HTP PHP199-119, PHP199-119D, PHP260-130, PHP320-130, PHP399-130 Installation, Start-up, And Operating Instructions Manual

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Phoenix Plus

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, personal injury, or death.

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

This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual before installing. Perform steps in the order given. Failure to comply will result in substantial property damage, severe personal injury, or death.

INSTALLATION

START-UP

MAINTENANCE

PARTS

Phoenix Plus Water Heater Models*

PHP199-119 / PHP199-119D / PHP260-130

PHP320-130 / PHP399-130

*A suffix of “LP” denotes propane gas

*A suffix of “S” denotes solar model

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

The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

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 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 provided by a qualified installer,

service agency, or the gas supplier.

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

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

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

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

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

damage.

NOTICE

NOTICE is used to address practices not related to personal injury.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the Phoenix Gas-Fired 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 Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or others having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ.

NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

This water heater must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the heater, 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

Valley Road, Cleveland, OH 44131.

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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 edition.

TABLE OF CONTENTS

PART 1 – GENERAL SAFETY INFORMATION .......................................................................................................................... 6

A. PRECAUTIONS .......................................................................................................................................................................... 6

B. IMPROPER COMBUSTION ........................................................................................................................................................ 6

C. GAS ............................................................................................................................................................................................ 6

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

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

PART 2 – BEFORE YOU START ................................................................................................................................................ 7

A. WHAT’S IN THE BOX ................................................................................................................................................................. 7

B. HOW THE HEATER OPERATES ............................................................................................................................................... 7

C. OPTIONAL EQUIPMENT ........................................................................................................................................................... 8

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

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

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

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

D. EXHAUST VENT AND INTAKE PIPE ....................................................................................................................................... 11

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

2. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ................................................................................ 12

3. OUTDOOR INSTALLATION ............................................................................................................................................................................... 12

E. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 13

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

G. WATER CHEMISTRY ............................................................................................................................................................... 14

PART 4 – HEATER PIPING ....................................................................................................................................................... 16

A. GENERAL PIPING INFORMATION .......................................................................................................................................... 16

B. SCALDING ................................................................................................................................................................................ 17

C. TEMPERATURE AND PRESSURE RELIEF VALVE................................................................................................................ 17

D. BACKFLOW PREVENTER ....................................................................................................................................................... 17

E. POTABLE EXPANSION TANK ................................................................ ................................................................ ................. 17

F. WATER PIPING ........................................................................................................................................................................ 18

G. AUXILIARY CONNECTIONS ................................................................................................................................................... 18

H. PIPING DIAGRAMS .................................................................................................................................................................. 19

PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL............................................................................ 21

A. GENERAL ................................................................................................................................................................................. 21

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B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE .................................................................................... 22

C. REQUIREMENTS FOR INSTALLATION IN CANADA .............................................................................................................. 22

D. EXHAUST VENT AND INTAKE PIPE LOCATION.................................................................................................................... 23

E. EXHAUST VENT AND INTAKE PIPE SIZING .......................................................................................................................... 24

F. EXHAUST VENT AND INTAKE PIPE INSTALLATION ............................................................................................................. 24

G. VENTING DRAWINGS ............................................................................................................................................................. 26

1. INDOOR DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE .......................................................................................... 26

2. VENTING THROUGH AN EXISTING SYSTEM .................................................................................................................................................. 29

3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE ................................................................................ 31

4. OUTDOOR INSTALLATION ............................................................................................................................................................................... 33

H. CONDENSATE REMOVAL SYSTEM ....................................................................................................................................... 34

PART 6 – WIRING ..................................................................................................................................................................... 36

A. LINE VOLTAGE INPUT ............................................................................................................................................................ 36

B. LINE VOLTAGE CONDENSATE OUTPUT ............................................................................................................................... 36

C. INTERNAL WIRING DIAGRAM ................................................................................................................................................ 37

PART 7 – GAS CONNECTIONS ............................................................................................................................................... 40

A. GAS PIPING ............................................................................................................................................................................. 40

B. GAS TABLE .............................................................................................................................................................................. 40

C. GAS VALVE .............................................................................................................................................................................. 41

PART 8 – START-UP PROCEDURE ......................................................................................................................................... 42

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

B. OVERALL WATER HEATER AND CONTROL OPERATION ................................................................................................... 43

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

D. TEST MODE ............................................................................................................................................................................. 43

E. MAINTENANCE ........................................................................................................................................................................ 44

PART 9 – SHUTDOWN.............................................................................................................................................................. 44

A. SHUTDOWN PROCEDURE ..................................................................................................................................................... 44

B. VACATION PROCEDURE ........................................................................................................................................................ 44

C. FAILURE TO OPERATE ........................................................................................................................................................... 44

PART 10 – TROUBLESHOOTING ............................................................................................................................................ 45

A. ERROR CODE .......................................................................................................................................................................... 45

B. HEATER ERROR...................................................................................................................................................................... 45

C. LOCKOUT ................................................................................................................................................................................ 45

PART 11 - MAINTENANCE ....................................................................................................................................................... 51

MAINTENANCE NOTES ........................................................................................................................................................................................ 55

HTP CUSTOMER INSTALLATION RECORD FORM ............................................................................................................................................. 56

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This water heater has a condensate disposal system that may freeze if exposed to sustained temperatures below 32oF. Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions. Failure to take precautions could result in property damage, severe personal injury, or death.

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. Have this heater serviced/inspected by a qualified service technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE AND HAVE THIS HEATER SERVICED/INSPECTED ANNUALLY CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

If the heater is exposed to the following, do not operate until all corrective steps have been made by a qualified service technician:

1. FIRE

2. DAMAGE

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

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The water heater MUST BE replaced if it has been submerged. Attempting to operate a water heater that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged water heater could result in property damage, severe personal injury, or death. NOTE: Water heater damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Altering any HTP, Inc. water heater with parts not manufactured and/or approved by HTP, Inc. WILL INSTANTLY VOID the water heater warranty and could result in property damage, serious personal injury, or death.

This water heater has been designed to heat potable water ONLY. Using this water heater to heat non-potable fluid WILL VOID product warranty, and could result in property damage, personal injury, or death.

Do not obstruct the flow of combustion and ventilating air. Adequate air is necessary for safe operation. Failure to keep the exhaust vent and intake pipe clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

INDOOR INSTALLATION

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 water heater has been approved for closet installation, and installation on combustible flooring. Do not install this water heater directly on carpeting. Use only Category IV vent systems.

OUTDOOR INSTALLATION

Clearance to combustible materials: 0” top, bottom, sides and back. Special attention should be paid to ensure that T&P valve discharge and drainage from the condensate line will not adversely affect the surrounding area or pose a hazard in freezing conditions.

B. IMPROPER COMBUSTION

C. GAS

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

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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 – BEFORE YOU START

A. WHAT’S IN THE BOX

Also included with the heater:

 Temperature and Pressure Relief Valve  Brass Tee and Bushing  Installation Manual  Warranty  LP Conversion Kit (Natural Gas Models Only)

B. HOW THE HEATER OPERATES

Modulation Condensing Technology is an intelligent system that delivers highly efficient water heating, 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.

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Dual Modulating Combustion Systems

The water heater is provided with two independent combustion systems. Each combustion system has a separate control that modulates burner output based on measurements taken by water temperature sensors located within the upper and lower portions of the storage tank, efficiently regulating burner output to match system demand. These systems increase efficiency and allow 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 energy 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 water heater, and therefore has a condensate removal system. Condensate is nothing more than water vapor, derived from combustion products and similar to that produced by an automobile when it is initially started. It is very important that the condensate line slopes away from the water heater and down to a suitable 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 can be installed 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 materials 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 allow condensate to drain properly. Support of the condensate 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.

