HTP PHE130-55, PHE130-80, PHE199-55, PHE199-80, PHE130-119 Installation Start-up Maintenance Parts

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Versa-Hydro

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

INSTALLATION

START-UP

MAINTENANCE

PARTS

Versa-Hydro Water Heater Models*

PHE130-55 / 199-55 PHE130-80 / 199-80

PHE130-119 / 199-119

“SNHX” indicates solar models without heat exchanger

*A suffix of “LP” denotes propane gas

“S” indicates solar models

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

avoided, may result in property damage.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the 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 entir e t y bef ore beginn ing 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 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

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 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.

National Fuel Gas Code

National Electrical Code

, ANSI Z223.1, from American Gas Association

, NFPA No. 70.

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TABLE OF CONTENTS

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

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

B. IMPROPER COMBUSTION.................................................................................................................. 8

C. GAS ....................................................................................................................................................... 8

D. WHEN SERVICING THE HEATER ...................................................................................................... 8

E. HEATER WATER .................................................................................................................................. 8

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

PART 3 – PREPARE WATER HEATER LOCATION ................................................................................ 10

A. BEFORE LOCATING THE HEATER .................................................................................................. 10

B. LEVELING ........................................................................................................................................... 10

C. CLEARANCES FOR SERVICE ACCESS .......................................................................................... 11

D. RESIDENTIAL GARAGE INSTALLATION ......................................................................................... 11

E. EXHAUST VENT AND INTAKE AIR VENT ........................................................................................ 11

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ....................................................... 12

2. INDOOR COMBUSTION AIR INSTALLATION IN C ONFINED OR UNCONFINED SPACE .......... 12

F. PREVENT COMBUSTION AIR CONTAMINATION ........................................................................... 13

G. REMOVING A HEATER FROM A COMMON VENT SYSTEM.......................................................... 13

H. WATER CHEMISTRY ......................................................................................................................... 14

PART 4: DOMESTIC WATER PIPING ....................................................................................................... 15

A. TEMPERATURE AND PRESSURE RELIEF VALVE FOR DHW ....................................................... 15

B. DOMESTIC HOT WATER EXPANSION TANK .................................................................................. 16

C. DOMESTIC WATER PIPING .............................................................................................................. 17

D. HEATER PIPING ................................................................................................................................ 17

E. MIXING VALVE INSTALLATION ........................................................................................................ 17

F. AUXILIARY PIPING ............................................................................................................................ 20

PART 5: HYDRONIC PIPING ..................................................................................................................... 20

A. HYDRONIC HEATING MODULE PIPING .......................................................................................... 20

B. PRESSURE RELIEF VALVE FOR THE HYDRONIC SYSTEM ......................................................... 21

C. HYDRONIC EXPANSION TANK AND MAKE UP WATER ................................................................ 21

D. HYDRONIC HEATING MODULE SYSTEM PIPING .......................................................................... 21

E. HYDRONIC HEATING MODULE OUTPUT ........................................................................................ 22

F. HYDRONIC PIPING ............................................................................................................................ 25

PART 6: FIELD WIRING ............................................................................................................................ 30

A. FIELD WIRING COMPLIANCE REQUIREMENTS ............................................................................ 30

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B. FIELD WIRING .................................................................................................................................... 30

C. LINE VOLTAGE WIRING.................................................................................................................... 30

D. LOW VOLTAGE WIRING ................................................................................................................... 30

E. FIELD CONNECTION BOARD ........................................................................................................... 31

F. INTERNAL WIRING ............................................................................................................................ 32

PART 7: GAS CONNECTION .................................................................................................................... 33

A. GAS SUPPLY ..................................................................................................................................... 33

B. GAS PIPING ....................................................................................................................................... 33

C. GAS TABLE ........................................................................................................................................ 34

D. GAS VALVE ........................................................................................................................................ 34

E. HOW TO VERIFY COMBUSTION ...................................................................................................... 35

PART 8: VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ............................................. 35

A. GENERAL ........................................................................................................................................... 36

B. APPROVED MATERIALS FOR EXHAUST AND INTAKE AIR VENTS ............................................. 36

C. EXHAUST AND INTAKE AIR VENT PIPE LOCATION ...................................................................... 36

1. DETERMINE EXHAUST VENT LOCATION.................................................................................... 36

2. DETERMINE AIR INTAKE VENT LOCATION ................................................................................ 37

D. EXHAUST AND INTAKE AIR VENT SIZING ...................................................................................... 39

