Vaughn TOP PERFORMER PLUS Specification sheet

Operation and Installation Manual
TOP PERFORMER PLUS
Indirect Fired Water Heater
Limited Warranty and Tank Replacement

These water heaters will absorb less than 200,000 BTU/hr when domestic water
outlet temperature is 194ºF and boiler water supply temperature is 240ºF. Listed
outputs are based on ASME Section VIII Interpretation VIII-1-86-136.

GENERAL INFORMATION
PLEASE READ INSTRUCTIONS CAREFULLY BEFORE INSTALLING
WATER HEATER
1. Vaughn Thermal Corporation (herein called the Company) intends
that this TOP PERFORMER INDIRECT FIRED WATER HEATER
be used as a separate zone to a heating system boiler.
The Company specifically does not expressly or impliedly warrant
the merchantability or the fitness for any particular purpose or the
performance of the heater within that system, nor does it assume
liability for any consequential damage to general property or other
components of the system.
2. This appliance is designed to heat water by circulating water from
the boiler through the internal coil in the tank. We specifically do not
warrant this tank for high temperature applications such as wood
stoves or steam producing systems. Such use of this product will
automatically void the warranty.
The design anticipates the proper installation and care in use of
the product. There is risk of property damage and personal injury
inherent in the use of any hot water system. The Company cannot
supervise the installation and therefore makes it a specific condition of
the warranty that the customer will supervise the installation and use of
this product to be sure they are performed in accordance with these
instructions, as well as safe industry guidelines and proper local or
national codes.
Generalized instructions and procedures cannot anticipate all
situations. For this reason, only qualified installers should perform the
installation. A qualified installer is a licensed person who has appropriate
training and a working knowledge of the applicable codes, regulations,
tools, equipment and methods necessary for safe installation of a boiler
system and an indirect water heater.
An installation checklist has been provided to help the customer
ensure that all procedures for a safe installation have been followed.
If questions regarding installation arise, check with your local
plumbing and electrical inspectors for proper procedures and codes.
Local codes take precedence over instructions in this manual.

INDEX
INSTALLATION GUIDELINES____________________________________2
INSTALLATION CHECKLIST_____________________________________7
SERVICE INFORMATION________________________________________8
Thermostat Diagram 1 ___________________________________________ 11
Thermostat Diagram 2 ___________________________________________ 11
Thermostat Diagram 3 ___________________________________________ 12
Thermostat Diagram 4 ___________________________________________ 13
Thermostat Diagram 5 ___________________________________________ 13
FIGURE 1_____________________________________________________ 14
FIGURE 2_____________________________________________________ 14
FIGURE 3_____________________________________________________ 15
FIGURE 4_____________________________________________________ 16
HOW TO OBTAIN SERVICE ASSISTANCE ________________________ 17
LIMITED WARRANTY _________________________________________ 18
Optional Lifetime Warranty Registration Card_________________ Back Cover
To fully understand the purchaser’s responsibilities for installing
the water heater, please read the warranty.
P.O. Box 5431 ·Salisbury, MA 01952-5431 · 978.462.6683

2
INSTALLATION GUIDELINES
A. INSPECTING AND PREPARING THE HEATER
Remove the cardboard box, which comes packaged with the
heater. It should contain the following: Thermostat, T&P valve
and “T” (no “T” for model S70DTPP), insulation, lid and screws.
B. LOCATION
CAUTION: All tanks will eventually leak at some
unpredictable time.
Do not place the heater where there is a risk of property damage
in the event of a leak.
Place the heater on a solid foundation in a clean, dry location
nearest the boiler.
The heater should be protected from freezing and water lines
should be insulated to reduce energy and water waste.
Leave sufficient headroom to service the heat exchanger and
electrical controls.
Do not install in an area where flammable liquids or combustible
vapors are present.
CAUTION: The heater’s outer jacket is plastic and can melt.
Do not install in close proximity to wood burning stove or other
high temperature apparatus.
NOTE: If Heater is Placed on Blocks To Raise It From the Floor,
Be Sure to Support The Entire Bottom With At Least ¾ "
Plywood On The Top Of The Blocks.