C. OPTIONAL EQUIPMENT

Below is a list of optional equipment available from HTP:

 3” Stainless Steel Outside Termination Vent Kit (V1000)  4” Stainless Steel Outside Termination Vent Kit (V2000)  3" PVC Concentric Vent Kit (Part # KGAVT0601CVT)  3” Polypro Vent Kit (Part # 8400P-001)  3” Polypro Pipe (33’ length Part # 8400P-002, 49.5’ length Part # 8400P-003)  PC Connection Kit (Part # 7250P-320)  Condensate Neutralizer (Part # 7450P-212)

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Carefully consider installation when determining heater location. Please read the entire manual before attempting installation. Failure to properly take factors such as heater venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

These heaters are design certified for outdoor installations. Heaters must not be installed under an overhang unless clearances are in accordance with local codes, the requirements of the gas supplier / utility, and the AHJ. Three sides must remain open in the area under the overhang. Roof water drainage must be diverted away from heaters installed under overhangs. Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the heater installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.

The water heater is heavy. Take precautions when moving the water heater into its installation location to avoid tipping, bumping, or dropping it. Failure to take such precautions may result in property damage, severe personal injury, or death.

Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty.

Figure 1 – Outdoor Installation Recommendations

PART 3 – PREPARE WATER HEATER LOCATION

A. BEFORE LOCATING THE HEATER

1. a. Indoor Installation Area (Mechanical Room) Operating Conditions

 Ensure ambient temperatures are higher than 32oF/0oC

and lower than 140oF/60oC.

 Prevent the air from becoming contaminated by the

products, places, and conditions listed in this manual, Part 3, Section F.

 Avoid continuously high levels of humidity  Never close existing ventilation openings  Ensure a minimum 1” clearance around hot water and

exhaust vent pipes

b. Outdoor Installation

 Heater must be placed in an area where the exhaust

plume will not be recirculated into the louver system located on the front access panel. Avoid fences or walls that extend above the exhaust vent termination. Pipe the exhaust vent so that it terminates level with or above the fence, wall, or enclosed area.

 Do not install heaters in locations where rain from

building runoff may spill onto the heater. Doing so could result in premature product failure. Such failures ARE NOT covered by warranty.

 Do not locate where sprinklers may spray directly onto

the heater cabinet and possibly into the louvers, which could damage the control system and internal components of the water heater. Such damages ARE NOT covered by warranty.

 Do not install directly on the ground, as the water heater

is heavy when filled with water. Install the heater level on a concrete pad, block, or pressure treated wood platform, designed to support the weight of the water heater and components when filled with water. The water heater must be properly supported and installed level in order to operate and drain condensate properly.

 Do not install the water heater under a deck or porch.

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When installing the heater outdoors, ensure the installation location is not near the exhaust or intake terminations of other gas-fired products – boilers, water heaters, furnaces, etc. Failure to do so could result in the recirculation of exhaust fumes. Exhaust recirculation could result in a hazardous condition and cause substantial property damage, severe personal injury, or death.

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. Failure to properly level the heater could result in improper heater operation, premature product failure, property damage, personal injury, or death.

All water heaters eventually leak. It is recommended to install a catch pan beneath the water heater. This catch pan should be sized

with a maximum depth of 2”, and a minimum diameter 2” greater than the diameter of the water heater. The catch pan should empty into an open drain line. This drain line should be ¾” ID minimum, piped to an open drain. Failure to follow these instructions could result

in property damage. Such damages ARE NOT covered by product warranty.

 Do not install the water heater in a well, stairwell, alcove, courtyard, or other recessed area.  Do not install the water heater on stack frames.  In areas where heater is exposed to sustained temperatures below 32oF, provisions must be made to protect the water heater,

condensate lines, and piping from freezing. The use of heat tape is recommended to avoid freezing. It is also recommended to

bush up the condensate line size to 1” and terminate condensate discharge as close to the unit as possible. Longer

condensate runs are more prone to freezing.

 Locate heater at least 10’ away from any forced air inlet. Maintain a clearance of at least 48” below or horizontal from any

window, door, walkway, or gravity air intake. Never place heater under a porch.

 In areas where it can get extremely hot (over 100oF), it is recommended to install the heater in an area that avoids direct

sunlight to keep the internal components cooler. Failure to follow this instruction could lead to premature heater failure. Such failures ARE NOT covered by warranty.

2. Check for nearby connections to:

 System water piping  Venting connections  Gas supply piping  Electrical power  Condensate drain

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

4. Gas control system components must be protected from dripping water during operation and service.

5. If the heater is to replace an existing heater, check for and correct any existing system problems, such as:

 System leaks  Location that could cause the system and heater to freeze and leak.  Incorrectly-sized expansion tank

6. Clean and flush system when reinstalling a heater. NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to

make note of the heater model and serial number.

B. LEVELING

C. CLEARANCES FOR SERVICE ACCESS

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The space must be provided with combustion/ventilation air openings correctly sized for all other water heaters located in the same space as the heater. The heater cover must be securely fastened to prevent the heater from drawing air from the heater room. This is particularly important if the heater is in a room with other water heaters. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

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

Do not attempt to vent this water heater 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 living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 1.

Figure 2 – Minimum Service Clearances

NOTE: If you do not provide the minimum clearances shown in Figure 2, it might not be possible to service the heater without removing

it from the space.

D. EXHAUST VENT AND INTAKE PIPE

The heater is rated ANSI Z21.10.3 Category IV (pressurized 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 the Venting section of this manual) are the lone venting options approved for this water heater. Failure to vent the water heater in accordance with the provided venting instructions WILL VOID the warranty.

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Vents must be properly supported. Heater exhaust and intake connections are not designed to carry heavy weight. Vent support

brackets must be within 1’ of the heater and the balance at 4’ intervals. Heater must be readily accessible for visual inspection for the first 3’ from the heater.

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

1. INDOOR DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the water heater intake, and exhaust vent 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 exhaust vent and intake 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 exhaust vent and intake piping lengths, routing and termination methods must all comply with the methods and limits given in the Venting section of this manual.

When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent

combustion air contamination, see Table 1 – Contaminant Table.

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 – Contaminant Table.

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 water heater input. Never obstruct the supply of combustion air to the water heater. If the water heater is installed in areas where indoor air is contaminated (see Table 1) it is imperative that the water heater be installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater 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.

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 (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2).

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 5 of this manual.

3. OUTDOOR INSTALLATION

This water heater is designed to draw combustion air through the louver system in the front of the heater cabinet. Before commissioning or starting a heater installed outdoors, the end cap must be removed so that the heater draws combustion air through the louvers. This combustion air also serves to cool the internal electronics when the heater is installed in very warm climates.

To prevent combustion air contamination or exhaust recirculation:

 Ensure the heater is located away from the building. Flue gas can cause damage to exterior walls and other devices.  Locate the heater at least 48” below or horizontally from any window, door, walkway, or gravity air intake.  Locate the heater 10’ away from any public area, outdoor sitting area, or forced air inlet.  Locate the heater away from areas that may change over time. Do not allow the growth of trees, shrubs, or plants to obstruct

proper operation of the exhaust vent system.

 If the heater is located in a fenced area, ensure the unit exhaust vent extends level with or above the top of the fence to

ensure flue gas does not get trapped and possibly recirculated into the louver system, which could contaminate the combustion air.

See Venting section for additional details.

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Do not attempt to vent this water heater 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.

