HTP PH100-55, PH160-55, PH199-55, PH100-80, PH130-55 Installation Manual

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Phoenix Gas-Fired

This manual must be used by a qualified installer/service technician. Read all instructions in this manual damage, severe personal injury, or death.

Water Heater

INSTALLATION

START-UP

MAINTENANCE

PARTS

Phoenix Water Heater Models* PH100-55 / 130-55 / 160-55 / 199-55 PH100-80 / 130-80 / 160-80 / 199-80

PH100-119 / 130-119 / 160-119 / 199-119

Phoenix Sanitizer Booster Models*

130-55SA / 199-55SA

*A suffix of “LP” denotes propane gas

*A suffix of “S” denotes solar model

before installing. Perform steps in the given order. Failure to comply could result in substantial property

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

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IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION

provided by a qualified installer, service agency, or the gas supplier.

MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE 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. Installation and service must be

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The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the Phoenix GasFired Water Heater. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the local code authorities and utility companies which pertain to this type of water heating equipment.

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This manual must only be used by a qualified heating installer/service technician. Read all instructions in personal injury, death or substantial property damage.

FOR THE INSTALLER

this manual before installing. Perform steps in the order given. Failure to comply could result in severe

This appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association

Laboratories, 8501 East Pleasant Va lley Road, Cleveland, OH 44131. In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale

Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing

tests specified in ANSI Z21.10.3 – latest ed iti on.

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TABLE OF CONTENTS

PART 1 – GENERAL SAFETY INFORMATION .......................................................................................... 7

A. PRECAUTIONS .................................................................................................................................... 7

B. IMPROPER COMBUSTION.................................................................................................................. 7

C. GAS ....................................................................................................................................................... 7

D. WHEN SERVICING THE HEATER ...................................................................................................... 7

E. HEATER WATER .................................................................................................................................. 7

PART 2 – HOW THE HEATER OPERATES ................................................................................................ 8

PART 3 – PREPARE WATER HEATER LOCATION .................................................................................. 9

A. BEFORE LOCATING THE HEATER .................................................................................................... 9

B. LEVELING ............................................................................................................................................. 9

C. CLEARANCES FOR SERVICE ACCESS .......................................................................................... 10

D. RESIDENTIAL GARAGE INSTALLATION ......................................................................................... 10

E. EXHAUST VENT AND INTAKE AIR VENT ........................................................................................ 10

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ....................................................... 11

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE .......... 11

F. PREVENT COMBUSTION AIR CONTAMINATION ........................................................................... 12

G. REMOVING A HEATER FROM A COMMON VENT SYSTEM.......................................................... 12

H. WATER CHEMISTRY ......................................................................................................................... 13

PART 4 – PREPARE THE HEATER .......................................................................................................... 14

PART 5 – HEATER PIPING ....................................................................................................................... 15

A. GENERAL PIPING INFORMATION ................................................................................................... 15

B. SCALDING .......................................................................................................................................... 15

C. TEMPERATURE AN D P R ES SURE RELIEF VALVE ......................................................................... 16

D. BACKFLOW PREVENTER ................................................................................................................. 16

E. POTABLE EXPAN SIO N T AN K ........................................................................................................... 16

F. WATER PIPING .................................................................................................................................. 17

G. AUXILIARY CONNECTIONS ............................................................................................................. 17

H. PIPING DIAGRAMS ............................................................................................................................ 18

PART 6 – ELECTRICAL CONNECTIONS ................................................................................................. 25

A. LINE VOLTAGE INPUT ...................................................................................................................... 25

B. LINE VOLTAGE CONDENSATE OUTPUT ........................................................................................ 25

C. LOW VOLTAGE OUTDOOR SENSOR INPUT .................................................................................. 25

PART 7 – GAS CONNECTIONS ................................................................................................................ 25

A. GAS PIPING ....................................................................................................................................... 26

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B. GAS TABLE ........................................................................................................................................ 26

C. GAS VALVE ........................................................................................................................................ 27

PART 8 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ........................................... 28

A. GENERAL ........................................................................................................................................... 28

B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS ............................................. 28

C. EXHAUST AND INTAKE AIR VENT PIPE LOCATION ...................................................................... 29

1. DETERMINE EXHAUST VENT LOCATION.................................................................................... 29

