HTP PH100-55 User manual

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

Phoenix Gas-Fired

Water Heater

INSTALLATION

START-UP

MAINTENANCE

PARTS

Phoenix Water Heater Models*

PH100-55 / 130-55 / 160-55 / 199-55

PH100-80 / 130-80 / 160-80 / 199-80

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

Phoenix Sanitizer Booster Models*

130-55SA / 199-55SA

*A suffix of “LP” denotes propane gas

*A suffix of “S” denotes solar model

This manual must be used by a qualified installer/service technician. Read all instructions in this manual

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

damage, severe personal injury, or death.

NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held

liable for typographical errors in literature.

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.

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.

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 local code authorities and utility

companies which pertain to this type of water heating equipment.

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

FOR THE INSTALLER

This appliance must be installed by qualified and licensed personnel. The installer should be guided by

the instructions furnished with the boiler, and with local codes and utility company requirements. In the

absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association

Laboratories, 8501 East Pleasant 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 specified in ANSI Z21.10.3 – latest edition.

This manual must only be used by a qualified heating installer/service technician. Read all instructions in

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

personal injury, death or substantial property damage.

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

C. TEMPERATURE AND PRESSURE RELIEF VALVE.........................................................................16

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

E. POTABLE EXPANSION TANK...........................................................................................................16

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides

and back. Unit must have room for service: 24” front and 12” sides are minimum recommended service

clearances. (A combustible door or removable panel is acceptable front clearance.) This appliance has

been approved for closet installation, and installation on combustible flooring. Do not install this appliance

directly on carpeting. Use only Category IV vent systems.

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

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

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

technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL

PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

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

by a qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER

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

company by the consignee.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified

service technician. Replace any part of the control unit that has been under water.

B. IMPROPER COMBUSTION

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

operation.

C. GAS

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

D. WHEN SERVICING THE HEATER

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

•To avoid severe burns, allow heater to cool.

E. HEATER WATER

•Do not use petroleum-based cleaning or sealing compounds in a heater system. Gaskets and

seals in the system may be damaged. This can result in substantial property damage.

•Do not use “homemade cures” or “heater patent medicines”. Substantial property damage,

damage to heater, and/or serious personal injury may result.

PART 2 – HOW THE HEATER OPERATES

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

Modulating Combustion System

Modulation during water heating operation is based on tank temperature. The control monitors the system

to regulate burner output during operation to match system demand. This increase in efficiency allows for

substantial fuel savings.

Gas Valve

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

combustion air is flowing.

Upper Supply Tank Sensor

This sensor monitors the upper portion water temperature (system supply) of the water heater. The

control module adjusts the burner firing rate so the outlet water temperature meets the set point.

Lower Return Tank Sensor

This sensor monitors the lower portion of the water heater inlet water temperature (system return). The

control module reduces or increases input, depending on how close the water temperature is to the outlet

water temperature set point.

Control

The integrated control system monitors upper and lower water temperature and regulates fan speed to

regulate the unit’s energy output. This allows the unit to deliver the required amount of heated 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 appliance, and therefore has a condensate removal system.

Condensate is nothing more than water vapor, derived from combustion products and similar to an

automobile when it is initially 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, 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 condensation line may be necessary to avoid blockage

of the condensate flow.

Spark Ignition

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

from electrode to ground.

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

disabled, and elderly are at the highest risk of being scalded. See instruction manual before

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

valves are available.

PART 3 – PREPARE WATER HEATER LOCATION

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

Removal are just a few of the issues that need attention prior to the installation of the heater. Please read

the entire manual, as it could save time and money.

A. BEFORE LOCATING THE HEATER

Check for nearby connections to:

•System water piping

•Venting connections

•Gas supply piping

•Electrical power

•Condensate drain

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

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

substantial property damage, severe personal injury, or death.

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

service.

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

•System leaks

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

•Incorrectly-sized expansion tank

•Clean and flush existing system when reinstalling a heater.

B. LEVELING

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.

C. CLEARANCES FOR SERVICE ACCESS

Figure 1

If you do not provide the minimum clearances shown, it might not be possible to service the heater

without removing it from the space.

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 form the heater room. This is particularly important if the heater is in a

room with other appliances. Failure to comply with the above warnings could result in substantial property

damage, severe personal injury, or death.

D. RESIDENTIAL GARAGE INSTALLATION

PRECAUTIONS

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

•Mount the bottom of the heater a minimum of 18” above the floor of the garage, to ensure the

burner and ignition devices are well off the floor.

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

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

E. EXHAUST VENT AND INTAKE AIR VENT

The heater is rated ANSI Z21.10.3 Category IV (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 Venting, Part 8 in 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.

This manual suits for next models

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