Ensure that the intake air will not contain any of the 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 or install water heater outdoors near a swimming pool. Also, avoid areas subject to exhaust fumes 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 COVERED BY WARRANTY.

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

Figure 3 - CO Warning Label

E. PREVENT COMBUSTION AIR CONTAMINATION

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

Table 1 – Contaminant Table

F. REMOVING A HEATER FROM A COMMON VENT SYSTEM

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 water heater 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.

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Chemical imbalance of the water supply may affect efficiency and cause severe damage to the water heater and associated equipment. HTP recommends having water quality professionally analyzed to determine whether it is necessary 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 water heater, as water quality will affect the reliability of the system. Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty.

Operating temperatures above 135oF will further accelerate the build-up of lime scale on the heating surface and may shorten the service life of the water heater. Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty.

CLASSIFICATION

MG/L OR PPM

GRAINS/GAL

Soft

0 – 17.1

0 - 1

Slightly Hard

17.1 – 60

1 – 3.5

Moderately Hard

60 – 120

3.5 – 7.0

Hard

120 – 180

7.0 – 10.5

Very Hard

180 and over

10.5 and over

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.

G. WATER CHEMISTRY

Outlined below are water quality parameters which need to be met in order for the system to operate efficiently for many years.

Water Hardness

Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in water. The concentration of these salts is expressed in mg/L, ppm, or grains per gallon as a measure of relative water hardness. 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 number. The minerals in the water precipitate out as the water is heated and cause accelerated lime scale accumulation on a heat transfer surface. This lime scale build-up may result in premature failure of the heat exchanger. Operating temperatures above 135oF will further accelerate the build-up of lime scale on the heating surface and may shorten the service life of the water heater.

Water that is classified as hard and very hard must be softened to avoid heat exchanger failure. See below for further information about water hardness.

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, resulting 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.

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

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 non-warrantable condition. Failure of a water heater due to lime scale build up on the heating surface

IS NOT covered by the warranty. Hardness: 7 grains

Chloride levels: 100 ppm pH levels: 6-8 TDS: 2000 ppm Sodium: 20 mGL

Figure 4 – *ALL DIMENSIONS ARE APPROXIMATE – A SUFFIX OF “LP” DENOTES PROPANE GAS

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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.

PERFORMANCE SPECIFICATIONS FOR PHOENIX PLUS MODELS

MODEL

GALLON CAPACITY

BTU/HR INPUT

TEMPERATURE RISE IN DEGREES FAHRENHEIT

100

110

120

130

140

PHP199-119

PHP199-119D

119

199,000

GPH

579

463

386

331

289

257

232

211

193

178

165

GPM

9.6

7.7

6.4

5.5

4.8

4.3

3.9

3.5

3.2

3.0

2.8

PHP260-119

260,000

GPH

756

605

504

432

378

336

303

275

252

233

216

GPM

12.6

10.1

8.4

7.2

6.3

5.6

5.0

4.6

4.2

3.9

3.6

PHP320-119

320,000

GPH

931

745

621

532

465

414

372

339

310

286

266

GPM

15.5

12.4

10.3

8.9

7.8

6.9

6.2

5.6

5.2

4.8

4.4

PHP399-119

399,000

GPH

1161

929

774

663

580

516

464

422

387

357

332

GPM

19.3

15.5

12.9

11.1

9.7

8.6

7.7

7.0

6.4

6.0

5.5

Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death.

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 components.

DO NOT pipe this water heater with black iron, galvanized steel, steel, or lead pipe. Doing so will result in premature product failure and property damage, and WILL VOID the product warranty.

The heater control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module also provides low water protection by sensing the water level in 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.

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

Table 2 – Phoenix Plus Performance – 95% Thermal Efficiency Used for Calculations

PERFORMANCE EQUATIONS

Rated Input x .95

GPM = Temp Rise (oF) x 500 GPH = GPM x 60

PART 4 – HEATER PIPING

A. GENERAL PIPING INFORMATION

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Overheated water and high pressures can cause water tank explosion. A properly sized temperature and pressure relief valve must be installed in the opening provided on the water heater. Failure to install a properly sized temperature and pressure relief valve could result in explosion and property damage, serious injury, or death.

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

 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 375oF 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, 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.

Table 3

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

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 3 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.

C. TEMPERATURE AND PRESSURE RELIEF VALVE

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.

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Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual heater failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY.

The expansion tank must be suitable for hot potable water.

Pump motors should not be supported by any type of stand, due to possible misalignment of pump and motor. Failure to follow this instruction may result in property damage or personal injury.

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.

Never connect auxiliary connections to any system that uses glycol or other solutions formulated for hydronic systems. These auxiliary connections are to be used only in a potable water system. Failure to follow this warning could result in serious injury or death.

EXPANSION TANK AND MAKE-UP WATER

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

2. The expansion tank must be located as shown in the Piping Diagrams, 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 ½” for all models.

The water heaters are shipped with a brass drain valve located on the inside of the cabinet. The water heater is also equipped with a 1” auxiliary port that can be used as a recirculation line. The auxiliary port is located between the upper and lower combustion systems. When used, the recirculation line will increase overall heater efficiency.

If there is a backflow preventer or any type of no return valve installed in the plumbing system, you must install an additional tee on the cold feed line to connect to a potable 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 provided to improve efficiency via recirculation. 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.

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The piping will not support the weight of the water heater circulator pump. Refer to the pump manufacturer’s installation instructions to properly support the circulator pump. Failure to comply with these instructions could result in substantial property damage, severe personal injury, or death.

H. PIPING DIAGRAMS

Figure 5 – Reverse Manifold and Piping Diagram

NOTES:

1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required.

2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet.

3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator.

4. All circulators should have an integral flow check.

5. Check with air handler manufacturer for proper sizing.

6. This drawing is meant to demonstrate system piping only. The installer is responsible for all equipment and detailing required by local codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR. With air handlers, outdoor reset is available with an outdoor sensor. See Part 8, Section D.

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Figure 6 – Phoenix with Recirculation Line and Thermostatic Mixing Valve

NOTES:

1. Minimum pipe size should match unit connection size. Upsize pipe accordingly if greater flow is required.

2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet.

3. Gas line must be rated to the unit maximum input capacity. Unit must have 10 feet of pipe after gas regulator.

4. All circulators should have an integral flow check.

5. Drains and check valve between unit and storage tank will assist in purging air from system.

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The heater must be vented as detailed in this Venting Section. Ensure exhaust and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake 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. Failure to properly install the vent system will result in severe personal injury or death.

This heater is certified as a “Category IV” appliance, and requires a special venting system. The vent system will operate with a positive pressure in the pipe. Exhaust gases must be piped directly outdoors using the vent materials and rules outlined in these instructions. Do not connect vent connectors serving 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 will result in substantial property damage, severe personal injury, or death.

Exhaust vent and intake pipes are to be piped separately. This heater cannot share a common exhaust or intake with multiple appliances. Failure to follow this instruction will result in substantial property damage, severe personal injury, or death.

Improper seating of vent pipe gaskets can cause eventual gasket failure and exhaust gas leakage. Ensure the exhaust vent pipe is properly beveled and seated before insertion into the flue adapter. Failure to do so could result in property damage, severe personal injury, or death.

Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes. Vent assemblies should be allowed to cure for a period of at least 8 hours before powering a connected appliance. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death. It is the installers’ responsibility to understand the hazards associated with explosive solvents and take the necessary precautions to avoid these risks.

PART 5 – VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL

A. GENERAL

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

2. Install the 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.

3. This water heater must be vented with materials, components, and systems listed and approved for Category IV appliances.