E. LONGER VENT RUNS ....................................................................................................................... 39

F. EXHAUST AND INTAKE AIR VENT INSTALLATION ........................................................................ 40

G. VENTING DRAWINGS ....................................................................................................................... 41

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE ....................................................... 41

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE .......... 47

H. CONDENSATE REMOVAL SYSTEM ................................................................................................ 49

PART 9: CONTROL OVERVIEW ............................................................................................................... 50

A. NAVIGATION OF THE DISPLAY ....................................................................................................... 50

B. PROGRAMMING THE CONTROL ..................................................................................................... 50

C. APPLIANCE SETTING PROGRAM NAVIGATION MENU ................................................................ 51

D. PROGRAMMING THE SYSTEM SETTING ....................................................................................... 53

E. SYSTEM SETTING PROGRAM NAVIGATION .................................................................................. 53

F. CONTROL STATUS MENU ................................................................................................................ 56

PART 10: START-UP PROCEDURE ......................................................................................................... 59

A. FILL AND PURGE DHW ..................................................................................................................... 60

B. FILL AND PURGE HYDRONIC HEATING LOOP .............................................................................. 60

C. PURGE AIR FROM HYDRONIC HEATING MODULE ....................................................................... 61

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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.

D. HEATER PUMP CONTROL TO ASSIST IN PURGING AIR FROM SYSTEM LOOPS ..................... 61

E. PROGRAMMING THE TOTAL SYSTEM CONTROL ......................................................................... 61

PART 11: SHUTDOWN AND MAINTENANCE ......................................................................................... 64

A. SHUTDOWN PROCEDURE ............................................................................................................... 64

B. VACATION PROCEDURE .................................................................................................................. 65

C. MAINTENANCE .................................................................................................................................. 65

D. FAILURE TO OPERATE..................................................................................................................... 65

PART 12: TROUBLESHOOTING .............................................................................................................. 65

A. APPLIANCE ERROR CODE .............................................................................................................. 65

B. APPLIANCE ERROR .......................................................................................................................... 66

C. APPLIANCE FAULT ........................................................................................................................... 66

D. APPLIANCE CONTROL FAULT CODES ........................................................................................... 66

PART 13: MAINTENANCE ......................................................................................................................... 80

MAINTENANCE NOTES ............................................................................................................................ 83

HTP CUSTOMER INSTALLATION RECORD FORM ........................................................................ 84

PART 1 – GENERAL SAFETY IN FO RMATIO N

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. Do not install this appliance directly on carpeting. For installation on combustible flooring. Use only Category IV vent systems.

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

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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.

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, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external 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

The Versa Hydro with Total System Control is truly revolutionary, providing high efficiency central heating and domestic hot water from one appliance. Total System Control manages system needs, assuring maximum comfort and efficient operation. Some features of the heater are:

Stainless Steel Water Storage Tank

The storage tank is constructed of 316L stainless steel to provide maximum corrosion resistance. Water blown foam insulation and a plastic jacket provide superior insulation, allowing no more than a ½ degree heat loss per hour.

High Efficiency Heat Exchanger

The highly efficient 90/10 copper nickel heat exchanger provides direct energy transfer from the combustion gases into domes tic water . Hot gases travel from the primary circuit to heat the combustion walls, which then transfer heat directly into the water. The secondary circuit then transfers the last bit of

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energy to the bottom of the tank, where the hot gases are converted to water vapor, giving the heater a combustion efficiency of 98% and thermal efficiency of up to 96%.

Modulating Combustion System

The modulating combustion system is designed to regulate firing rate based on heat demand. Total System Control monitors tank operation, system parameters, and controls the firing rate of the burner, providing only the energ y required to satisfy both the domestic hot water and central heating needs.

Total System Control

Total System Control automatically manages the needs of both the central heating and domestic hot water systems through the use of sensors. These sensors monitor inputs (such as outdoor temperature, tank temperature, and heating module outlet temperature) providing data that allows accurate control of the entire system. You may choose to use the control’s factory default settings or reprogram the system parameters to provide design flexibility.

Hydronic Heating Module

The hydronic heating module connects to the storage tank through two dip tubes. The first dip tube draws heated water from the top of the storage tank and circulates it through a brazed plate heat exchanger that transfers the water’s stored energy to the hydronic side of the plate. Once the energy is transferred, the water returns through the second dip tube to a lower section of the storage tank to continue circulating. A stainless steel circulator pump modulates output, varying flow through the brazed plate heat exchanger to meet domestic hot water and central heating demand. An outlet sensor provides feedback to the control to assure accurate temperature control.