2. DETERMINE AIR INTAKE VENT LOCATION ................................................................................ 29

D. EXHAUST AND INTAKE AIR VENT SIZING ...................................................................................... 30

E. LONGER VENT RUNS ....................................................................................................................... 31

F. EXHAUST VENT AND INTAKE AIR PIPE INSTALLATION ............................................................... 32

G. VENTING DRAWINGS ....................................................................................................................... 33

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ....................................................... 33

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE .......... 38

H. CONDENSATE REMOVAL SYSTEM ................................................................................................ 41

PART 9 – START-UP PROCEDURE ......................................................................................................... 42

A. OPERATING INSTRUCTIONS ........................................................................................................... 42

B. OVERALL APPLIANCE AND CONTROL OPERATION ..................................................................... 42

C. STATUS MENU .................................................................................................................................. 43

D. OUTDOOR RESET ............................................................................................................................. 43

E. TEST MODE ....................................................................................................................................... 45

F. MAINTENANCE .................................................................................................................................. 45

G. INTERNAL WIRING ............................................................................................................................ 46

PART 10 – SHUTDOWN ............................................................................................................................ 47

A. SHUTDOWN PROCEDURE ............................................................................................................... 47

B. VACATION PROCEDURE .................................................................................................................. 47

C. FAILURE TO OPERATE..................................................................................................................... 47

PART 11 – TROUBLESHOOTING ............................................................................................................. 47

A. ERROR CODE .................................................................................................................................... 47

B. HEATER ERROR ................................................................................................................................ 47

C. LOCKOUT ........................................................................................................................................... 48

PART 12: MAINTENANCE ......................................................................................................................... 54

MAINTENANCE NOTES ............................................................................................................................ 57

HTP CUSTOMER INSTALLATION RECORD FORM ........................................................................ 58

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INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.

USER – This manual is for use only by a qualified heating installer/service technician. Refer to user’s technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the heater is exposed to the following, do not operate until all corrective steps have been made

company by the consignee.

NOTE: Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation.

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Unit must have room for service: 24” front and 12” sides are minimum recommended service clearances. (A combustible door or removable panel is acceptable front clearance.) This appliance has been approved for closet installation, and instal lat ion o n combustible flooring. Do not install this appliance directly on carpeting. Use only Category IV vent systems.

information manual for your reference. Have this heater serviced/inspected by a qualified service

by a qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician. Replace any part of the control unit that has been und er water.

B. IMPROPER COMBUSTION

C. GAS

Should overheating or gas supply fail to shut off, turn off the manual gas control valve to the appliance.

D. WHEN SERVICING THE HEATER

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow heater to cool.

E. HEATER WATER

• Do not use petroleum-based cleaning or sealing compounds in a heater system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

• Do not use “homemade cures” or “heater patent medicines”. Substantial property damage, damage to heater, and/or serious personal injury may result.

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PART 2 – HOW THE HEATER OPERATES

Modulation Condensing Technology is an intelligent system that delivers highly efficient water heatin g, while maximizing efficiency by measuring the data parameters of your water heating system. Some of its features are:

Stainless Steel Water Storage Tank

The stainless steel water storage tank has a combustion chamber submerged into the tank water. When the water heater is fired, combustion gases heat the combustion chamber walls, transferring heat directly into the surrounding water. These hot gases are blown into secondary heat exchanger coils, where more heat is transferred into the water, removing even more heat from the gases.

Modulating Combustion System

Modulation during water heating operation is based on tank temperature. The control monitors the system to regulate burner output during operation to match system demand. This increase in efficiency allows for substantial fuel savings.

Gas Valve

The gas valve senses suction from the blower, allowing gas to flow only if the gas valve is energized and combustion air is flowing.

Upper Supply Tank Sensor

This sensor monitors the upper portion water temperature (system supply) of the water heater. The control module adjusts the burner firing rate so the outlet water temperature meets the set point.

Lower Return Tank Sensor

This sensor monitors the lower portion of the water heater inlet water temperature (system return). The control module reduces or increases input, depending on how close the water temperature is to the outlet water temperature set point.

Control

The integrated control system monitors upper and lower water temperature and regulates fan speed to regulate the unit’s energy output. This allows the unit to deliver the required amount of heated ener g y and nothing more.

