outlet of water heater or each hot water faucet.
DANGER
Table 4 - Piping dimensions
Water
Heater Model
Connections (inches) Minimum
Boiler Piping*
Domestic Water
Inlet/Outlet (M - NPT)
Boiler Water Supply/
Return (F - NPT)
Temperature and Pressure Relief
Valve Connection (F - NPT) Diameter (Inches)
MONARCH 30 3/4 1 3/4 1
MONARCH 40 3/4 1 3/4 1
MONARCH 50 3/4 1 3/4 1
MONARCH 60 3/4 1 3/4 1
MONARCH 80 1 1 3/4 1
MONARCH 100 1 1 3/4 1
*recommended minimum boiler piping diameter is based on the installer correctly sizing the piping and pump to account for pressure
drop as well as any glycol in the system.
2.10. Multiple Water Heater Systems
• Parallel Pipe Recirculation Systems - Manifold recircu-
lation return to all water heaters.
• Install an automatic mixing valve either at the hot wa-
ter outlet of water heater or each hot water faucet.
Failure to install automatic mixing valve
where recommended will result in serious in-
jury, or death.
DANGER

8
A1009091 - 661A0600_EN • A
8
CHAPTER 2
2.11. Boiler Piping
• All PEX tubing used to connect the indirect tank wa-
ter heater to the boiler must have an oxygen barrier.
• If PEX tubing is used for boiler water piping, it must
have a maximum oxygen diusion rate of 0.1 mg/
liter-day for boiler and water heater protection.
The MONARCH IDWH must be installed on a
closed loop type hydronic system. Failure to
provide such a system will result in premature
failure of the tank and void the warranty.
• Boiler water (including additives) must be practical-
ly non-toxic, having toxicity rating or class of 1, as
listed in Clinical Toxicology of Commercial Prod-
ucts, 5th Edition.
• If antifreeze is used in the boiler system, local codes
may require a backow preventer on cold water
supply line. Use antifreeze specically intended for
hydronic heating systems. A maximum percentage
of 50% is allowed for inhibited propylene glycol.
Do not use automotive, ethylene glycol or
petroleum-based antifreeze. Do not use any
undiluted antifreeze. This can cause substan-
tial property damage, serious injury, or death.
NOTICE
DANGER
CHAPTER 2 - INSTALLATION - PIPING

9
A1009091 - 661A0600_EN • A 9
CHAPTER 2
Fig. 2 - Standard Installation - Domestic Piping - MONARCH Series
1. Shut-o valve
2. Recirculation Circulator
3. Flow Check Valve
4. T&P relief valve
5. Unions
6. Backow preventer or pressure reducing valve(*)
7. Drain valve
8. Thermal expansion tank (potable)
9. Recirculation connection
10. Thermostatic mixing valve (*)
(*) Recommended devices may be required by local codes.
Cold Water
Inlet
61
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
15
51
8
7
10
MH
C
4
Cold Water
Inlet
61
Recirculating
Loop
23
4
15
51
8
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
9
10
MH
C
7
Fig. 3 - Optional Installation - Domestic Piping with Recirculation - MONARCH Series
CHAPTER 2 - INSTALLATION - PIPING

Recirculated water
Circulator
Hot water outlet
Cold water inlet
Thermostatic
mixing valve
Recirculated water
Circulator
Cold water inlet
Thermostatic
mixing valve
Hot water
outlet
Cold water
inlet
Fig. 4 - Multiple MONARCH Series Water Heater System Domestic Piping - Parallel
Fig. 5 - MONARCH System Piping with Zone Circulators
• Recommended for most applications.
• Utilize the boiler to control system tem-
perature.
• Install automatic mixing valve at either the
hot water outlet of the water heater system
or at each hot water xture.
• Each tank should be equipped with a drain
valve, see Fig. 2 on page 9
• Recommended for applications in
which there is a large water consump-
tion in short period of time.
• A maximum of 3 water heaters may
be piped in series.
• Utilize the boiler to control system
temperature.
• Install automatic mixing valve at ei-
ther the hot water outlet of the water
heater system or at each hot water
xture.
• Each tank should be equipped with a
drain valve, see Fig. 2 on page 9.
10
A1009091 - 661A0600_EN • A
10
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING

1
2
1
3- Port
Zone
Valve
31
6
5
Cold water inlet
4
1
3
2
2-Port
Zone Valve
(normally open)
2-Port
Zone Valve
(normally closed)
1
6
5
Cold water inlet
4
Fig. 6 - MONARCH System Piping with 3-Port Zone Valve (Domestic Priority)
Fig. 7 - MONARCH System Piping with 2-Port Zone Valves (Domestic Priority)
11
A1009091 - 661A0600_EN • A 11
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
1. Shut-o valves
2. Circulator
3. Expansion tank
4. Drain valve
5. Feed valve
6. Air separator

1
3
2
Zone valve
Zone valve
Zone
valve
1
6
5
Cold water inlet
1
4
1
3
Zone circulator
Zone circulator
Zone
circulator
1
6
5
Cold water inlet
1
2
22
7
7
7
4
Fig. 8 - MONARCH System Piping with Zone Valves (Non Domestic Priority)
Fig. 9 - MONARCH System Piping with Zone Circulators
12
A1009091 - 661A0600_EN • A
12
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
1. Shut-o valves
2. Circulator
3. Expansion tank
4. Drain valve
5. Feed valve
6. Air separator
7. Flow check valve

31
6
5
2
1
7
4
Cold water
inlet
31
6
5
2
1
7
4
Cold water
inlet
Fig. 10 - Multiple MONARCH Series Water Heater System Boiler Piping Reverse Return Balanced Flow
Fig. 11 - Multiple MONARCH Series Water Heater System Boiler Piping - Manifold
13
A1009091 - 661A0600_EN • A 13
CHAPTER 2
CHAPTER 2 - INSTALLATION - PIPING
1. Shut-o valves
2. Circulator
3. Expansion tank
4. Drain valve
5. Feed valve
6. Air separator
7. Flow check valve

Low Voltage Terminals
LGN L G N L G NLG N LG N L GN L GN
FLAME PUMP 4 PUMP 3 DHW PUMPCH PUMP POWER SUPPLY ALARM
Line Voltage Terminals
CH2
Thermostat
6 5
System
Sensor
4 3
Modulation
Signal
- +
2 1
CH2
Thermosta
t
CH1
Thermostat
4 3
Outdoor
Sensor
2 1
DHW
Sensor or
Aquastat
2 1
Modbus
+ G -
3 2 1
X7X4
X6X5
External Limit
Terminals
Manual Auto
Mix Sensor
Terminals
Fig. 12 - MONARCH Tank Temperature Sensor Connected to Gallant Boiler Low Voltage Terminal
14
A1009091 - 661A0600_EN • A
14
CHAPTER 3 - INSTALLATION - WIRING
3.1. Temperature Sensor and Drywell
Gallant and Exalt boilers are equipped with a sensor
that can be used with the tank.
A drywell is provided with the tank, to be installed in
the designated location (refer to Fig. 15 on page 22
for the exact location).
The drywell shall be installed using appropriate sealing
material and tightened with a torque of 51 Lb.ft (70 Nm).
3.2. Thermostat (Aquastat)
The tank can be equipped with a thermostat of the fol-
lowing type : Resideo L4080B1352.
The thermostat should be set at 120°F or lower.
NOTICE