Venting System

This appliance vents in plastic pipe. Use only the approved venting material outlined in the venting section (Part 8) of this manual. Vent size can vary from 2” to 3” depending on the appliance input rate. The venting system requires an intake and exhaust vent. Speci al atte ntion should be taken when selecting vent location. Vents can run horizontally or vertically, depending on system design. Support the vents as shown in the Venting Details Part 8.

Burner

The burner is constructed of high grade stainless steel and uses pre-mixed air and gas to provide a wide range of firing rates.

Condensate Drain Connection

This is a condensing high efficiency appliance, and therefore has a condensate removal system. Condensate is nothing more than water vapor derived from combustion products. Heater condensate is similar to that of an automobile when it is initially started.

It is very important that the condensate line slopes away from the heater, down to a suitable drain. If the condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200, available from HTP).

A condensate filter, if required by local authorities, will neutralize the condensate, and can be made up of lime crystals, marble or phosphate chips. This filter can be purchased from HTP (p/n 7450P-212) and installed in the field.

It is also very important that the condensate line not be exposed to freezing temperatures or any other type of blockage. Plastic pipe must be the only material used for condensate line. Steel, brass, copper, or other materials will be subject to corrosion or deterioration.

In a long, horizontal condensate line, a second vent may be necessary to prevent vacuum lock. Also, an increase in pipe size and support of the condensation line may be necessary to allow condensate to drain properly.

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

valves are available.

substantial property damage, severe personal injury, or death.

heater must be level. Location must also fully support the weight of the filled water heater.

Spark Ignition

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

Outdoor Sensor

The outdoor sensor monitors outdoor temperature and adjusts the set point to provide greater efficiency.

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 location, many factors need to be addressed. Piping, Venting, and Condensation 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.

Failure to keep heater area clear and free of combustible materials, liquids, and vapors can result in

The heater gas control system components must be protected from dripping or spraying 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

In order for the condensate to properly flow out of the collection system, the area where you locate the

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A water heater pan must be installed to protect the surrounding area from damage caused by leaking water.

The space must be provided with combustion/ventilation air openings correctly sized for all other result in substantial property damage, severe personal injury, or death.

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

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.

C. CLEARANCES FOR SERVICE ACCESS

Figure 1 - If you do not provide the minim um clear an ces shown above, it might not be possible to service the heater without removing it from the space.

appliances located in the same space as the heater. Failure to comply with the above warnings could

D. RESIDENTIAL GARAGE INSTALL AT IO N

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, be certain to fully support its entire f illed wei ght.

• 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 (pressurized vent, likely to form condensate in the ve nt) 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 appro ved fo r this water heater. Failure to vent the water heater in accordance with the provided venting instructions will void the warranty.

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

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

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.

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.

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 sufficient combustion air based on the appliance 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 25, p. 48 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.

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Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter

contamination, see Table 1.

You must pipe outside air to the heater air intake. Ensure that the intake air will not contain any of the

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 CONTAM INATION

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.

contaminants below. Contaminated air will damage 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 from laundry facilities. These areas always contain

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

Table 1 – Contaminant Table

G. REMOVING A HEATER FROM A COMMON VENT SYSTEM

When removing an existing heater, follow the steps below.

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

heating surface, low pH or other imbalance IS NOT covered by the warranty.

Figure 2

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. It is important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the heater, as water quality will affect the reliability of the system.

Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years. Failure of a heat exchanger due to lime scale build-up on 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

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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 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 7 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, resu lti ng 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 warran ty. 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. T his 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 o n th e heating surface IS

NOT covered by the warranty. Hardness: 7 grains

Chloride levels: 100 pH levels: 6-8 TDS: 2000

PART 4: DOMESTIC WATER PIPING

A. TEMPERATURE AND PRESSURE RELIEF VALVE F OR DHW

Install a temperature and pressure relief valve into the marked port (upper right). We recommend a WATTS 40XL5 valve or equivalent for 130,000 BTU models or above input. The valve must meet the ANSI Z21.22B requirements for relief valves for hot water heaters as per a nationally recognized lab that maintains a periodic inspection of production of such listed safety device. The pressure rating of the valve must not exceed the listed working pressure of this appliance, and must be rated to the proper BTU/hr capacity of the water heater.

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

SEVERE PERSONAL INJURY, OR DEATH.