Burner

Constructed of high grade stainless steel, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

Condensate Drain Connection

This is a condensing high efficiency applianc e, and therefore has a condensate removal system. Condensate is nothing more than water vapor, derived from combustion products and similar to an automobile when it is initially starte d. It is ver y impor t ant that the condensate line slopes away from the water heater and down to a suitable inside drain.

If the condensate outlet on the heater is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP.) In addition, local authorities may require a condensate neutralizer to neutralize the condensate. Condensate neutralizers are made up of lime crystals, marble or phosphate chips. Neutralizers c an be i ns tal led in the field by the installer and purchased from HTP (p/n 7450P-212).

It is also very important not to expose the condensate line to freezing temperatures or any type of blockage. Plastic tubing must be the only material used for the condensate line. Steel, brass, copper or other materia ls will be subject to corrosion or deterioration. A second vent may be necessary to prevent condensate line vacuum lock on a long horizontal run. Also, an increase in pipe size may be necessary to

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Water temperature over 125oF can instantly cause severe burns, or death, from scalds. Children,

valves are available.

Failure to keep heater area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

In order for the condensate to properly flow out of the collection system, the area where you locate the heater must be level. Location must also fully support the weight of the filled water heater.

allow condensate to dra in p roper ly. Support of the condensation line may be necessary to avoid blockage of the condensate flow.

Spark Ignition

The burner flame is ignited by applying high voltage to the system spark electrode. This causes a spark from electrode to ground.

disabled, and elderly are at the highest risk of being scalded. See instruction manual before setting temperature at water heater. Feel water before bathing or showering! Temperature limiting

PART 3 – PREPARE WATER HEATER LOCATION

Before considering locat ion , many factors need to be addressed. Piping, Ven tin g, and Cond ens at io n Removal are just a few of the issues that need attention prior to the installation of the heater. Please read the entire manual, as it could save time and money.

A. BEFORE LOCATING THE HEATER

Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

Check area around heater. Remove any combustible materials, gasoline, and other flammable liquids.

The heater gas control system components must be protected from dripping water during operation and service.

If replacing an existing heater, check for and correct any existing system problems, such as:

• System leaks

• Heater is located in a condition that could cause the system to freeze and leak.

• Incorrectly-sized expansion tank

• Clean and flush existing system when reinstalling a heater.

B. LEVELING

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The space must be provided with combustion/ventilation air openings correctly sized for all other

damage, severe personal injury, or death.

Failure to vent the water heater prope rly will result in serious personal injury or death.

C. CLEARANCES FOR SERVICE ACCESS

Figure 1

If you do not provide the minimum clearances shown, it might not be possible to service the heater without removing it from the space.

appliances located in the same space as the heater. The heater cover must be securely fastened to prevent the heater from drawing air form the heater room. This is particularly important if the heater is in a room with other appliances. Failure to comply with the above warnings could result in substantial property

D. RESIDENTIAL GARAGE INST AL LAT ION

PRECAUTIONS

If the heater is located in a residential garage, per ANSI Z223.1:

• Mount the bottom of the heater a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor.

• When raising the heater, fully support the entire bottom of the appliance.

• Locate or protect the heater so it cannot be damaged by a moving vehicle.

E. EXHAUST VENT AND INTAKE AIR VENT

The heater is rated ANSI Z21.10.3 Category IV (pres sur i zed vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.

NOTE: The venting options described here (and further detailed in Venting, Part 8 in this manual) are the lone venting options approved for this water heater. Failure to vent the water h eater in accordance with the provided venting instructions will void the warranty.

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Vents must be properly supported. Heater intake and exhaust connections are not designed to carry Heater must be readily accessible for visual inspection for the first 3’ from the heater.

adequate freeze protection.

heavy weight. Vent support brackets must be within 1’ of the heater and the balance at 4’ intervals.

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Sid e Wall Venting, 2. Roof Venting, and 3. Unbalanced Venting.

Be sure to locate the heater such that the air intake and exhaust vent piping can be routed through the building and properly terminated. Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in Venting Section). The air intake and exhaust vent piping lengths, routi ng and termination methods must all comply with the methods and limits given in the Venting section, Part 8 of this manual.

When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. NOTE: To prevent combustion air contamination, see Table 1.

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE

This heater requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air

contamination, see Table 1.

Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply suffic ient com bus tio n air based on the app li anc e input. Never obstruct the supply of combustion air to the appl iance. If the appliance is installed in areas where indoor air is contaminated (see Table 1) it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance intake connection.

Unconfined space is space with volume greater than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space. See Figure 22, p. 40 for details.

Confined space is space with volume less than 50 cubic feet per 1,000 Btu/hour (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space, through openings not furnished with doors, are considered part of the space.

When drawing combustion air from inside a conventionally constructed building to a confined space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space floor. Each opening should have a free area of one square inch per 1,000 Btu/hr (22cm inches (645cm

/kW) of the total input of all appliances in the space, but not less than 100 square

If the confined space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section, Part 8 of this manual.

When drawing combustion air from the outside into the mechanical room, care must be taken to provide

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Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty, and may result in severe personal injury or death.

Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter contamination, see Table 1.

Ensure that the intake air will not contain any of the contaminants below. Contaminated air will damage

from laundry facilities. These areas always contain contaminants.

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops Adhesives used to fasten building products

Do not install the heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

NOTE: DAMAGE TO THE HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT

living space, which could result in severe personal injury or death. NOTE: To prevent combustion air

F. PREVENT COMBUSTION AIR CONTAMINATION

Install intake air piping for the heater as described in the Venting Section. Do not terminate exhaust in locations that can allow contamination of intake air.

COVERED BY WARRANTY. (Refer to the limited warranty for complete terms and conditions).

the heater, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air vent near a swimming pool. Also, avoid areas subject to exhaust fumes

Table 1 – Contaminant Table

G. REMOVING A HEATER FROM A COMMON VENT SYSTEM

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Chemical imbalance of your water can cause severe damage to your water heater and associated

warranty.

Figure 3 - CO Warning Label Figure 2

When removing an existing heater, follow the steps below.

1. Seal any unused openings in the common venting system.

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 doors between the space in which the appliance 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 in operation the appliance being inspected. 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 to conform to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the system should approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

H. WATER CHEMISTRY

equipment, and may also affect efficiency. You may have to have your water quality professionally analyzed to determine whether you need to install a water softener. Failure of a heat exchanger due to

lime scale build-up on the heating surface, low pH or other imbalance IS NOT covered by the

Water Hardness

Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water. The concentration of these salts is expressed in mg/L, ppm or grains per gallon, as a measure of relative hardness of water. Grains per gallon is the common reference measurement used in the U.S. water heater industry. Hardness expressed as mg/L or ppm may be divided by 17.1 to convert to grains per gallon. Water may be classified as very soft, slightly hard, moderately hard, or hard based on its hardness

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UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the plastic components come to room temperature.

number. The minerals in the water precipitate out when the water is heated and cause accelerated lime and scale accumulation on a heat transfer surface.

If the hardness of the water exceeds the maximum level of 25 grains per gallon, water should be softened to a hardness level no lower than 5 grains per gallon. Water softened as low as 0 to 1 grain per gallon may be under-saturated with respect to calcium carbonate, res u lting in water that is aggressive and corrosive.

pH of Water

pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water pH. The pH scale ranges from 0 to 14. Water with a pH of 7.0 is considered neutral. Water with a pH lower than 7 is considered acidic. Water pH higher than 7 is considered alkaline. A neutral pH (around 7) is desirable for most potable water applications. Corrosion damage and heater failures resulting from water pH levels of lower than 6 or higher than 8 ARE NOT covered by the warranty. The ideal pH range for water used in a storage tank or a water heater system is 7.2 to 7.8.

Total Dissolved Solids

Total Dissolved Solids (TDS) is a measurement of all minerals and solids dissolved in a water sample. The concentration of total dissolved solids is usually expressed in parts per million (ppm).

Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system. Most high TDS concentrations precipitate out of the water when heated. This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a water heater. This scale accumulation can also impede the ability of the heat exchanger to transfer heat into the water. A heat exchanger damaged or blocked by lime/scale accumulation must be replaced.

The manufacturer of the water heater has no control of water quality, especially TDS levels in your system. Total dissolved solids in excess of 2,000 ppm will accelerate lime and scale formation in the heat exchanger. Heat exchanger failure due to total dissolved solids in excess of 2,000 ppm is a nonwarrantable condition. Failure of a water heater due to lime scale build up on th e heating surface IS

NOT covered by the warranty.