NOTE: To avoid contamination often contained in indoor air, it is best to pipe all intake combustion air directly to the outdoors.

NOTE: If exhaust vent pipe system passes through an unheated space, such as an alcove or attic, the space must be heated or the pipe must be insulated. The insulation must have an R value sufficient to prevent freezing of the condensate.

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APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or Intake

pipe and fittings

PVC schedule 40/80

ANSI/ASTM D1785

PP, CPVC, and PVC venting must be

ULC-S636 Certified. IPEX is an

approved manufacturer in Canada,

supplying vent material listed to ULC-

S636.

PVC-DWV*

ANSI/ASTM D2665

CPVC schedule 40/80

ANSI/ASTM F441

Polypropylene

ULCS636

Stainless Steel AL29-4C

Certified for Category IV and direct vent appliance venting

Certified for Category IV and direct

vent appliance venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements & Primers

CPVC

ANSI/ASTM F493

 The exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the

approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID heater warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.  DO NOT use Foam Core Pipe in any portion of the exhaust piping from this water heater.  DO NOT connect PVC/CPVC to PP without an approved vent connector.  When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the heater vent connection, and at the termination

when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

 *PVC-DWV for air intake applications ONLY.  A double wall vent may be used when using stainless steel vent material in a freezing climate.  Contact the venting material manufacturer if there is any question about the applicability of the proposed venting material.

Failure to follow these directions will result in substantial property damage, severe personal injury, or death.

DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in Table 4. Failure to do so could result in property damage, severe personal injury, or death.

Exhaust vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the water heater as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this water heater and related components near high heat sources.

B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE

Table 4 – Approved Materials for Exhaust Vent and Intake Pipe

NOTE: The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent

the condensation of airborne moisture in the incoming combustion air.

C. REQUIREMENTS FOR INSTALLATION IN CANADA

1. Installations must be made with a vent pipe system certified to ULC-S636. IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. Additionally you may use AL29-4C stainless steel venting to comply with Canadian requirements.

2. The first three (3) feet of vent pipe from the water heater flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe / fittings. Cellular foam core piping may be used on air inlet piping only.

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You must not use “B” vent in an exhaust application. “B” vent is for intake applications ONLY. Using “B” vent in an exhaust application

will result in serious injury or death.

D. EXHAUST VENT AND INTAKE PIPE LOCATION

Figure 7 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 7 NOTES:

A. Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation

level. Snow removal may be necessary to maintain clearance.

B. Provide a minimum of 1 foot distance from exhaust vent termination to any door, operable window, or gravity intake into any building. C. Provide a minimum of 1 foot distance from exhaust vent termination to any permanently closed door or window. D. Provide a minimum of 4 feet vertical clearance from the exhaust vent to all roof overhangs. E. Locating exhaust vent termination near roof overhangs will result in the formation of icicles in freezing weather, and could result in

blockage of the exhaust vent. To prevent icicles from forming, maintain 4 feet vertical clearance from the exhaust vent to all roof overhangs. F. Provide 4 feet clearance from the outside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs. G. Provide 6 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs. H. Provide 4 feet clearance from center line within a height of 15 feet above electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets. I. 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.

J. 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. K. When venting with a two pipe system, maximum distance between exhaust vent and intake pipe is 6 feet (1.8 m). Minimum distance

between exhaust vent and intake pipe on single direct vented appliance is 10” (0.255 m) center-to-center. Minimum distance between exhaust vents and intake pipes on multiple water heaters is 10” (0.255 m) center-to-center. L. When adjacent to a public walkway, locate exit terminal at least 7 feet above grade.

In addition:

 Total length of vent piping shall not exceed the limits specified in this manual.  The vent piping for this direct vented appliance is approved for zero clearance to combustible construction.  The flue products coming from the exhaust vent will create a large plume when the water heater is in operation. Avoid venting

in areas that will affect neighboring buildings or be considered objectionable.

 DO NOT locate exhaust vent or intake pipe in a parking area where machinery may damage the pipe.  DO NOT locate the exhaust vent or intake pipe terminals under a porch, balcony, or veranda.  Avoid terminating exhaust vents near shrubs, air conditioners, or other objects that will obstruct the exhaust stream.  DO NOT vent over a public walkway. Condensate could drip or freeze and create a nuisance or hazard.

NOTE: Due to potential moisture build-up, sidewall venting may not be the preferred venting option. Carefully consider venting installation and location to save time and cost.

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The building owner is responsible for keeping the exhaust vent and intake pipe terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the heater could result in property damage, severe personal injury, or death.

For each floor containing bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms, as well as in the room that houses the heater. Detectors and alarms shall comply with NFPA 720 (latest edition). Failure to comply with requirements for detectors and alarms could result in property damage, severe personal injury, or death.

FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS

FITTINGS OR PIPING

EQUIVALENT FEET

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

N/A

V1000 3” VENT KIT

1’

V2000 4” VENT KIT

1’

Do not reduce the vent size on any model other than the PHP199-119. Doing so could result in water heater shutdown and property damage.

Do not exceed the maximum lengths for vent pipes. Excessive length could result in water heater shutdown and property damage.

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space. Failure to do so could result in property damage, severe personal injury, or death.

E. EXHAUST VENT AND INTAKE PIPE SIZING

1. The exhaust vent and intake pipe size is 4" for all PHP models.

2. The total equivalent length of exhaust vent and intake pipe should not exceed 200 feet. a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table, Table 5:

Table 5 - *Friction loss for long radius elbow is 1 foot less. NOTE: Consult Polypropylene venting instructions for friction loss and pressure drop equivalents.

b. For example: If the exhaust vent has two 90° elbows and 10 feet of PVC pipe we will calculate: Exhaust Vent Equivalent Length = (2x5) + 10 = 20 feet. Further, if the intake pipe has two 90° elbows, one 45° elbow and 10 feet of PVC pipe, the following calculation applies: Intake Pipe Equivalent Length = (2x5) + 3 + 10 = 23 feet. Finally, if a concentric vent kit is used we find: Total Equivalent Length = 20 + 23 + 3 = 46 feet. Therefore, the total equivalent length is 46 feet which is well below the maximum of 85 feet. c. The exhaust vent and intake pipe 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 exhaust vent and intake pipe. e. The vent size on the PHP 199-119 can also be reduced down to a 3” vent from a 4” vent in order to accommodate existing vent sizes. When reducing down to a 3” vent from a 4” vent on PHP199-119 models, the total length shall not exceed 100 equivalent feet. Vent reduction must begin at the heater.

3. The minimum total equivalent length is 16 feet.

F. EXHAUST VENT AND INTAKE PIPE INSTALLATION

NOTE: To ensure proper cooling and ventilation of components, do not block any air openings in the cabinet.

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NOTICE

When venting in an Indoor Installation: Remove cap installed outside the water heater cabinet from the air intake and leave the cap inside the water heater cabinet installed. When venting in an Outdoor Installation: Remove cap from the air intake inside the water heater and leave the cap outside the water heater installed. See Figure 8 for detail.

Failure to follow the above instructions will result in improper water heater operation, and could result in property damage, serious personal injury, or death.

DESCRIPTION

STOCK CODE

3” PVC CONCENTRIC VENT TERMINATION KIT

KGAVT0601CVT

3” STAINLESS STEEL VENT TERMINATION KIT

V1000

4” STAINLESS STEEL VENT TERMINATION KIT

V2000

3” POLYPRO VENT KIT

8400P-001

Figure 8 – Air Intake Instructions

1. Use only solid PVC, CPVC, or stainless steel pipe, or a

Polypropylene vent system approved for use with Category IV appliances.