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C. PROTECTION FROM WATER DAMAGE
CAUTION: All water heaters have a risk of leakage at some
unpredictable time.
IT IS THE CUSTOMER’S RESPONSIBILITY TO PROVIDE A
CATCH PAN OR OTHER ADEQUATE MEANS, SO THAT THE
RESULTANT FLOW OF WATER WILL NOT DAMAGE
FURNISHINGS OR PROPERTY. (See Figure 1)
The Warranty provided assures replacement within its terms, but
specifically does not warrant against consequential damage caused by a
leaking water heater.
D. RELIEF VALVE
WARNING: A POTENTIAL HAZARD TO LIFE AND PROPERTY
MAY EXIST IN ANY WATER HEATER IF AN APPROVED
TEMPERATURE-AND-PRESSURE RELIEF VALVE IS NOT
PROPERLY INSTALLED.
For protection against excessive pressures and temperatures in
this water heater, install temperature-and-pressure protective
equipment by local codes, but not less than a combination
temperature-and-pressure relief valve certified by a nationally
recognized testing laboratory that maintains periodic inspection of
production of listed equipment of materials, as meeting the
requirements for Relief Valves and Automatic Gas Shutoff for Hot
Water Supply Systems, ANSI Z21.22-1971. This valve must be
marked with maximum set pressure not to exceed the marked
maximum allowable working pressure of the water heater
(150psi). Install the valve into an opening provided and marked
for this purpose in the water heater, and orient it or provide the
tubing so that any discharge from the valve will exit only within 6
inches above, or at any distance below the structural floor and
cannot contact any live electrical parts. The discharge opening
must not be blocked or reduced in size under any circumstances.
CAUTION: A relief valve is designed to discharge excessively hot
water. THE CUSTOMER IS RESPONSIBLE TO PROTECT
PROPERTY AND PERSONNEL FROM HARM WHEN THE
VALVE FUNCTIONS.
Install the T&P provided on hot water outlet of tank as shown in
Figures 1 and 2. (Except model S70DTPP, see next)
For model S70DTPP, Install the T&P provided on the ¾” NPT
brass connection that is installed on the side of the heater. (See
Figure 3)
Care must be taken to be sure that the stem of the pressure-and-
temperature relief valve is immersed in the water within the top 6
inches of the tank.

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The drain line from the relief valve must not be concealed or
blocked and must be protected from freezing.
WARNING: IF THE WATER SUPPLY IS FROM A WELL, OR
KNOWN TO HAVE HARD WATER, IT IS RECOMMENDED TO
USE A PRESSURE RELIEF VALVE IN THE COLD WATER
LINE AS WELL AS A T&P VALVE IN THE HOT WATER LINE.
E. INSTALLING THE REMOVABLE HEAT EXCHANGER
Heat exchanger is installed at the factory. The following is
provided for servicing or removing the heat exchanger.
Insert heat exchanger with plastic o-ring housing and align holes
in cover plate with holes in flange and plastic o-ring housing.
WARNING: Plastic o-ring housing must be properly installed.
(See Figure 4). Failure to do this will void the warranty.
Insert and secure the bolts to the nuts one at a time in the
following manner:
Place the nut beneath the flange opening.
Hold the nut in place with one hand –insert the bolt with the
other.
Thread the bolt into the nut and tighten in proper order. (See
Figure 4)
NOTE: Be sure to place bolts in all of the openings.
WARNING: Plastic o-ring housing must be installed properly (See
Figure 4) to prevent corrosive action. Failure to do this will void the
warranty. Must use new o-ring if replaced or removed.
F. WATER SUPPLY CONNECTIONS
WARNING: Some local codes mandate the use of a backflow
preventer or check valve or pressure-reducing valve. An
adequate expansion tank (or other adequate means) must be
installed to prevent pressure build up or damage from
thermal expansion when a check valve or backflow preventer
or pressure-reducing valve is used. Failure to do so could
result in tank leakage and therefore void the warranty. (See
Figures 1 and 2 for proper location, see Figure 3 for
S70DTPP)
All water supply fittings on this heater are brass –do not over
tighten or strip threads.
It is recommended to use unions as per Figures 1 and 2. (See
Figure 3 for S70DTPP)
Do not apply heat directly to the cold-water inlet as it
includes a plastic dip tube which will melt.