PART 4 – PREPARE THE HEATER

Remove all sides of the shipping crate to allow the heater to be lifted into its installation location.

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components.

The heater control module uses temperature sensors to provide both high limit protection and modulating the tank. Some codes/jurisdictions may require additional external controls.

Never use dielectric unions or galvanized steel fittings when connecting to a stainless steel storage tank or heater. Use only copper or brass fittings. Teflon thread sealant must be used on all connections.

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120oF

More than 5 minutes

125oF

1 ½ to 2 minutes

130oF

About 30 seconds

135oF

About 10 seconds

140oF

Less than 5 seconds

145oF

Less than 3 seconds

150oF

About 1 ½ seconds

155oF

About 1 second

Table 2

PART 5 – HEATER PIPING

A. GENERAL PIPING INFORMATION

Use two wrenches when tightening water piping at heater. Use one wrench to prevent the heater return or supply line from turning. Failure to prevent piping connections from turning could cause damage to heater

temperature control. The control module also provides low water protection by sensing the water level in

B. SCALDING

This heater can deliver scalding water. Be careful whenever using hot water to avoid scalding injury. Certain appliances, such as dishwashers and automatic clothes washers may require increased water temperature. By setting the thermostat on this heater to obtain the increased water temperature required by these appliances, you may create the potential for scald injury.

To protect against injury, you should install a mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

Table 2 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

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To avoid water damage or scalding due to relief valve operation:

SEVERE PERSONAL INJURY, OR DEATH.

Do not thread a cap or plug into the relief valve under any circumstances! Explosion and property damage, serious injury, or death may result.

C. TEMPERATURE AND PRESSURE RELIEF VALVE

• Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375

• Do not pipe discharge to any location where freezing could occur.

• No shutoff valve may be installed between the relief valve and heater or in the discharge line. Do

not plug or place any obstruction in the discharge line.

• Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, immediately replace with a new properly rated relief valve.

• Test T&P valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the heater “off” and call a plumber immediately.

• Take care whenever operating relief valve to avoid scalding injury or propert y damage.

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE,

F or greater.

D. BACKFLOW PREVENTER

Use a backflow preventer specifically designed for water heater installations. This valve should be installed on the cold water fill supply line per local codes.

E. POTABLE EXPANSION TANK

A potable hot water expansion tank is required to offset heated water expansion. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent back flowing of water into city mains. Some local codes require back flow preventers on all incoming water supplies. The hot water expansion tank must be listed for potable water use. The expansion tank should be located on the cold inlet piping close to the water heater.

EXPANSION TANK AND MAKE-UP WATER

1. Ensure that the expansion tank is sized to correctly handle heater and system water volume and temperature.

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Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water FAILURE IS NOT COVERED BY WARRANTY.

The expansion tank must be suitable for hot potable water.

Never use dielectric unions or galvanized steel fittings on any domestic water or auxiliary connections. Use only copper or brass fittings. Thread sealant must be use d on all connections.

Never connect auxiliary connections to any system that uses glycol or other solutio n s formulated Failure to follow this warning could result in serious injury or death.

to be added. Eventual heater failure can result due to excessive make-up water addition. SUCH

2. The expansion tank must be located as shown in the Heater Piping Details, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

F. WATER PIPING

The domestic water connections must be installed in accordance to all local and national plumbing codes, or any applicable standard which prevails. The inlet and outlet ports are 1" on 55 gallon models, and 1 ½” on 80 and 119 gallon models.

On the cold inlet, install a 1" brass tee on 55 gallon models, or a 1 ½" tee on 80 and 119 gallon models. On the run of the 1" brass tee, install a 1" brass drain cock or equivalent with pipe sealant compound. In the branch of the 1" or a 1 ½" brass tee, install a copper male adapter to match your copper plumbing system. For convenience, you may install a sweat shut off valve and a union in the cold inlet piping to ease future servicing. If there is a back flow preventer or any type of a no return valve in the system, you must install an additional tee here, suitable for a potable hot water expansion tank.

In the hot outlet, install a suitable adapter to match the copper tubing of the plumbing system. A thermal trap or heat trap loop may be installed here to provide additional energy savings and prevent the thermal siphoning of domestic hot water.