FOAM CORE PIPING IS NOT APPROVED FOR EXHAUST VENT APPLICATIONS. Foam core piping may be used on air inlet piping only.

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

3. When using PVC or CPVC pipe, 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. NOTE: DO

NOT CEMENT POLYPROPYLENE PIPE.

4. Ensure the vent is located where it will not be exposed to

prevailing winds.

5. In all roof venting applications, exhaust discharge must point away

from the pitch of the roof.

6. To prevent water leakage, install adequate roof flashing where the

pipe enters the roof.

7. Do not locate vent over public walkways, driveways, or parking

lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.

8. Due to potential moisture build-up, sidewall venting may not be

the preferred venting option. To save time and cost, carefully consider venting installation and location.

9. Horizontal lengths of exhaust vent must slope back towards the

water heater not less than ¼" per foot to allow condensate to drain from the vent pipe.

10. The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.

11. In vacant chimney applications, install and seal a rain cap over existing chimney openings.

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

condensate may form.

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

14. It is recommended to install screens in outside vent terminations to prevent debris from entering the exhaust vent and intake pipes.

Table 6 lists optional exhaust/intake terminations available from HTP:

Table 6

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Take extra precaution to adequately support the weight of vent pipes terminating through the roof. Failure to properly support roof terminated vent piping could result in property damage, serious personal injury, or death due to flue gas leakage.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate. When placing support brackets on vent piping, the first bracket must be within 1 foot of the water heater and the balance at 4 foot intervals on the vent pipe. Heater venting must be readily accessible for visual inspection for the first three feet from the heater.

G. VENTING DRAWINGS

1. INDOOR DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE

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

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

Figure 9– Two Pipe Roof and Sidewall Venting with Tee (Intake) and Coupling (Exhaust) NOTE: 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 10 – Venting with Optional Kits (NOT INCLUDED WITH THE WATER HEATER) NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

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Figure 11 – 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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VENT / AIR INLET SIZE

MINIMUM EXISTING VENT / CHASE SIZE

3”

5”

4”

7”

Figure 12 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY.

NOTES:

A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]).

B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D. Minimum 12” between vents when installing multiple vents. E. 12” minimum beyond air intake.

2. VENTING THROUGH AN EXISTING SYSTEM

This heater may be vented through an existing unused vent system. The inner diameter of the existing vent system is utilized for the combustion air source. Two methods have been approved for such venting: Concentric Venting Through an Existing System and Venting as a Chase.

Table 7 – Minimum Existing Vent / Chase Sizing

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

Contractors must check state and local codes before installing through an existing vent opening. State and local codes always take precedence over manufacturer’s instructions. Failure to check state and local codes before installing through an existing opening could result in property damage and add significantly to installation costs.

If an existing venting system is converted for use with this heater, the installer must ensure that the existing venting system is clean and free from particulate contamination that could damage the heater. Failure to do so could result in property damage and heater failure. Such failure IS NOT covered under warranty.

The upper and lower vent terminations as well as all joints in the venting system must be properly sealed to ensure that all combustion air is drawn properly and exhaust does not leak from the system. Failure to properly seal the venting system will result in property damage, severe personal injury, or death.

CONCENTRIC VENTING THROUGH AN EXISTING SYSTEM NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional

concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.

Concentric venting through an existing system must run vertically through the roof. See Table 7 for proper minimum vent sizing. Use only the approved venting materials specified in Table 4 for piping the system. All instructions listed in Part 5 - Venting apply. See Figures 13-1 and 13-2 for venting demonstrations.

CHASE VENTING THROUGH AN EXISTING SYSTEM

When venting as a chase, follow all instructions included in Part 5 – Venting of this manual, as well as the previous Concentric Venting section. See Figure 13-3 for chase venting demonstration.

Figures 13 – 1, 13 – 2 Concentric Venting Through an Existing System, 13 – 3 Chase Venting Through an Existing System 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 14 – LP-325-X

3. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE

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 water heater input. Never obstruct the supply of combustion air to the water heater. If the water heater is installed in areas where indoor air is contaminated (see Figure 14) it is imperative that the water heater be installed as direct vent so that all combustion air is taken directly from the outdoors into the water heater intake connection.

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 of this manual. See Figure 15.

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Figure 15

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When drawing combustion air from the outdoors, care must be taken to provide adequate freeze protection. Failure to do so could result in property damage and premature product failure. Such damages and failures ARE NOT covered by product warranty.

4. OUTDOOR INSTALLATION

This water heater is designed to draw combustion air through the louver system in the front of the heater cabinet. Before a heater installed outdoors is started, the end cap must be removed so that the heater draws combustion air through the louvers. This combustion air also serves to cool the internal electronics when the heater is installed in very warm climates.

To prevent combustion air contamination or exhaust recirculation:

proper operation of the exhaust vent system.

 If the heater is located in a fenced area, ensure the unit exhaust extends level with or above the top of the fence to ensure flue

gas does not get trapped and possibly recirculated into the louver system, which could contaminate the combustion air.

Figure 16

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Figure 17

Figure 18

H. CONDENSATE REMOVAL SYSTEM

NOTE: Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of Massachusetts, condensate must be neutralized before entering a drain.

This condensing high efficiency water heater has a condensate removal system. Condensate is water vapor derived from combustion products, similar to that produced by an automobile when it is initially started. It is very important that the condensate line is sloped down away from the heater and to a suitable drain.

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The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the water heater tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for use with condensing heaters and furnaces. The condensate pump should have an overflow switch to prevent property damage from spillage. Condensate from the heater will be slightly acidic (pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes.

If the heater condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP). If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate. This can be installed in the field and purchased from HTP (p/n 7450P-212).

Figure 19 – Condensate Installation NOTES:

1. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a condensate hose greater than 5 feet in length is

used, increase the condensate line to a minimum of 1” ID and place a tee in the line after the condensate neutralizer to properly reduce vacuum lock in

the drain line.

2. PVC or CPVC pipe should be the only material used for condensate line. Steel, brass, copper, and other metals will be subject to corrosion or

deterioration.

3. A frozen condensate line could result in a blocked vent condition. It is very important to protect the condensate line from freezing temperatures or any

type of blockage. In installations that may encounter sustained freezing conditions, the use of heat tape is recommended to avoid freezing of the condensate line. It is also recommended to bush up the condensate line size to 1” and terminate condensate discharge as close to the unit as possible. Longer condensate runs are more prone to freezing. Damages due to frozen or blocked condensate lines ARE NOT covered by warranty.

4. Support of the condensate line may be necessary to avoid blockage of the condensate flow.

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Label all wires prior to disconnecting them when servicing the heater. Wiring errors can cause improper and dangerous operation. Failure to follow these instructions may result in property damage or personal injury.

To avoid electrical shock, turn off all power to the heater prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death. Such product failure IS NOT covered by warranty.

Jumping out control circuits or components WILL VOID product warranty, and can result in property damage, personal injury, or death.

It is of extreme importance that this unit be properly grounded. It is very important that the building system ground is inspected by a qualified electrician prior to making this connection. Electrical power must only be turned on when the heater is completely filled with cold water.

PART 6 – WIRING

A. LINE VOLTAGE INPUT

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

NOTE: The current draw listed on the rating plate does not include circulator current.

