HTP PHP260-119, PHP199-119, PHP320-119, PHP399-119 Installation, Setup, Maintenance

Download

Installation

Start-Up

Maintenance

Parts

Warranty

Phoenix Plus

Water Heater

PHP Models*

* “LP” Denotes Propane Gas Operation

This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.

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

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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 potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

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

This Manual For Use With Water Heaters Manufactured After

April 10, 2017

272 Duchaine Blvd. New Bedford, MA 02745 www.htproducts.com

LP-454 Rev. 004 Rel. 002 Date 12.1.17

WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

• Do not store or use gasoline or other ammable 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 re department.

• Installation and service must be provided by a qualied installer, service agency or the gas supplier.

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this manual. Installation and service must be performed by a qualied installer, service agency, or gas supplier.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

The following dened 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 serious personal injury or death.

companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state, local government, or individual such as a re chief, re marshal, chief of a re prevention bureau, labor department or health department, building ocial 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 ocer or departmental ocial may be the AHJ.

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

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

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

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

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 water heater. This includes all related control information. It is important that this manual, all other documents included in this system, and additional publications including the Code for the Installation of Heat Producing Appliances and National Fuel Gas Code - ANSI Z223.1 (latest versions), 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

For the Installer

This water heater must be installed by qualied and licensed personnel. The installer should be guided by the instructions furnished with the water heater, and by 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, latest version.

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.

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 specied in ANSI Z21.10.3

- latest edition.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

Table of Contents

Part 1 - General Safety Information 4

A. Improper Combustion 5 B. Gas 5 C. When Servicing the Water Heating System 5 D. Heater Water 5 E. Freeze Protection 5 F. High Elevation Installations 5 G. Water Temperature Adjustment 5

Part 2 - Before You Start 6

A. What’s in the Box 6 B. How the Heater Operates 6 C. Optional Equipment 6

Part 3 - Prepare the Water Heater 6

A. Locating the Water Heater 6 B. Leveling 8 C. Clearances for Service Access 8 D. Residential Garage and Closet Installations 8 E. Exhaust Vent and Intake Pipe 9

1. Indoor Direct Vent of Exhaust and Intake 9

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space

3. Outdoor Installation 9

F. Carbon Monoxide Detectors 10 G. Prevent Combustion Air Contamination 10 H. Removing a Heater from a Common Vent System 10 I. Water Chemistry Requirements 11

Part 4 - Piping 13

A. Heater Plumbing 13 B. Auxiliary Connection 13 C. Backow Preventer 13 D. Potable Expansion Tank 13 E. Temperature and Pressure Relief Valve 13 F. Scalding 14 G. Filling the Heater 14 H. Applications 15

Part 5 - Venting 16

A. General 16 B. Approved Materials for Exhaust Vent and Intake Pipe 17 C. Additional Requirements for Installation in Canada 17 D. Exhaust Vent and Intake Pipe Location 18 E. Exhaust Vent and Intake Pipe Sizing 19 F. Exhaust Vent and Intake Pipe Installation 19 G. Applications 20

1. Indoor Direct Vent Installation of Exhaust and Intake 20

2. Venting Through an Existing System 22

3. Power Venting, Indoor Combustion Air in Conned or Unconned Space 23

4. Outdoor Installation 25

Part 6 - Condensate Removal 26 Part 7 - Wiring 27

A. Line Voltage Input 27 B. Line Voltage Condensate Output 27 C. Internal Wiring Diagram 28

Part 8 - Gas Connections 30

A. Gas Pipe Sizing Tables 31

1. Gas Pipe Sizing 31

2. Natural Gas Pipe Sizing 31

3. LP (Liquid Propane) Gas Pipe Sizing 31

B. Gas Piping Requirements 31 C. Gas Valve 32 D. Checking Gas Pressure at the Water Heater for Proper Operation

Part 9 - Start-Up Procedure 33

A. Operating Instructions 33 B. Overall Water Heater and Control Operation 33 C. Status Menu 33 D. Test Mode 33

E. Maintenance 34

Part 10 - Shutdown 34

A. Shutdown Procedure 34 B. Vacation Procedure 34 C. Failure to Operate 34 D. Important Notice 34

Part 11 - Troubleshooting 35

A. Error Code 35 B. Heater Error 35 C. Lockout 35

Part 12 - Installation Checklist 37 Part 13 - Maintenance 38 Part 14 - Replacement Parts 40

Limited Warranty 42 Maintenance Notes 44 Customer Installation Record Form 45

Part 1 - General Safety Information

Indoor Installation

This water heater is approved for indoor installations and is not intended for use as a pool heater. Clearance to combustible

materials: 0” top, bottom, sides, and back. Heater 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 ooring. Do not install directly on carpeting. Install the water heater in a location where temperature and pressure relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan. Use only Category IV vent systems.