5
G. BOILER SUPPLY CONNECTIONS
WARNING: Heat exchanger fluid must be non-toxic.
WARNING: Boiler temperature must be controlled by the
boiler hi limit not to exceed 200°. Failure to do so will create
a hazardous installation and void the warranty.
All fittings on this heater are brass –do not strip threads.
It is recommended to use unions as per figures 1 and 2. (See
Figure 3 for S70DTPP)
Heat exchanger connections are 3/4" male threaded fittings
(Exception: They are 1" male on the S70DTPP).
Connect the supply line (from the boiler) to the “Hx In” fittings of
the heat exchanger. Connect the return line (back to the boiler) to
the “Hx Out” fittings.
For closed-loop systems that do not use water as the heat-
transfer fluid, the total volume of the heat-transfer fluid in the
closed loop shall be less than 10% of storage tank volume.
Max loop length = (tank capacity/10) / (PI * pipe radius * pipe radius)
NOTE: Be sure to connect Boiler Supply Line (from the boiler) to
the “HX in” fitting and Boiler Return Line (to the boiler) to the
“HX Out” fitting.
H. FILLING THE HEATER
Check that the temperature-and-pressure relief valve has been
properly installed (mandatory requirement).
Completely close the drain valve.
Open the highest hot water faucet to allow air to escape from
piping.
Open the valve to the cold-water inlet and allow the heater and
piping system to completely fill, as indicated by a steady flow of
water from the open faucet.
I.THERMOSTAT INSTALLATION
Attaching Thermostat to tank:
Place hole in back of Thermostat over immersion well or
temperature sensor leads. It should fit flush against the tank. Use
the provided self-tapping screw (Screw A) to attach case back
directly to the Top Performer. (See Thermostat Diagram 1)
Slide temperature sensor all the way into the immersion well (if
equipped) –until it contacts the end. (See Thermostat Diagram 2)
Connect temperature sensor wires to press release connector (if
equipped). (See Thermostat Diagram 4)
Run all 24VAC wiring thru the square notch on bottom of
thermostat case. (See Thermostat Diagram 3)

6
(Note: Sensor does NOT need to make intimate contact with
entire well surface to work properly)
The TOP PERFORMER may operate as a separate heating zone
using either the heating system circulator and an appropriate
zone valve, or a separate circulator dedicated for water heating.
(See Figure 1 & 2). (See Figure 3 for S70DTPP)
In both systems, the TOP PERFORMER is controlled through the
thermostat on the heater. (See Figures 1 & 2). (See Figure 3 for
S70DTPP)
Be certain to replace thermostat cover using Black Screw
provided.
J. ETC101 WIRING CONTROLS
WARNING: Do not use ETC101 with 110V circuits. For Switching
110V, use a standard TPI Control.
For controlling zone valves, multi-zone controllers and switching
relays, follow applicable wiring diagrams for typical low voltage
thermostat circuits.
Some newer switching relay models do not work properly with
“Power Stealing” thermostats. The ETC101 is a power stealing
thermostat unless powered separately. Connect 24VAC Power
(From the the switching relay board or from a step down
transformer to the screws to the right of the Probe Connector.
(See Thermostat Diagram 5)
K. TPI WIRING CONTROLS
NOTE: THE TPI THERMOSTAT MUST BE POWERED WITH 24VAC
24VAC power must be connected to 24VAC connectors on the
bottom right corner of TPI. (See THERMOSTAT Diagram 3)
The TPI 24VAC only requires 20mA, or about 0.5 Watts.
Connect control wiring to PUMP/TT normally open relay
connections (rated for both 24V and 110V wiring) on the bottom
left corner of TPI. (See Thermostat Diagrams 3 and 5)
All and only 110VAC wiring must go through an appropriate chase
nipple installed in the knockout at bottom of TPI case.
TPI Wiring will vary depending on the type of boiler and valve
controls in the system. Consult attached Wiring Diagrams for
appropriate wiring configuration for your system.
CAUTION: If Sensor is soldered directly to TPI, DO NOT BEND
SHARPLY OR OVERWORK.
L. INSULATION INSTALLATION
Place included fiberglass insulation between and around the
water supply and boiler supply connections. Attach lid using
screws provided. Insulate hot water pipes with pipe insulation.