Do not, under any circumstances, thread a cap or plug into the relief valve! Explosion, serious injury or death may result. Relief valve piping must be directed to the floor or an open drain, but not connected.

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 used on all connections.

• 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

F or greater.

• 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 property damage.

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

There must be a 6" space between the outlet of relief valve piping and drain or floor. Do not hook up to drain system directly without an air space. The relief valve must be checked periodically for proper operation.

B. DOMESTIC HOT WATER EXPANSION TANK

A potable hot water expansion tank is required to offset the expansion as the water is heated. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent water flowing back 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.

Page 17

reduce the risk of scalding. This mixing valve only reduces the risk of scalding injury.

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

C. DOMESTIC WATER PIPING

Domestic water connections must be installed in accordance with all local and national plumbing codes or any applicable prevailing standards. The appliance is supplied with a rated mixing valve certified to ASSE

1017. You must completely follow the instructions included with the mixing valve for proper installation. This mixing valve must be installed on the domestic outlet to assure that hot water temperature does not vary more than +/– 5°F, as the unit adjusts its stored water automatic set point to meet the requirements of the hydronic heating module. The valve MUST NOT be allowed to freeze. If the mixing valve is installed in a potentially freezing situation, suitable insulation must be fitted to prevent damage. DO NOT use excess thread sealant (in liquid, tape or other form) as this may cause the mixing valve to fail. Toxic chemicals shall not be introduced into the mixing valve system.

Recommend to the user that the mixing valve be checked annually to ensure its continued function.

D. HEATER PIPING

The domestic inlet and outlet ports on the heater are 1” NPT connections. We recommend the installation of shut-off valves and unions on both the inlet and outlet ports to isolate the appliance for future service.

It is important that the connections on the inlet and outlet are brass or copper. Never use dielectric unions or galvanized steel fittings. Teflon thread sealant must be used to seal all tank connections. An approved ASSE 1017 mixing valve is provided with ev er y appliance and must be installed on the outlet to protect the user from scalding temperatures. This valve reduces the point of discharge temperature by mixing the hot and cold water from the discharge outlet or mixed outlet port. This device alone will not protect the user from scalding temperature. To install and set up the mixing valve, follow the pre-installation steps in this manual and also follow the enclosed instructions included with the mixing valve.

E. MIXING VALV E INSTALLATION

The mixing valve provided with this appliance must be installed on the hot water outlet connection to

1. All installations must be carried out by licensed professionals.

2. The installer must ensure compatibility of all installations. Example: Temperature of hot water – marked “H”, cold water inlet – marked “C”, and mixed outlet – marked with directional arrow.

3. The mixing valve may be installed in any position.

Page 18

Hotter water increases the risk of scald injury. Scalding may occur within 5 seconds at a setting of

manual before setting temperature at water heater. Feel water before bathing or showering!

container. DO NOT OPERATE THIS WATER HEATER WITHOUT AN ASSE APPROVED

4. Local codes shall take priority over any inconsistency in these instructions.

5. During startup, you must ensure that the valve is set to the desired temperature (the mixing valve preset is 120

F). If the valve temperature needs to be adjusted, please refer to the mixing valve

instructions and/or the following settings.

140oF (60oC). Water temperature over 125oF can instantly cause severe burns, or death, from scalds. Children, disabled, and elderly are at the highest risk of being scalded. See instruction

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot wat er t o a voi d s cal din g inj ur y. By setting the thermostat on this water hea ter to obtain increased water tem perature, you may create a h igher potential f or scald injur y. To protect aga inst injur y, you should install an A S SE appro ve d ther mostatic mixing valv e (a de vice to limit the temperatur e of wat er to protect against scal ed injur y by mixing hot and cold wat er suppl y) in the syst em. This valve will red uce point of discharge temperature in branch supply lines. This water heater was shipped with an ASSE approved thermostatic mixing valve. Install this valve according to the directions in the mixing device

THERMOSTATIC MIXING DEVICE. If this water heater was shipped without an ASSE approved thermostatic mixing valve, contact the manufacturer.

Mixing Valve Specification

Max. Hot Water Inlet Temperature 210 Min. Cold Water Inlet Temperature 39

F Inlet Pressure 200 PSI Outlet Water Temperature Range 85 Min. Temperature Differential 20

F – 150oF

F (Between Hot Supply and Outlet)

Performance – CV – ½” 3.3 Max Flow – 1” 24 gpm

The mixing valve maintains a constant outlet temperature of +/– 5˚ F given limited variation of water inlet temperature and pressure.