Outdoor Installation

This water heater is approved for outdoor installations and is not intended for use as a pool heater. Clearance to combustible materials: 0” top, bottom, sides, and back. Heater must have room for service: 24” front and 12” sides are minimum recommended service clearances. Special attention should be paid to ensure that T&P valve discharge and drainage from condensate line will not adversely aect the surrounding area or pose a hazard in freezing conditions.

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 freezing conditions. Failure to take precautions could result in property damage, serious personal injury, or death.

Installer - Read all instructions in this manual before installing. Perform steps in the given order.

User - This manual is for use only by a qualied heating installer / service technician. Have this water heater serviced / inspected annually by a qualied service technician.

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

NOTE: Obey all local codes. Obtain all applicable permits before

installing the water heater.

NOTE: Install all system components and piping in such a manner that does not reduce the performance of any re rated assembly.

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

LP-454 Rev. 004 Rel. 002 Date 12.1.17

NOTE: If the water heater is exposed to the following, do not operate. Immediately call a qualied service technician.

1. Fire

2. Damage

3. Water Failure to follow this information could result in property damage, severe personal injury, or death.

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied 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 re 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 ood or submersion is considered an Act of God, and IS NOT covered under product warranty.

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

To avoid severe burns, allow water heater and associated equipment to cool before servicing.

D. Heater Water

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

Do not use “homemade cures” or “patent medicines”. Damage to the water heater, substantial property damage, and/or serious personal injury may result.

E. Freeze Protection

NOTE: Consider piping and installation when determining heater

location.

Failure of the water heater due to freeze related damage IS NOT covered by product warranty.

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (non-potable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

Do not use this water heater for anything other than its intended purpose (as described in this manual). Doing so could result in property damage and WILL VOID product warranty.

High heat sources (sources generating heat 100 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.

F / 37

C or

A. Improper Combustion

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

B. Gas

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

C. When Servicing the Water Heating System

Be sure to disconnect electrical power before performing service. Failure to do so could result in electrical shock, property damage, serious personal injury, or death.

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

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the water heater rating label.

UNCRATING THE WATER HEATER - Any claims for damage or shortage in shipment must be led immediately against the transportation company by the consignee.

F. High Elevation Installations

Natural gas at high elevation might contain less heating value than typical 1,000 BTU/cu ft and therefore can cause improper air / gas mix leading to improper combustion. For natural gas installations above 3,000 ft, call your gas provider to determine the heating value of the supplied natural gas.

G. Water Temperature Adjustment

If the water heater is going to have a set temperature above 120oF, you must use an ASSE 1017 rated mixing valve to avoid severe burns or death from scalding temperatures.

Households with small children, disabled, or elderly persons may require a 120oF or lower temperature setting to prevent severe personal injury or death due to scalding.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

Table 1 - Approximate Time / Temperature Relationships in Scalds

LP-454 Rev. 004 Rel. 002 Date 12.1.17

Part 2 - Before You Start

Remove all sides of the shipping crate of the water heater.

A. What’s in the Box

Components included with the water heater:

• Temperature and Pressure Relief Valve

• Brass Tee and Bushing

• LP Conversion Kit (NG Models Only)

• Installation Manual and Warranty

• User’s Information Manual

B. How the Heater Operates

Modulating Condensing Technology is an intelligent system that

delivers highly ecient water heating, maximizing eciency 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 red, 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 from these gases is transferred into the water.

Dual Modulating Combustion Systems

The water heater is provided with two independent combustion systems (PHP-199-119 models have a single combustion system). 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, eciently regulating burner output to match system demand. These systems increase eciency and allow for substantial fuel savings.

Gas Valve

The gas valve senses suction from the blower, allowing gas to ow only if the gas valve is energized and combustion air is owing.

Upper Outlet Tank Sensor

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

Lower Inlet Tank Sensor

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

Control

The integrated control system monitors upper and lower water temperature and adjusts fan speed to regulate the heater’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 ring rates.