7
INSTALLATION CHECKLIST
A. INSPECTING AND PREPARING THE HEATER
Remove the cardboard box, which comes packaged with the
heater. It should contain the following: Thermostat, T&P valve
and “T” (no “T” for model S70DTPP), insulation, lid and screws.
B. LOCATION
Solid foundation and dry location.
Protect heater water lines from freezing.
Area free of flammable vapors.
Sufficient room to service heater.
Not in close proximity to wood burning stove.
Where leak will not damage property.
C. PROTECTION FROM WATER DAMAGE
Be sure to make provisions to protect area from water
damage if a leak should occur in the tank or connected
fittings.
D. RELIEF VALVE
Warning: Improper installation will present potential hazard
to life and property.
Check to be sure that proper relief valve requirements are met.
T&P installed as shown in Figures 1 and 2. (See Figure 3 for
S70DTPP)
3/4" discharge pipe –properly protected from freezing and
restrictions.
No valve between tank and relief valve or in drain line.
Provision for hot water discharge from relief valve.
E. BOILER SUPPLY CONNECTIONS
Return line (back to the boiler) connected to the “Hx Out” fitting.
Supply line (from the boiler) connected to the “Hx In” fitting.
F. WATER SUPPLY CONNECTIONS (See Figure 1 & 2). (See Figure
3 for S70DTPP)
Do not over tighten brass threads.
Mark the water shutoff for future reference.
Do not apply heat to cold inlet.
If there is a check valve (sometimes in water meter),
backflow preventer or pressure-reducing valve, install an
adequate size expansion tank.

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G. FILLING THE HEATER
Water connections completed and free of leaks.
H. WIRING
Check that water heats to desired temperature
SERVICE INFORMATION
WATER TEMPERATURE REGULATION
WARNING: Exposure to 125° F or hotter water can cause scalding
injuries. Appropriate caution must be taken when using hot water.
Special supervision must be given to those who cannot act quickly
such as children, invalids or elderly persons.
The input of heat into the tank is controlled by an immersion thermostat.
These automatic controls are set at the factory to maintain a water
temperature of 120° F*.
*Although these thermostats are designed to industry standards, they
can fail to control temperature properly without any notice, and therefore
should be tested periodically for your protection.
DANGER: IF YOU DISCOVER EXTREME HOT WATER COMING
FROM THE FAUCET, IMMEDIATELY SHUT OFF THE MAIN SWITCH
TO THE BOILER AND CALL COMPETENT SERVICE PERSONNEL.
ANY OVERHEATED WATER IS A POTENTIAL HAZARD TO LIFE
AND PROPERTY. DO NOT OPERATE UNTIL THE SOURCE OF THE
PROBLEM HAS BEEN DETERMINED AND ELIMINATED.
Water temperature over 125° F
can cause severe burns instantly
or death from scalds.
Children, disabled and elderly are
at the highest risk of being
scalded.
See instruction manual before
setting temperature at the water
heater.
Feel water before bathing or
showering.
Properly maintained, your water heater can provide years of dependable,
trouble free service. It is suggested that the purchaser follow the
preventive maintenance program outlined below.

9
WATER TEMPERATURE CONTROLS
A periodic inspection of the operating controls, heat exchanger and
wiring should be made by qualified service personnel.
Temperature of the water should be tested periodically at the faucet to
be sure thermostat is working properly.
TEMPERATURE ADJUSTMENT
The water heater is delivered with either a TPI thermostat or an ETC101
thermostat. Both have a factory set temperature setting of 120F and
differential setting of 10F. Any temperature adjustment of the thermostat
must be made by qualified service personnel, as shown below.
WARNING: See SERVICE INFORMATION Water Temperature
Regulation, regarding safe water temperature before proceeding.
Hot water can cause scalding injuries.
1. Shut off or disconnect all electrical supply to heater.
2. Remove cover to Thermostat.
3. Adjust right side lever to the desired temperature. Moving lever down
will decrease temperature. (See Thermostat Diagram 1).
NOTE: Markings on slide are approximate. Check temperature
at faucet to ensure safe operating temperature.
4. Adjust left side lever to the desired differential. The thermostat will
call for heat when the tank temperature has fallen to the set
differential degrees below the Temperature set point.
5. Reattach cover.
6. Reconnect electrical supply.
7. Check faucet temperature to verify desired temperature is achieved.
In order to set the temperature above 140F {NOT RECOMMENDED}
you must remove the SCALD DANGER label attached to the
temperature slide.
Caution: Do not increase temperature above 140° without a properly
installed mixing valve in the system –See Water Temperature
Regulation and SCALD WARNING.
Indicator LED operation:
The thermostat has an indicator LED at the top of the case. (See
Thermostat Diagram 1 or Inside Cover of thermostat)
When thermostat is calling for heat, the Indicator LED will blink green.
When thermostat is satisfied, the Indicator LED will be solid green.
If the thermostat detects no probe, the Indicator LED will flash Red. Ensure
connections are tight.