NOTE: At low flow operation, the outlet temperature may vary slightly more. Differential pressure at the valve inlet should be within a 5 to 1 ratio under normal flow conditions.

Inline fittings, pipe work, layout and sizing must be taken into consideration. In installations where the valve is supplied with unbalanced hot cold pressures greater than a 5 to 1 ratio, please call HTP Technical Support Department.

Page 19

The mixing valve is certified to ASSE 1017. It is not to be used to provide anti-scald service resulting from temperature controls are required.

Do not solder unions while attached to th e valve body. Solder connections prior to conne cting unions to the valve body to avoid damaging th e valve and its function.

system pressure fluctuations, and should not be used where more sophisticated compensating

Installation of the Mixing Valve

1. Flush all pipe work thoroughly (with water only) before installing the mixing valve.

2. The mixing valve comes complete with union type connections for ease of installation and service.

3. The mixing valve must be removed from the pipe work prior to soldering the end connections. It is recommended to use a spacer piece while soldering.

Setting the Mixing Valve Outlet Temperature

1. Remove the green knob by inserting a small screw driver in the notch and gently prying up as shown in Fig. 3-1.

2. Set the mixing valve after the tank has heated to its set point. To set the valve, disconnect the outdoor sensor from the control so the domestic hot water will reach its set point temperature (default setting is 160°F). Once domestic hot water has reached its set point, turn both the hot and cold water supplies on. Open an outlet, preferably a sink or basin faucet rather than a shower. To calibrate, let water run for 2 minutes and measure the outlet temperature with a thermometer. Using the groove on the top of the cover provided to fit over adjustment nut, adjust the knob counter clockwise to increase temperature and clockwise to decrease temperature, as shown in Fig. 3-2.

Figure 3 – 1 and 2

3. Once the desired outlet temperature has been achieved, refit the green top so that it snaps onto the body of the mixing valve.

4. Re-connect the outdoor sensor.

MIXING VALVE MAINTENANCE AND SERVICE

• It is recommended to check the mixing valve annually to ensure proper system capabilities. More frequent checks are recommended in adverse water conditions.

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Never connect auxiliary connections to any system that uses glycol or other solutions formulated for follow this warning could result in death or serious injury.

Figure 4

• When checking the mixed water supply temperature, use the same faucet used in the initial installation temperature adj us tment.

• There may be some variation in the water temperature from the mixing valve due to seasonal temperature variations in the cold water supply.

If the water supply is of poor quali ty, the internal components may jam, requiring an additional filter or strainer to be fitted to the system. Contact a plumbing professional for appropriate materials and installation.

F. AUXILIARY PIPING

Auxiliary connections are provided to connect to an air handler, plate exchanger or other additional devices. Auxiliary ports can also be used for recirculation line connections. These connections must be installed in accordance with all local and national codes or any applicable prevailing standards. Auxiliary connections are 1” on all models. Never use dielectric unions or galvanized steel fittings. Use only copper or brass fittings. Teflon sealant must be used on all connections. The top port has a dip tube that draws hot water from the dome of the unit and the bottom port dip tube returns the water to bottom of the unit.

hydronic systems. These auxiliary connections are to be used only in a potable water system. Failure to

PART 5: HYDRONIC PIPING

A. HYDRONIC HEATING MODULE PIPING

The hydronic heating module comes pre-plumbed and connected directly to the storage tank. The heated water inside the tank will be circulated through one side of the brazed plate heat exchanger while the heating system water flows through the other side. The heating system piping is connected to the return and supply pipes located on the top of the hydronic heating module (see Figure 4). Piping of the module to the system is not complex and does not require any of the primary or secondary piping normally used on high efficiency low mass boilers.

Page 21

B. PRESSURE RELIEF VALVE FOR THE HYDRONIC SYSTEM

The pressure relief valve supplied with the heater is designed to relieve pressure greater than 30 psi. The hydronic heating module is designed to withstand pressure up to 150 psi. If you are changing the pressure relief valve for a higher pressure rating, you must make sure that the system components are designed for the higher pressure. The relief valve must be rated for the 135,000 Btu maximum capacity of the brazed plate heat exchanger. Pipe the discharge line in copper piping to a drain. Provide 6” clearance from the floor drain.