Condensate Drain System

This is a condensing high eciency water heater with a condensate removal system. Condensate is nothing more than water vapor derived from combustion products, similar to that of 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 inside drain. If the condensate outlet on the heater is lower than the drain, us a condensate removal pump (Part # 554200, available from HTP). In addition, local authorities may require an additional condensate neutralizer to neutralize the condensate. Condensate neutralizers are made up of lime crystals, marble, or phosphate chips. Neutralizers can be installed in the eld 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 ow.

Spark Ignition

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

C. Optional Equipment

Optional equipment available from HTP (and Part #):

• 3” Stainless Steel Vent Termination Kit (V1000)

• 4” Stainless Steel Vent Termination Kit (V2000)

• 3” PVC Concentric Vent Kit (KGAVT0601CVT)

• 3” Polypro Vent Kit (8400P-001)

• 3” Polypro Pipe

(33’ length # 8400P-002, 49.5’ length # 8400P-003)

• PC Connection Kit (7250P-320)

• Condensate Neutralizer (7450P-212)

• MODBUS / BACnet Adapter (7350P-636)

Part 3 - Prepare the Water Heater

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

COLD WEATHER HANDLING - If the water heater has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the components come to room temperature. Failure to do so could result in damage to the water heater.

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.

A. Locating the Water Heater

These heaters are design certied 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 installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death. Failure of heater or components due to incorrect operating conditions IS NOT covered by product warranty.

This 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.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

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.

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

• 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 runo 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 lled 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 lled 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.

• 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 line 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 failure. Such failures ARE NOT covered by warranty.

Figure 1 - Outdoor Installation Recommendations

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 ammable liquids.

When installing the heater outdoors, ensure the installation location is not near the exhaust or intake terminations of other gas-red 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.

This water heater must be installed upright in the vertical position as described in this manual. DO NOT attempt to install this water heater in any other orientation. Doing so will result in improper water heater operation and property damage, and could result in serious personal injury or death.

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

The service life of the water heater’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly inuenced by proximity to damp and salty marine environments. In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of water heater components. In these environments, heaters must not be installed using direct vent systems which draw outdoor air for combustion. Such heaters must be installed using room air for combustion. Indoor air will have a much lower relative humidity, and hence potential corrosion will be minimized.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

High heat sources (generating heat 100oF / 37oC or greater, such as boiler ue 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.

Locate the water heater where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower oors of the building. The water heater should be located near a oor drain or installed in a drain pan. Leakage damages ARE NOT covered by warranty.

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

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 ush 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

Figure 2 - Minimum Service Clearances and Catch Pan Dimensions

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.

NOTE: A combustible door or removable panel is acceptable front clearance.

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

C. Clearances for Service Access

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 3/4” 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.

The space must be provided with combustion / ventilation air openings correctly sized for all other appliances 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 appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

D. Residential Garage and Closet Installations

Check with your local Authority Having Jurisdiction for requirements when installing the water heater in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

Precautions

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

• Install the water heater burner and ignition devices a minimum of 18” above the oor of the garage. This will ensure the burner and ignition devices are well o the oor.

• When raising the water heater ensure the entire bottom and fully lled weight of the water heater are fully supported.

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

LP-454 Rev. 004 Rel. 002 Date 12.1.17

The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the water heater. For power venting installations using room air for combustion, refer to the venting section, this manual, for descriptions of conned and unconned spaces. Do not install the water heater in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.

E. 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, 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.

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

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 2) 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. Unconned space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details. Conned space is space with volume less than 50 cubic feet per 1,000 BTU/hr (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 conned 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 oor. 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 conned 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.

The exhaust discharged by this water heater may be very hot. Avoid touching or other direct contact with the exhaust gases of the vent termination assembly. Doing so could result in severe 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.

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 rst 3’ from the water heater. Failure to properly support vents could result in property damage, severe personal injury, or death.

1. Indoor Direct Vent of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the water heater intake and exhaust must terminate outdoors. 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. Dierent 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, 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 2.

2. Power Venting, Indoor Combustion Air in Conned or Unconned 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 2. 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 sucient combustion air based on the water heater input.

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

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

See Venting section for additional details.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

G. Prevent Combustion Air Contamination

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

Ensure that the intake air will not contain any of the contaminants in Table 2. Contaminated air will damage the heater, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool or laundry facilities. These areas always contain contaminants.

Figure 3 - CO Warning Label

Failure to provide an adequate supply of fresh combustion air can cause poisonous ue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 2.