G. AUXILIARY CONNECTIONS

The auxiliary connections are additional connections for air handlers, plate exchangers, or other devices that supply hot water. These connections must be installed in accordance with all local and national codes or any applicable standard that prevails. Auxiliary connections are 1" on all models. Never use dielectric unions or galvanized steel fittings. Use only copper or brass fittings. Sealant must be used on all connections. The top port is the supply outlet and the bottom port is the return inlet.

for hydronic systems. These auxil iary connections are to be used only in a potable water system.

Page 18

An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial property damage, serious injury, or death.

H. PIPING DIAGRAMS

Figure 4 – LP-179-L - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR. With air handlers, outdoor reset is available with a n outdoor sensor. See Part 9, Section D.

Page 19

An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial property damage, serious injury, or death.

PHOENIX WITH AIR HANDLER ON SIDE

Figure 5 – LP-179-M - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR. With air handlers, outdoor reset is available with an outdoor sensor. See Part 9, Section D.

Page 20

Figure 6 – LP-179-N - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR.

Page 21

Figure 7 – LP-179-U - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR.

Page 22

Figure 8 – LP-179-O - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR.

Page 23

An ASSE 1017 thermostatic mixing valve MUST be installed when using outdoor reset. Failure to do so could result in substantial property damage, serious injury, or death.

Figure 9 – LP-179-Z - NOTE: This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR. NOTE: For proper operation, it is important to pipe recirculation lines with thermostatic mixing valve as shown above.

Page 24

The standard Phoenix Water Heater does not meet the required temperature settings for sanitizer booster the booster must be supplied at 140oF.

applications. Use only the Phoenix Sanitizer Booster that delivers temperatures of 184oF. Inlet water to

PHOENIX SANITIZER BOOSTER INSTALLATION

p/n PH130-55SA / PH199-55SA

Figure 10 LP-179-SA - NOTE: In Massachusetts, you must install a vacuum relief valve per 248 CMR. For further energy savings, install the Phoenix Sanitizer Booster on the same electrical circuit as the dishwasher.

Page 25

Failure to follow all precautions could result in fire, explosion, severe injury or death!

It is of extreme importance that this unit be properly grounded. It is very important that the building system be turned on when the heater is completely filled with cold water.

PART 6 – ELECTRICAL CONNECTIONS

A. LINE VOLTAGE INPUT

The heater must be wired to a 120 volt circuit by a qualified electrician. It is recommended that the heater be wired on its own circuit to minimize the possibility of circuit failure due to outside causes. The heater requires a maximum of 8 amps at 120 volts in use.

B. LINE VOLTAGE CONDENSATE OUTPUT

The heater has the capability of supplying power to a condensate pump. The connection is 120 VAC +/10% at a max of 2 amps. Power is supplied to the pump only when the heater is connected to power, and the power switch is in the on position.

C. LOW VOLTAGE OUTDOOR SENSOR INPUT

The heater has the capability of an outdoor reset. Connecting an outdoor sensor allows the heater to operate at optimum efficiency. HTP offers an outdoor sensor, p/n 7250P-319

The outdoor sensor must be a 12K NTC sensor. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs up to 150 feet. Instructions are included with the outdoor sensor to correctly mount the sensor on the exterior surface of the building. It is preferable to mount the sensor on the north side in an area that will not be affected by direct sunlight but will be exposed to varying weather conditions. Connect the outdoor sensor to terminals marked “Outdoor”.

Figure 11 – LP-179-Y

ground is inspected by a qualified electrician prior to making this connection. Electrical power must only

PART 7 – GAS CONNE CTION S

Page 26

Nominal

(Inches)

.824

1.049

1 ¼

1.380

1,050

730

590

500

440

400

370

350

320

305

275

250

225

210

1 ½

1.610

Figure 12 LP-179-Q

The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 3.5" water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" WC 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.

Do not remove the adaptor in Figure 12! It is mandatory that this fitting is used for connection to a field fabricated drip leg per the National Fuel Gas Code. You must ensure that the entire gas line to the connection at the water heater is no smaller than ¾".

Once all inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum gas inlet pressure, you must isolate the heater from the gas line to continue leak testing. To do this, you must turn off the factory and field-installed gas cocks. This will

minimize the possibility of damaging the gas

valve. Failure to do so may damage the gas valve. In the event the gas valve is exposed to a pressure greater than ½ PSI, 14" water column, the gas valve must be replaced. Never use an open flame (match, lighter, etc.) to check gas connections.