B. LINE VOLTAGE CONDENSATE OUTPUT

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

Figure 20 – Line Voltage Wiring

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C. INTERNAL WIRING DIAGRAM

Figure 21 – Stage 1 Wiring Diagram

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Figure 22 – Stage 2 Wiring Diagram – Not Applicable to 199kBTU Models

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LP-454 REV. 1.6.15

Figure 23 – LP-179-L

Page 40

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

Ensure the gas on which the water heater will operate is the same type specified on the rating plate. Failure to do so could result in water heater malfunction, property damage, serious personal injury, or death.

UL recognized fuel gas detectors are recommended in all enclosed propane and natural gas applications where there is a potential for an explosive mixture of fuel gas to accumulate. The installation of these detectors should be made in accordance with the detector manufacturer’s recommendations, and/or local laws. Failure to install fuel gas detectors in these applications could result in fire, explosion, property damage, severe personal injury, or death.

Support gas supply piping with hangers, not by the heater or its accessories. The heater gas valve and blower will not support the weight of the piping. Make sure the gas piping is protected from physical damage and freezing, where required. Failure to follow these instructions could result in gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.

Do not use Teflon tape on gas line pipe thread. Use a pipe compound rated for use with natural and propane gases. Apply sparingly on male pipe ends, leaving the two end threads bare. Failure to follow these instructions could result in gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.

Figure 24 – Gas Connection

PART 7 – GAS CONNECTIONS

The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 3.5" water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" WC as stated in the National Fuel Gas Code. This information is listed on the rating plate.

It is very important that you are connected to the type of gas as noted on the rating plate: "LP" for liquefied petroleum, propane gas, or "Nat" for natural or city gas. All gas connections must be approved by the local gas supplier or utility, in addition to the governing authority, prior to turning the gas supply on.

Do not remove the adaptor in Figure 24! It is mandatory that this fitting is used for connection to a field fabricated drip leg per the National Fuel Gas Code. You must ensure that the entire gas line to the connection at the water heater is no smaller than ¾".

Once all inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum gas inlet pressure, you must isolate the heater from the gas line to continue leak testing. To do this, you must turn off the factory and field-installed gas cocks. This will minimize the possibility of damaging the gas valve. Failure to do so may damage the gas valve. In the event the gas valve is exposed to a pressure greater than ½ PSI, 14" water column, the gas valve must be replaced. Never use an open flame (match, lighter, etc.) to check gas connections.

NOTE: A drip leg is installed inside the water heater. Local codes may require a visible drip leg installed outside of the water heater.

A. GAS PIPING

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

B. GAS TABLE

Refer to the table below to size the supply piping to minimize pressure drop between meter or regulator and unit. Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of .5 psi or less and a pressure drop of .3 inch water column.

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Nominal Iron

Pipe Size (In.)

Internal

Dia. (In.)

Length of Pipe (Feet)

BTU’s

Per Hour

1,000

100

125

150

175

200

.824

278

190

152

130

115

105

1.049

520

350

285

245

215

195

180

170

160

150

130

120

110

100

1 ¼

1.380

1,050

730

590

500

440

400

370

350

320

305

275

250

225

210

1 ½

1.610

1,600

1,100

890

760

670

610

560

530

490

460

410

380

350

320

Table 8 – Source – ANSI Z223.1

It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. The gas piping must be sized for proper flow and length of pipe to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1" WC, the meter, regulator or gas line is undersized or in need of service. You can attach a manometer to the incoming gas drip leg by removing the cap. The gas pressure must remain between 3.5" WC and 14" WC during stand-by (static) mode and while in operating (dynamic) mode at full output.

If an in-line regulator is used, it must be a minimum of 10 feet from the heater. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines or improper line sizing will result in ignition failure. This problem is especially noticeable in NEW LP

installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines. The gas valve must not be replaced with a conventional gas valve under any circumstances. As an additional safety feature, the gas valve in this water heater has a flanged connection to the swirl plate and blower.

C. GAS VALVE

Figure 25 – Gas Valve

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Do not do a gas conversion on this water heater without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the heater to fire on Natural or LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.

Strain on the gas valve and fittings may result in vibration, premature component failure and gas leakage, and result in fire, explosion, property damage, severe personal injury, or death.

Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO2 and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death.

FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This water heater does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

2. BEFORE OPERATING: smell all around the water heater area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any water heater.  Do not touch any electric switch; do not use any phone in your building.  Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers' instructions.  If you cannot reach your gas supplier, call the fire department.  Turn off gas shutoff valve (located outside of the water heater) so that the handle is crosswise to the gas pipe. If the handle will

not turn by hand, don't try to force or repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

4. Do not use this water heater if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control that has been damaged.

5. The water heater shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during water heater operation and service (circulator replacement, condensate trap, control replacement, etc.)

Failure to follow these instructions could result in property damage, serious personal injury, or death.

Ensure the water heater is full of water before firing the burner. Failure to do so will damage the heater. Such damage IS NOT covered by warranty, and could result in property damage, serious personal injury, or death.

PART 8 – START-UP PROCEDURE

If you smell gas, STOP. Follow listed safety instructions above. If you do not smell gas, follow the next steps.

1. Turn on all electric power to water heater. Make sure tank is full with cold water and purge all piping. To assure adequate purging,

open all hot water faucets.

A. OPERATING INSTRUCTIONS

2. Adjust the temperature set point to the desired level on both the upper and lower controls of the heater. To increase efficiency, it is

recommended to set the upper control temperature higher than that of the lower control. The factory default setting is 119oF. If changes are necessary, follow “Overall Water Heater and Control Operation” in this section.

3. If the water heater fails to start, refer to the Troubleshooting section in the back of this manual.

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Function

Value

|d1|

Actual temperature from upper tank sensor

|d2|

Actual temperature from lower sensor

|d3|

|0| (Not used)

|d4|

|308| (Not used)

|d5|

Outdoor sensor

|d6|

Actual fan speed multiplied by 10 (Example: If fan speed displayed is |410| RPM x 10 = 4100 actual fan speed)

|d7|

Actual ionization current read from flame rectification probe

|d8|

|0| (Not used)

|d9|

|1| (Not used)

|d10|

Actual status of bus communication |co| = connected, |nc| = not connected

|d11|

|32| (Not used)

|d12|

Power on hours in thousands (display will not read until 100 hrs.)

|d13|

Total water heating hours in thousands (display will not read until 100 hrs.)

|d14|

|0| (Not used)

|d15|

Passed ignition attempts in thousands

COMBUSTION SETTINGS ON ALL MODELS

Natural Gas

Propane LP

Fan Speed

Low

Ignition

High

Low

Ignition

High

Carbon Monoxide PPM

1 – 10

2 - 15

2 – 20

1 – 10

2 - 15

2 – 20

Carbon Dioxide (CO2)

8 - 10%

8 – 10%

8 - 10%

8 ½ - 10 ½%

9 - 11%

Ignition issues may result if Low Fire CO2 measures greater than .5% of the High Fire Measurement.

B. OVERALL WATER HEATER AND CONTROL OPERATION

These water heaters have two control systems: one to regulate the bottom combustion system, and one to regulate the top.* To adjust the temperature of stored water, press and hold {S3} for 2 seconds. The first item is: DU: Water Temperature Set Point –

factory set at 119°F. Adjust down by pressing {S1} to a temperature as low as 95°F. Adjust up as high as 160°F by pressing the {S2}. Press {S3} again to display DH, the differential which is factory set at 7°F and adjustable down to 1°F by pressing {S1} and up to 18°F by pressing {S2}. Note: Due to the highly advanced control on this water heater, which compensates for varying inlet water temperature, the actual differential temperature may vary slightly from your setting. Press {S3} again to display the factory default temperature measurement in Fahrenheit. Change the default to Celsius by pressing {S1}. When finished, press {S3} one final time to place unit back into operation. The control automatically re-starts if no key is pressed for 2 minutes.

