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
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
2
3
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.
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
5
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
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
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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.
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.
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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
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
10
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
2
/kW) of the total input of all appliances in the space, but not less than 100 square
2
).
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
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).
12
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
13
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
14
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.
15
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.
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,
o
F or greater.
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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.
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
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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.
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