A. GAS PIPING

Run the gas supply line in accordance with all applicable codes. Locate and install manual shutoff valves in accordance with local and state requirements.

B. GAS TABLE

Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit.

Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of .5 psi or less and a pressure drop of .3 inch water column.

Iron Pipe

Size

Table 3 – Source – ANSI Z223.1

Internal

Diameter

(Inches)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

278 190 152 130 115 105 96 90 84 79 72 64 59 55 520 350 285 245 215 195 180 170 160 150 130 120 110 100

1,600 1,100 890 760 670 610 560 530 490 460 410 380 350 320

Length of Pipe (Feet)

BTU’s

Per

Hour x

1,000

Page 27

Do not do a gas conversion on this water heater without an officially approved conversion kit and instructions supplied by HT P.

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 proper flow and length of pipe to avoid excessive 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. The gas pressure must remain between 3.5" WC and 14" WC during stand-by (static) mode and while in operating (dynamic) mode at full output.

If an in-line regulator is used, it must be a minimum of 10 feet from the heater. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to prope rly 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. The gas valve must not be replaced with a conventional gas valve under any circumstances. As an additional safety feature, the gas valve in this appliance has a flanged connection to the swirl plate and blower.

C. GAS VALVE

Figure 13 – Gas Valve LP-179-P

Page 28

Failure to provide a properly installed vent system will cause severe personal injury or death.

This vent system will operate with a positive pressure in the pipe. Do not connect vent connectors serving

damage, severe personal injury, or death.

APPROVED VENTING MATERIAL

Standards for Installation in:

United States

Canada

PVC schedule 40/80

ANSI/ASTM D1785

S636.

PVC-DWV

ANSI/ASTM D2665

PVC

ANSI/ASTM D2564

Cements & Primers

CPVC

ANSI/ASTM F493

Do not use Foam Core Pipe in any portion of the exhaust piping from this water heater. Use of Foam Core Pipe may result in substantial property damage, severe personal injury, or death.

PART 8 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL

The heater must be vented as detailed in this Venting Section. Ensure exhaust and intake piping complies with these instructions regar di ng vent syst em.

Inspect finished combustion air intake and exhaust piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements , as well as with the ins truc tions prov id ed in this manual.

A. GENERAL

appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure.

Follow the venting instructions below carefully. Failure to do so may result in substantial property

1. Install the water heater venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes.

2. This water heater is a direct vent appliance and is listed as a Category IV appliance with Underwriters Laboratories, Inc. VENT AND INTAKE AIR VENT.

B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS

Item Material

CPVC and PVC venting

must be ULC-S636

Vent or air pipe and

fittings

Pipe cement/primer

Table 4

CPVC schedule 40/80 ANSI/ASTM F441

Certified. IPEX is an

approved manufacturer in

Canada, supplying vent

material listed to ULC-

IPEX System 636

Page 29

C. EXHAUST AND INTAKE AIR VENT PIPE LOCATI ON

1. DETERMINE EXHAUST VENT LOCATION

a. The vent piping for this water heater is approved for zero clearance to combustible construction. b. See illustration within this section of clearances for location of exit terminals of direct-vent venting systems. c. This water heater vent system shall terminate at least 3 feet (0.9 m) above any forced air intake located within 10 ft (3 m). Note: this does not apply to the combustion air intake of a direct-vent appliance. d. Provide a minimum of 1 foot distance from any door, operable window, or gravity intake into any building. e. Provide a minimum of 1 foot clearance from the bottom of the exhaust above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. f. Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained. g. When adjacent to a public walkway, locate exit terminal at least 7 feet above grade. h. Do not locate the exhaust directly under roof overhangs to prevent icicles from forming. i. Provide 4 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs.

2. DETERMINE AIR INTAKE VENT LOCATION

a. Provide 1 foot clearance from the bottom of the intake air vent and the level of maximum snow accumulation. Snow removal may be necessary to maintain clearances. b. Do not locate intake air vent in a parking area where machinery may damage the pipe. c. When venting with a two pipe system, maximum distance between intake air vent and exhaust vent is 6 feet (1.8 m). Minimum distance between exhaust vent and intake air vent on single water heater is 10” (0.255 m) center-to-center. Minimum distance between exhaust vents and intake air vents on multiple water heaters is 10” (0.255 m) center-to-center.