To increase system efficiency, it is advised to set the top control at a higher temperature (for example, 125oF), and the bottom control at a lower temperature (110oF). This allows the water heater to stage the combustion system.*

*NOTE: PHP199-119 models have one combustion system, and one control system.

C. STATUS MENU

Installers are also able to check the current status of the heater parameters by pressing {S4} for 3 seconds. Once activated, the display will show |d1| alternating value of the actual upper supply tank temperature. Actual values are displayed for each function. To view the next value, simply press {S/4} to go to the next displayed value. Listed in Table 9 are the values which can be displayed. These values cannot be changed. To exit this menu, press {S3} to resume normal operation.

Table 9 – Status Menu

D. TEST MODE

This function is intended to simplify the gas valve adjustment if needed. Listed below are the recommended limits on each heater and the combustion settings. Automatic modulation does not take place when the controller is in Test mode, only temperature limitation based on the heater set point. The user will be allowed to increase or decrease the fan speed by pressing in either the {S1} or {S2} keys.

To activate the Test Mode simply press the {S2} and {S3} key together for 1 second. Once activated, you will see in the display {Ser} and the actual fan speed. The measurement of the combustion levels should always be taken at the highest and lowest fan speed. When in Test Mode, the heater’s limit will shut down the burner if temperature limit is exceeded. It is recommended to draw water out of the tank to lower temperature so tests can be performed.

After 10 minutes, Test Mode stops automatically. To exit Test Mode manually, press {S1} and {S2} key together for 1 second.

Table 10 – NOTE: Low Fire CO2 shall be Equal to or Less than .5% of the High Fire Measurement

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TOP AND BOTTOM FAN SPEEDS

TOTAL BTU

IGNITION

MIN

MAX

199,000*

3000

2000

9100

199,000 D Model

3000

2000

5700

260,000

3000

2000

7300

320,000

3000

2000

7450

399,000

3000

2000

9100

In unusually dirty or dusty conditions, care must be taken to keep water heater burner door in place. Failure to do so VOIDS WARRANTY!

Allowing the heater to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in heater failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

RESISTANCE TABLE FOR

SUPPLY TEMPERATURE

SENSOR

HIGH/LOW

TEMP.

SENSOR

TEMP. (oF)

RESISTANCE

(ohms)

32550

25340

19870

15700

12490

10000

8059

6535

104

5330

113

4372

122

3605

131

2989

140

2490

149

2084

158

1753

167

1481

176

1256

185

1070

194

915

202

786

212

667

Table 12

Table 11 - *Model has a single combustion system

E. MAINTENANCE

The control system requires no periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended. In dirty environments, such as construction sites, care must be taken to keep the water heater burner cover in place and drywall or saw dust away from water heater.

PART 9 – SHUTDOWN

A. SHUTDOWN PROCEDURE

If the burner is not operating, disconnect the electrical supply. If the burner is operating, lower the set point value to 70oF and wait for the burner to shut off. Continue

to wait for the combustion blower to stop, so all latent combustion gases are purged from the system. This should take a maximum of 40 to 90 seconds.

B. VACATION PROCEDURE

If there is danger of freezing, change the set point to 70oF. DO NOT turn off electrical power. If there is no danger of freezing, follow “Shutdown Procedure”.

C. FAILURE TO OPERATE

Should the burner fail to light, the control will perform two more ignition trials prior to entering a lockout state. Note that each subsequent ignition trial will not occur immediately. After a failed ignition trial, the blower must run for approximately 10 seconds to purge the system. Therefore, a time period of approximately 40 to 90 seconds will expire between each ignition trial.

If the burner lights during any one of these three ignition trails, normal operation will resume. If the burner lights, but goes off in about 4 seconds, check the polarity of the wiring. See electrical connection section.

If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout state indicates that a problem exists with the water heater, the controls, or the gas supply. Under such circumstances, a qualified service technician should be contacted immediately to properly service the water heater and correct the problem. If a technician is not available, depressing the {S4} button once will remove the lockout state so additional trials for ignition can be performed. The unit will try to re-light once every 6 minutes.

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When servicing or replacing any components of this water heater be certain that:

 The gas is off.  All electrical power is disconnected.

When servicing or replacing components that are in direct contact with heater water, be certain that:

 There is no pressure in the heater. Pull the release on the relief valve to relieve pressure in the heater.  Heater water is not hot.  The electrical power is off.

NOTE: Water heater damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

The water heater has wire function labels on all internal wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.

926 CONTROL BOARD ERROR CODES

CODE

DESCRIPTION

DURATION

CORRECTIVE ACTION

E131

Heater combustion air fan speed less than 70% of expected.

60 Sec.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

E14

Heater combustion air fan speed is more than 130% of expected.

60 Sec.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

LEO

Water Level in Tank is Low

Until Corrected

1. Be sure all air is bled from system.

2. Inspect low level switch and wiring for damage and repair if necessary.

FLU

Blocked Vent, Pressure Switch open, Condensate cup Full, Condensate Cup not present

Until Corrected

1. Check the flue vent to be sure it is not blocked or damaged.

2. Check the blocked vent pressure switch operation by applying a jumper. (If the switch is not functioning properly, replace it.

PART 10 – TROUBLESHOOTING

A. ERROR CODE

An error code may occur during installation of the heater. This condition may lead to a lock out condition of the controller, which will need to be manually reset by pressing the {S4} button. These following will help the installer correct the problem before going into a lock out condition, which will require a manual reset.

B. HEATER ERROR

1. When an error condition occurs the controller will display an error code on the display module.

2. These error codes and several suggested corrective actions are included in Table 13.

3. In the case of |E00|, |E13|, and |E14| this error, if uncorrected, will go into a fault condition as described in Paragraph C.

C. LOCKOUT

1. When a fault condition occurs the controller will illuminate the red “fault” indication light and display a fault code in the format

(Example: |F00|) on the display module.

2. Note the fault code and refer to Table 14 for an explanation of the fault code along with several suggestions for corrective actions.

3. Press the reset key to clear the fault and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of

the fault.

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LOU

24 Volt Low

Until Corrected

1. Check line voltage. Must be between 100 – 128 volts.

2. If available, connect a PC and, using HTP service software, check the 24v supply display in the lower left corner of the screen. The number displayed must be greater than 128 and should be greater than 250. Use this as a troubleshooting guide as you follow the steps below.

3. Remove 10 pin Molex connector from customer connection board. If LOU clears, the problem is with external sensor wiring. Examine external sensor wiring for shorts to ground, repairing as necessary. If LOU code is still present and the heater is so equipped, disconnect high gas pressure switch, then low gas pressure switch, then UL 353 low water cutoff in this order, one at a time, to see if LOU code clears. Replace faulty part. Check low voltage wire harness in heater for shorts to ground.

4. If LOU only occurs when burner tries to light, check gas valve for excessive current draw.

5. If LOU is present with the low voltage harness disconnected from the 926 control board, replace the 926 control board.

Table 13 – Control Board Error Codes

926 CONTROL BOARD FAULT CODES

CODE

DESCRIPTION

REMEDY

F00

High temperature switch limit

exceeded 194oF.

1. Try reset. If F00 repeats, create a demand for hot water. (DANGER: Use caution to prevent burn injury.) If water is above 194oF, test upper and lower temperature sensor with an ohmmeter. (Refer to resistance chart, this section.) Replace bad sensor. If water is below 194oF, test high temperature switch and wiring with ohmmeter. Switch should be closed at this point. If not, replace switch.