C. HYDRONIC EXPANSION TANK AND MAKE UP WATER

Ensure that the expansion tank is sized to the system volume, brazed plate capacity, and related piping for the hydronic heating module. The capacity of the module and brazed plate is ½ gallon. Most chilled water systems are piped using a closed type expansion tank.

Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator. The hydronic heating module has a water line connection of ½” NPT to connect into the pressure reducing valve and back flow preventer. Normal system pressure is 15 psi.

D. HYDRONIC HEATING MODULE SYSTEM PIPING

The hydronic heating module is designed to function in a closed loop hydronic system. The included temperature and pressure gauge allows the user to monitor the system pressure and temperature from the hydronic heating module. The gauge should be installed on the supply outlet piping from the heating module. The installation of an air elimination device will remove air from the system which is necessary to avoid an air lock in the central heating circulator. It is recommended that all the piping is insulated to improve on the system’s overall efficiency. In the system piping, heating coils in air handler, flow control valves, or other devices must be installed to prevent gravity circulation of heated water from the heating module.

Freeze protection for new or existing systems must be composed of glycol that is specifically formulated to include inhibitors that will prevent the glycol from attacking the metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level. The system should be tested at least once a year or as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping. Example: 50% by volume glycol solution expands 4.8% in volume for the temperature increase from 32oF to 180oF, while water expands 3% with the same temperature rise.

Listed below are the basic steps that will help guide you through the ins ta llat ion of the hydronic heating module to the system piping.

1. Connect the system return marked “Return”.

2. Connect the system supply marked “Supply”.

3. Install a balance and purge valve (or shut off drain valve) on the system return to purge air out of the zone at start-up.

4. Install a back flow preventer on the cold feed make–up water line.

5. Install a pressure reducing valve on the cold feed make up water line (15 psi operating pressure). Check temperature and pressure gauge when operating. It should read minimum pressure of 15 psi.

Page 22

Never block the outlet of the safety relief valve.

6. Install the system circulator as shown in the piping details in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the expansion tank manufacturer’s instructions for specific information related to expansion for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of system to blow out the system if needed. NOTE: The hydronic heating module cannot be drained completely of water without purging the unit with an air pressure greater than 15 psi but not exceeding 40 psi. If winterizing the unit it is recommended, use glycol on the closed loop hydronic side only.

10. The relief valve is installed at the factory. A pipe discharge line should be installed to release 6” above a drain, so discharge will be visible when pressure is relieved. The pipe size must be the same size as the relief valve outlet.

E. HYDRONIC HEATING MODULE OUTPUT

Hydronic heating module output is based on the burner input and the flow rate supplied by the selected system circulator through the closed loop side of the brazed plate exchanger. Included in this section are graphs that will help you size the appropriate circulator and output needed to meet your system design requirements. Below is an example on the steps needed to determine the correct circulator for the system.

Example: System design requires 120,000 Btu at 20 Delta Step 1

Using the graphs, select the input rate of the heater. In this example, we would have to select a minimum input of 199K (the 130K max. output is 100,000 Btu, which falls below our operating point).

Step 2

Next, go to the chart for the 199K burner input and select the point of operation where the Btu and Delta T line intersect. Mark the point on the chart and go to bottom of the chart to determine flow rate needed to achieve the rated output from the module. This example is 12 GPM.

Step 3

Select the correct circulator to meet the flow and resistance requirements for the system design. To calculate this, you must determine the flow and resistance through the system and heating module. The heating module requires 12 GPM at 10 feet of head. The system requires 12 GPM at 5 feet of head. To select a circulator, add the resistance 10 feet of head (module) + 5 feet of head (system) at 12 GPM. This system requires a circulator that operates at a resistance of 15 feet at 12 GPM (See examples in Figure 5, Figure 6, and Figure 7).

Page 23

Figure 5

Figure 6

Page 24

Figure 7

Page 25

F. HYDRONIC PIPING

Figure 8

Page 26

Figure 9

Page 27

Figure 10

Page 28

Figure 11

Page 29

Figure 12

Page 30

ELECTRICAL SHOCK HAZARD – For your safety, to avoid possible electrical shock hazard, turn off so can result in severe personal injury or death.

NOTE: Wiring must be N.E.C. Class 1.

edition.

PART 6: FIELD WIRING

A. FIELD WIRING COMPLIANCE REQUI REMENTS

electrical power supply at service entrance panel before making any electrical connections. Failure to do

If original wiring as supplied with boiler must be replaced, use only TEW 105 Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest

INSTALLATION MUST COMPLY WITH:

1. National Electrical Code and any other national, state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

C wire or equivalent.