10
EMERGENCY
Should the heater be subject to flood, fire or other damaging conditions,
turn the power and water to the heater off. DO NOT place water heater in
operation again until it has been thoroughly checked by qualified service
personnel.
Construction of Single Wall Heat Exchanger
Consists of one copper tube, wound into a coil. The ends of the tube are
soldered into the brass fittings that mate with the hot water supply.
Construction of Double Wall Heat Exchanger
Consists of two copper tubes, one inside the other, wound into a coil.
The outer tube is soldered into the brass fitting that mates into the tank.
The inner tube is soldered into the brass fitting that mates with the hot
water supply. The gap between the two tubes is open to the air, allowing
visible detection of any leaks, as well as preventing any cross
contamination between liquids.
CLEANING THE HEAT EXCHANGER
Shut off water supply to tank and boiler. Remove the heat exchanger.
Flush inside of heat exchanger with water. Rinse outside of heat
exchanger with water and scrub with soft bristled brush.
Install heat exchanger, turn on water and bleed air from system.

11
Thermostat Diagram 1
Thermostat Diagram 2

12
Thermostat Diagram 3
ETC101 (Low Voltage Only)
(Red Circuit Board)
TPI (Green Circuit Board)
OUTPUT CONTACTS 24V IN

13
Thermostat Diagram 4
Inserting the probe wires into the press release connector
4.A –Position tool on top of white buttons
4.B –Push Down on buttons and push wires Down into holes in top of
connector (This can also be done one side at a time)
4.C –Tug on each wire to make sure they are secure
Wires Buttons
Thermostat Diagram 5
Typical Wiring Wiring with optional 24V, if needed
For TPI Thermostats, the 24V Power is required.
4.A Buttons
up
4.B Buttons down,
Wires pushed down
4.C Buttons up,
Wires tight

14
FIGURE 1
Installation Diagram Using Zone Valves
FIGURE 2
Installation Diagram Using Separate Circulator

15
FIGURE 3
S70DTPP Installation Diagram Using a Single Tank
S70DTPP Installation Diagram Including One Hotstow Storage Tank

16
FIGURE 4

17
HOW TO OBTAIN SERVICE ASSISTANCE
Vaughn Thermal Corporation does not have a service department
or personnel to service your heater in the field. A qualified installer
or service technician must do all service work. Therefore, if you
have any questions about your new water heater concerning
service adjustment, repair, routine maintenance, or replacement -
first contact your installer, plumbing contractor or service
agency.
In the event that the contractor, for whatever reason, is unable to help,
refer to the telephone directory commercial listings for qualified service
assistance.
If neither action has solved your problem, please have your plumbing
contractor contact us for assistance.
CUSTOMER RELATIONS DEPARTMENT
[email protected]
978-462-6683
VAUGHN THERMAL CORPORATION
26 OLD ELM STREET
P.O BOX 5431
SALISBURY, MA 01952
When contacting Vaughn the following information should be made
available:
A. Model and serial number of the water heater as listed on inside
back cover of this manual or on the rating plate on the heater.
B. Address where water heater is installed.
C. Name and address of dealer from whom the heater was
purchased and installer’s name and address.
D. Date of original installation and any service work performed
since then.
E. Details of the problem as you can best describe.
F. List of people who have been contacted regarding the problem.