2. If unit did reset successfully, let the heater run and go into the status menu to check the upper and lower temperature sensor. If either reading displayed does not make sense, check appropriate sensor with ohmmeter. (Refer to resistance chart, this section.) Replace bad sensor. Do an OHMs reading on both sensors to check continuity.

F01

Vent temperature limit

exceeded.

1. Inspect all flue piping. If the flue is damaged or shows signs of overheating, repair or replace the flue parts as necessary before proceeding.

2. If the flue piping system is intact, not damaged and there is no sign of the flue overheating (such as discoloration or melting), push the red reset button on the flue switch

3. Be sure the heater is connected to a water supply and full of water.

4. Push the RESET button on the heater control panel. The water heater should light. If the water heater lights, proceed to step 5. If the water heater does not light and the display again begins to flash F01, inspect the wiring to the flue switch, repairing or replacing as necessary. If the wiring is intact, replace the flue switch, using care to mount the new flue switch in the same position and mounting holes as the old one. If the display flashes a code other than F01, follow the troubleshooting guide for that code.

5. Observe operation for 5 minutes. Place the probe of an exhaust analyzer into the flue system within 6 feet of the heater. The exhaust temperature should not rise above 190oF after several minutes of operation.

6. If the flue temperature is below 190oF and the heater again goes into lockout displaying F01, replace the flue switch, using care to mount the new flue switch in the same position and mounting holes as the old one. If the display flashes a code other than F01, follow the troubleshooting guide for that code.

7. If the flue temperature increases to over 190oF, consult HTP for further assistance.

F02

Interrupted or shorted upper

temperature sensor.

1. Check the electrical connection to the appropriate temperature sensor.

2. If connection is okay, replace bad sensor.

F03

Interrupted or shorted lower

temperature sensor.

F05

Upper temperature sensor

exceeds 194oF.

1. If water in tank is not greater than 194oF, check wiring. Repair if faulty.

2. If wiring is okay, check appropriate sensor with ohmmeter and compare to reading in resistance chart

above. If reading does not agree with water temperature, replace bad sensor.

F06

Lower temperature sensor

exceeds 194oF.

F09

No flame detected – Heater

will make three attempts at

ignition before the control goes

into this lockout condition. Will

reset in 1 hour.

1. Watch the igniter through the observation window provided.

2. If there is no spark, check the spark electrode for the proper ¼” gap.

3. Remove any corrosion from the spark electrode and flame rectifier probe.

4. If there is a spark but no flame, check the gas supply to the heater.

5. If there is a flame, check the flame sensor.

6. Check any flue blockage or condensate blocks.

F10

Loss of flame signal – The

heater will relight 4 times

before the control goes into

this lockout condition. Will

reset in 1 hour.

1. Monitor the gas pressure to the unit while in operation.

2. Assure that the flame is stable when lit.

3. Check to see if the green light on the display module is out while the heater is running.

4. If the green light doesn’t come on or goes off during operation check the flame signal on the status menu.

5. If the signal reads less than 1 microampere, clean the flame rectifier probe.

6. If the flame rectifier probe continues to read low, replace it.

F11F

False flame signal – The

heater will lock out if it senses

a flame signal when there

should be none present.

1. Turn the gas off to the unit at the service valve.

2. If the flame signal is still present replace the igniter.

3. If the flame signal is not present after turning off the gas supply, check the gas valve electrical connection.

4. If there is no power to the gas valve, remove the valve and check for obstruction in the valve seat or

replace the gas valve.

5. Turn the gas on at the service valve after corrective action is taken.

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F13

Combustion fan speed

incorrect – The heater will lock

out if it senses that the fan

speed is less than 70% of

expected rate for more than 60

seconds.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

Table 14 - NOTE: If you replace a part to remedy a fault, it is recommended that you cycle the unit at least three or four times to assure the fault has been resolved.

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LP-454 REV. 1.6.15

Figure 26 – LP-454-W

Page 49

Figure 27 – LP-454-Y

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LP-454 REV. 1.6.15

Figure 28 – LP-454-X

Page 51

In unusually dirty or dusty conditions, care must be taken to keep water heater cabinet door in place at all times. Failure to do so VOIDS WARRANTY!

Allowing the water heater to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in water heater failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.

Hydrogen gas can build up in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). When opening a hot water faucet in a system that has been out of use for a time, keep all ignition sources (electrical appliances, open flame, etc.) away from the faucet. If hydrogen is present, there will be a sound of air escaping as water begins to flow. Allow the water to run for a few minutes to dissipate built up hydrogen from the system. Failure to follow these instructions can result in property damage, personal injury, or death.

INSPECTION ACTIVITIES

DATE LAST COMPLETED

PIPING

1st YEAR

2nd YEAR

3rd YEAR

4th YEAR*

Near heater piping

Check heater and system piping for any sign of leakage; make sure they are properly supported.

Vent

Check condition of all vent pipes and joints. Ensure the vent piping terminations are free of obstructions and blockages.

Gas

Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.

SYSTEM

Visual

Do a full visual inspection of all system components.

Functional

Test all functions of the system (Heat, Safeties)

Temperatures

Verify safe settings on heater or Anti-Scald Valve

Temperatures

Verify programmed temperature settings

ELECTRICAL

Connections

Check wire connections. Make sure they are tight.

Smoke and CO detector

Verify devices are installed and working properly. Change batteries if necessary.

Circuit Breakers

Check to see that the circuit breaker is clearly labeled. Exercise circuit breaker.

CHAMBER/BURNER

Combustion Chamber

Check burner tube and combustion chamber coils. Clean according to maintenance section of manual. Vacuum combustion chamber. Replace any gaskets that show signs of damage.

Spark Electrode

Clean. Set gap at ¼”. Clean probe with plumbers cloth to remove oxides.

Flame Probe

Check ionization in uA (d7 on status menu in Start-up Procedures). Record high fire and low fire. Clean probe with plumbers cloth to remove oxides.

CONDENSATE

Neutralizer

Check condensate neutralizer. Replace if necessary.

Condensate hose

Disconnect condensate hose. Clean out dirt. Fill with water to level of outlet and re-install. (NOTE: Verify the flow of condensate, making sure that the hose is properly connected during final inspection.)

GAS

Pressure

Measure incoming gas pressure (3.5” to 14” W.C.)

Pressure Drop

Measure drop in pressure on light off (no more than 1” W.C.)

Check gas pipe for leaks

Check piping for leaks. Verify that all are properly supported.

PART 11 - MAINTENANCE

The water heater requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended.

Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.

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COMBUSTION

CO/CO2 Levels

Check CO and CO2 levels in Exhaust (See Start-up Procedures for ranges). Record at high and low fire.

SAFETIES

ECO (Energy Cut Out)

Check continuity on Flue and Water ECO. Replace if corroded.

Upper/Lower Sensors

Check wiring. Verify through ohms reading.

FINAL INSPECTION

Check list

Verify that you have completed entire check list. WARNING: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

Building Owner

Review what you have done with the building owner.

Table 15 - *Continue annual maintenance beyond the 4th year as required.

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MAINTENANCE NOTES

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Customer’s Name:

Installation Address:

Date of Installation:

Installer’s Code/Name:

Product Serial Number(s):

Comments: Installer’s Phone Number:

Signed by Installer:

Signed by Customer:

HTP CUSTOMER INSTALLATION RECORD FORM

The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.

IMPORTANT: Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the

system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative.

Distributor/Dealer: Please insert contact details.

LP-454 REV. 1.6.15

HTP PHP199-119, PHP199-119D, PHP260-130, PHP320-130, PHP399-130 Installation, Start-up, And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

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