B. FIELD WIRING

All the wiring connections made to the heater in the field are done on the field connection board located on the right side of the cabinet. The cabinet has multiple knockouts available to route field wiring into and out of the field connection board. The control provides a pump output thermostat and outdoor sensor inputs to operate the central heating system.

C. LINE VOLTAGE WIRING

1. Connect the normal incoming power to the terminals marked as shown in Figure 14. A line volta ge fused disconnect switch may be required to be externally mounted and connected according to local codes and standards.

2. Connect the central heating pump as shown in the terminals marked CH/DHW PUMP (see Figure

14). The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts. If the pump requires more current or voltage than the 120 volts supplied, an external motor starter will be required.

3. Please not that the solar pump connectors on the field connection board are not functional at this time.

D. LOW VOLTAGE WIRING

1. Make all low voltage connections to the terminal strip located on the field connection board (shown in Figure 13) as outlined below.

2. The room thermostat should be connected to the terminals marked T STAT (shown in Figure 13). Alternately, any dry contact closure across these terminals will cause the unit to operate the hydronic heating module. NOTE: Caution must be used to ensure neither of the terminals becomes connected to ground. Mount the thermostat on an inside wall as central as possible to the area being heated, away from drafts or heat producing devices such as a television, which could influence the ability of the thermostat to measure room temperature accurately. NOTE: If the thermostat is equipped with a directly connected anticipator, the anticipator should be set at .1 amps. If the thermostat is connected to other

Page 31

devices, the anticipator should be set to match the power requirements of those connected devices. Refer to the instruction manuals of the connected devices for further information.

3. The outdoor sensor must be connected for the unit to operate at optimum efficiency. 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” in

Figure 13.

E. FIELD CONNECTION BOARD

Figure 13 – Hydronic heating module

Page 32

F. INTERNAL WIRING

Figure 14 – Internal connection diagram

Page 33

It is of extreme importance that this unit be properly grounded. Prior to making any electrical connections, that electrical power is only turned on when the unit is complete l y filled with co ld water.

Failure to follow all precautions in this section could result in fire, explosion, or death!

Failure to isolate gas line while leak testing may damage the gas valve. In the event the gas valve is an open flame (match, lighter, etc.) to check gas connections.

Figure 15

It is very important that the building system ground is inspected by a qualified electrician. Make certain

PART 7: GAS CONNECTION

A. GAS SUPPLY

The gas supply shall have a maximum inlet pressure of less than 14” water column (350 mm), ½ pound pressure (3.5 k{a), and a minimum of 3.5” water column (WC). As stated in the National Fuel Gas Code, the entire piping system, gas meter, and regulator must be sized properly to prevent pressure drop greater than .5” WC. This information is listed on the unit rating plate.

It is very important that you are connected to the type of gas noted on the rating plate: “LP” for liquefied petroleum, propane gas, or “Nat” for natural or city gas. Prior to turning the gas supply on, all gas connections must be approved by the local gas supplier or utility in addition to the governing authority. Do not remove the reducing

coupling attached to the gas valve! Per the National Fuel Gas Code, it is mandatory that this fitting be used for connecti o n to a field

fabricated drip leg as shown in the illustration at left.

Ensure that the entire gas line to the connection at the 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. In order to do this, you must turn off the factory and field-installed gas cocks. This will minimize the possibility of damaging the heater gas valve.

exposed to a pressure greater than ½ psi, 14” water column, the gas valve must be replaced. Never use

B. GAS PIPING

1. Run the gas supply line in accordance with all applicable codes.

2. Locate and install manual shutoff valves in accordance with state and local requirements.

Page 34

C. GAS TABLE

Refer to the following table to si ze 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” water column:

Table 3

It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. To avoid excessive pressure drop, the gas piping must be sized for the proper flow and length of pipe. Both the gas meter and regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1” WC, the meter, regulator, and/or gas line is undersized or needs service. By removing the cap, you can attach a manometer to the incoming gas drip leg. 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 installed 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

properly purge or size the lines will result in ignition failure. This problem is especially noticeable in

NEW LP installations and 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 service feature, the gas valve in this appliance has a flanged connection to the swirl plate and blower.

D. GAS VALVE

Figure 16 – LP-314-M

Page 35

Do not do a gas conversion on this unit without an officially approved conversion kit and instructions supplied by HTP. Failure to do so could result in serious injury or death.