F. Carbon Monoxide Detectors

In the Commonwealth of Massachusetts and As Required by State and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation or replacement of the vented gas fueled appliance, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas appliance is installed, unless the appliance is located in a detached, uninhabitable structure separate from the dwelling, building, or structure used in whole or in part for residential purposes. In addition, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on each additional level of the dwelling, building, or structure served by the vented gas appliance. It shall be the responsibility of the property owner to secure the service of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent oor level. b. In the event that these requirements cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

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.

Approved Carbon Monoxide Detectors: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certied.

Products to Avoid

Spray cans containing uorocarbons

Permanent wave solutions Swimming pools

Chlorinated waxes / cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water softening

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Adhesives used to fasten building products

Table 2 - Products and Areas Likely to Have Contaminants

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.)

Areas Likely to Have

Contaminants

Dry cleaning / laundry areas and establishments

Beauty shops

Photo processing plants

Furniture renishing areas and establishments

Remodeling areas

Garages and workshops

H. Removing a Heater from a Common Vent System

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

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

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 deciencies 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

LP-454 Rev. 004 Rel. 002 Date 12.1.17

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 replace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, replace dampers, and any other gas burning appliances 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 of ANSI Z223.1.

I. Water Chemistry Requirements

Chemical imbalance of the water supply may aect eciency and cause severe damage to the appliance and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality. Adverse water quality will aect the reliability of the system. In addition, operating temperatures above 135oF will accelerate the build-up of lime scale and possibly shorten appliance service life. Failure of an appliance due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger. Potable water is dened as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3). If the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more frequent maintenance may be required.

If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

• Water pH between 6.5 and 8.5

• pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale build-up

• Maintain water pH between 6.5 and 8.5. Check with litmus paper or have it chemically analyzed by a local water treatment company.

• If the pH is not between 6.5 and 8.5, consult a local water treatment company for solutions.

• Hardness less than 7 grains (120 mg/L) (Commercial Use

- water temperatures of 140oF and greater)

• Hardness levels above the required amounts can lead to lime scale build-up throughout the system. Water below 5 grains/gallon (85 mg/L) may be over softened.

• Consult local water treatment companies for unusually hard water areas (above the required amounts) or for other treatment solutions if water is being over softened (below 5 grains/gallon [85 mg/L]).

• Chloride concentration less than 100 ppm (mg/L)

• Do not ll appliance or operate with water containing chlorides in excess of 100 ppm (mg/L).

• Using chlorinated fresh water should be acceptable as levels are typically less than 5 ppm (mg/L).

• Do not connect the appliance to directly heat swimming pool or spa water.

• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)

• Total dissolved solids are minerals, salts, metals, and charged particles that are dissolved in water.

• The greater the amounts of TDS present, the higher the corrosion potential due to increased conductivity in the water.

• If using softened water to ll the appliance, it is still possible to have high TDS. This water can be corrosive. Consult local water treatment companies for other treatment solutions to reduce this eect.

*NOTE: To promote appliance service life, it is strongly recommended to follow the maintenance procedures in this manual.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

AIR INLET

GAS CONNECTION

CONDENSATE

PHP199-119

PHP260-119

PHP320-119

PHP399-119

LINE

MODEL A B C D E F G H J

11-3/16"

28.42 cm

MODEL

PHP199-119

PHP260-119

PHP320-119

PHP399-119

5-1/2"

13.97cm7"17.78cm

COLD WATER

INLET

1-1/2" MNPT

3.81 cm

42-1/8"

107 cm

PORT SIZES

HOT WATER

OUTLET

1-1/2" FNPT

3.81 cm

77"

195.58 cm

32"

81.28 cm

AUXILIARY VENTING GAS LINE CONDENSATE

1" MNPT

2.54 cm

85"

215.9 cm

10.16 cm

Figure 4 - Water Heater Dimensions - NOTE: All Dimensions Are Approximate

Performance Specications for Phoenix Plus Models

Temperature Rise in Degrees Fahrenheit (F) and Celsius (C)