Page 30

Figure 14 – Venting

D. EXHAUST AND INTAKE AIR VENT SIZING

1. The exhaust and intake vent size is 2" for the PH100 and PH130 and 3" for the PH160 and PH199.

2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet.

Page 31

FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS

EQUIVALENT FEET

2”

3”

4”

90 DEGREE ELBOW*

5’

3’

45 DEGREE ELBOW

3’

1’

COUPLING

0’

AIR INLET TEE

0’

STRAIGHT PIPE

1’

CONCENTRIC VENT

KIT

V500 2’ VENT KIT

1’

N/A

V1000 3’ VENT KIT

N/A

1’

V2000 4’ VENT KIT

N/A

1’

VENT CONNECTION

REDUCING COUPLING

VENT TRANSITION

2”

3” X 2”

3”

4” X 3”

4”

a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table below:

FITTINGS OR PIPING

3’ 3’ N/A

Table 5 - *Friction loss for long radius elbow is 1 foot less.

b. For example: If the exhaust vent has two 90° elbows and 10 feet of PVC pipe we will calculate: Exhaust Vent Pipe Equivalent Length = (2x5) + 10 = 20 feet. Further, if the intake air vent pipe has two 90° elbows, one 45° elbow and 10 feet of PVC pipe, the following calculation applies: Intake Air Vent Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. Finally, if a concentric vent kit is used we find: Total Combined Equivalent Length = 20 + 23 + 3 = 46 feet. Therefore, the total combined equivalent length is 46 feet which is well belo w the maximum of 85 feet. c. The intake air vent pipe and the exhaust vent are intended to penetrate the same wall or roof of the building. d. Effort should be made to keep a minimum difference in equivalent length between the intake air vent pipe and the exhaust vent.

3. The minimum combined equivalent length is 16 equivalent feet.

E. LONGER VENT RUNS

1. The maximum combined equivalent length can be extended by increasing the diameter of both exhaust vent and intake air vent pipe equally. However, the transitions should begin a minimum of 15 equivalent feet from the water heater.

a. The maximum equivalent length for increased diameter vent pipes is 125 feet. b. Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe.

Table 6 – Vent Run Transition

c. If the transition occurs at a distance greater than 15 equivalent feet from the water heater, the maximum equivalent length will be reduced.

Page 32

125

77-1/2

117-1/2

60-1/2

110-1/2

103

8-1/2

88-1/2

NONE

into living space.

DESCRIPTION

STOCK CODE

2” PVC CONCENTRIC VENT TERMINATION KIT

KGAVT0501CVT

3” PVC CONCENTRIC VENT TERMINATION KIT

KGAVT0601CVT

2” STAINLESS STEEL VENT TERMINATION KIT

V500

3” STAINLESS ST EEL VE N T TERMINATION KIT

V1000

4” STAINLESS STEEL VENT TERMINATION KIT

V2000

TRANSITION POINT (FT.

FROM WATER HEATER)

Table 7 – TEL = Total Equivalent Length *Oversized vent pipe diameter is 1” or greater than factory supplied connection.

TEL OF OVERSIZED VENT

PIPE (FT.)*

MAXIMUM TEL OF ALL VENT

PIPE (FT.)

F. EXHAUST VENT AND INTAKE AIR PIPE INSTALLAT ION

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products

1. Use only solid PVC or CPVC pipe. FOAM CORE PIPING IS NOT APPROVED.

2. Remove all burrs and debris from joints and fittings.

3. All joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe.

4. Horizontal lengths of exhaust vent must slope back towards the water heater not less than ¼" per foot to allow condensate to drain from the vent pipe.

5. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

6. Do not use the heater to support any piping.

7. A screened straight coupling is provided with the heater for use as an outside exhaust termination.

8. A screened inlet air tee is provided with the heater to be used as an outside intake termination.

9. The following information on Table 5-8 lists optional intake air/exhaust vent terminations available from HTP.

Table 8

Page 33

G. VENTING DRAWINGS

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3. Unbalanced Venting.

When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. NOTE: To prevent combustion air contamination, see Table 1.

Figure 15 – LP-179-C - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

Page 34

Figure 16 – LP-179-D

NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all