COMBUSTION SETTINGS

HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS

Natural Gas

Propane LP

low

high

low

high

Carbon Monoxide (CO%)

0-10 ppm

0-20 ppm

0-10 ppm

0-20 ppm

Carbon Dioxide (CO2%)

8 ½ - 9 ½ %

9 ½ - 10 ½ %

FAN SPEEDS

BTU

IGNITION

MIN

MAX

130,000

3000

2000

6950

199,000

3000

2000

8500

The heater must be vented as detailed in this Venting Section. Ensure exhaust and intake piping

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

E. HOW TO VERIFY COMBUSTION

To activate service mode, press the up arrow ▲ and ENTER key together for 1 second. The unit will go through the ignition sequence. Press ▲ to increase, or ▼ to decrease fan speed.

To leave service mode, press ▲ and ▼ simultaneously.

Table 4

Table 5

PART 8: VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL

complies with these instructions regarding vent system. 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 instructions provided in this manual.

Page 36

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

CPVC and PVC venting

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 propert y dam age, s evere pers ona l injury, or death.

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

Vent or air pipe and

fittings

Pipe cement/primer

Table 6

CPVC schedule 40/80 ANSI/ASTM F441

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.

must be ULC-S636

Certified. IPEX is an

approved manufacturer in

Canada, supplying vent

material listed to ULC-

S636.

IPEX System 636

Page 37

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 38

Figure 17

Page 39

FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS

FITTINGS OR PIPING

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

3’

N/A

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”

D. EXHAUST AND INTAKE AIR VENT SIZING

1. The exhaust and intake vent size is 2” for the PHE130 and 3” for the PHE199.

2. The total combined equivalent length of exhaust and intake air vents should not exceed 85 ft. a. The equivalent length of elbows, tees, and other fittings are listen in the Friction Loss Table below.

Table 7 - *Friction loss for long radius elbow is 1’ less.

b. For example: If the exhaust vent has two 90o elbows and 10 ft of PVC pipe, we will calculate: Exhaust Vent Pipe Equivalent Length = (2x5) + 10 = 20 ft.

Further, if the intake air vent pipe has two 90o elbows, one 45o elbow, and 10 ft of PVC pipe, the following calculation applies: Intake Air Vent Pipe Equivalent Length = (2x5) + 3 + 10 = 23 ft. Therefore, the total combined equivalent length is 46 ft, which is well below the maximum of 85 ft. c. The intake air and exhaust vents 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 and exhaust vents.

3. The minimum combined equivale nt lengt h is 16 equivalent feet.

E. LONGER VENT RUNS

1. The maximum combined equivalent length can be extended by increasing the diameter of both the

exhaust and intake air vents equally. However, the transitions should begin a minimum of 15 equivalent feet from the water heater. a. The maximum equivalent length for the increased diameter vents is 125 ft.

b. To prevent condensate from pooling in the vent pipe, transitions should always be made in vertical sections.

Table 8

c. If the transition occurs at a distance greater than 15 equivalent feet from the water heater, the maximum equivalent length will be reduced. See Table 7.

Page 40

Transition Point (ft

from water heater)

TEL of Standard 2”

Vent Pipe (ft)

TEL of Oversized 2”,

3”, or 4” Vent Pipe (ft)

Maximum TEL of all

Vent Pipe (ft)

125

77-1/2

117-1/2

60-1/2

110-1/2

103

8-1/2

88-1/2

None

85 0 85

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space.

VENT TERMINATION KITS

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 Steel Vent Termination Kit

V1000

4” Stainless Steel Vent Termination Kit

V2000

Table 9 – TEL = Total Equivalent Length

F. EXHAUST AND INTAKE AIR VENT INSTALLATIO N

1. Use only solid PVC or CPVC pipe. FOAM CORE PIPING IS NOT APPROVED. Refer to Table 6 for

approved materials.

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 towards the water heater not less than ¼” per ft to allow

condensate to drain from the vent pipe. If the exhaust pipe must be piped around an obstacle that results in the creation of a low point, condensate will collect and form a blockage. This condensate must be drained away using a field-installed condensate drain assembly (see Figure 26).

5. All piping must be fully supported. Use pipe hangers at a minimum of 4 ft intervals to prevent sagging

of the pipe where condensate may form.

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

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

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

9. The following table lists optional intake air/exhaust vent terminations available from HTP.

Table 10

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G. VENTING DRAWINGS

1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE

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.

Figure 18 – LP-314-C - NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

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Figure 19 – LP-314-D

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