BTU/Hr Eciency

(°F) 40 50 60 70 80 90 100 110 120 130 140

(°C) 22 28 33 39 44 50 56 61 67 72 78

199,000

260,000

95%

320,000

399,000

Table 3 - 95% Thermal Eciency Used for Calculations

GPH 579 463 386 331 289 257 232 211 193 178 165

LPH 2192 1753 1461 1253 1094 973 878 799 731 673 625

GPH 756 605 504 432 378 336 303 275 252 233 216

LPH 2862 2290 1908 1653 1431 1272 1147 1041 954 882 818

GPH 931 745 621 532 465 414 372 339 310 286 266

LPH 3524 2820 2351 2014 1760 1567 1408 1283 1174 1083 1007

GPH 1161 929 774 663 580 516 464 422 387 357 332

LPH 4395 3517 2930 2510 2196 1953 1756 1597 1465 1351 1257

Performance Equations Rated Input x .95 GPM = Temp Rise (oF) x 500 GPH = GPM x 60

EXHAUST

COLD WATER

40.64 cm

7.62 cm

INLET

16"

3/4" FNPT

1.905 cm

9-3/4"

24.76 cm

49"

124.46 cm

58-3/4"

149.22 cm

3/4" MNPT

1.905 cm

HOT WATER OUTLET

AUXILIARY

SHIPPING

WEIGHT

LBS/KG

475

215.46 kg

555

251.74 kg

575

260.82 kg

LP-454-K

10/27/14

LP-454 Rev. 004 Rel. 002 Date 12.1.17

Part 4 - Piping

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

Dielectric unions or galvanized steel ttings must not be used in a system with this water heater. Doing so WILL VOID the warranty. Use only copper, brass, or stainless steel ttings. Teon thread sealant must be used on all connections.

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 warranty.

A. Heater Plumbing

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.

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.

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.

The domestic water connections must be installed in accordance to all local and national plumbing codes, or any applicable standard which prevails. The inlet (cold) and outlet (hot) ports are 1 1/2” on 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 eciency. If there is a backow preventer or any type of a no return valve in the system, install an additional tee on the cold feed line to connect to a potable hot water expansion tank. In the hot outlet, install a suitable adapter to match the copper tubing of the plumbing system. A thermal trap or heat trap loop may be installed here to provide additional energy savings and prevent the thermal siphoning of domestic hot water.

B. Auxiliary Connection

The auxiliary connection is provided to improve eciency via recirculation. This connection must be installed in accordance with all local and national codes or any applicable standard that prevails. Auxiliary connection is 1” on all models. Never use dielectric unions or galvanized steel ttings. Use only copper or brass ttings. 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.

C. Backow Preventer

Use a backow preventer specically designed for water heater installations. This valve should be installed on the cold water ll supply line per local codes.

D. Potable Expansion Tank

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

Expansion Tank and Make-Up Water

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

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 systems.

2. The expansion tank must be located as shown in Applications, this manual, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

E. Temperature and Pressure Relief Valve

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 oor 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 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 lling 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 “o ” 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.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

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

RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a licensed plumbing contractor or qualied service

technician to ensure that the product has not been aected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occuring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected. Do not attempt to conduct an inspection on your own. Contact your plumbing contractor for a re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILD-UP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

F. Scalding

This water 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 temperatures. 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, install a mixing valve in the water system. This valve will reduce point of use discharge temperatures by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

Table 4 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.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

Table 4 - Approximate Time / Temperature Relationships in Scalds

G. Filling the Heater

The water heater must be full of water and the system fully purged BEFORE powering the water heater. When lling the water heater, open a hot water tap to release air in the tank and piping. All air has been purged from the system when water runs freely from the faucets. Applying power to the water heater when it is not full of water will damage the heat exchanger, and could result in property damage, serious personal injury, or death. Such damages ARE NOT covered by water heater warranty.

• Make certain the drain valve is completely closed.

• Open the shut-o valve in the cold water supply line.

• Open the hot water faucets to allow air to vent from the heater and piping.

• Allow sucient time for the heater to completely ll with water.

An ASSE 1017 or ASSE 1070 temperature limiting or mixing valve is recommended in installations servicing disabled or elderly persons, or children. Mixing valves do not eliminate the risk of scalding. To avoid scalding:

• Set the water heater set point temperature as low as possible.

• Feel water before bathing or showering.

• If thermostatic valves are required, use devices specically designed for such purpose. Install these devices in accordance with instructions provided by the manufacturer.

Failure to install a temperature limiting or mixing valve and follow these instructions could result in property damage, severe personal injury, or death due to scalds.

LP-454 Rev. 004 Rel. 002 Date 12.1.17

+ 31 hidden pages

HTP PHP260-119, PHP199-119, PHP320-119, PHP399-119 Installation, Setup, Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual