HTP PHP Phoenix Plus Gas Fired Water Heaters Instruction Manual

PHP Phoenix Plus Gas Fired Water Heaters

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Product Specifications

• Product Name: Phoenix Plus Gas Fired Water Heaters

• Manufacturer: HTP

• Model: PHP Models*

• Fuel Type: LP (Propane Gas Operation)

• Manufacture Date: After September 1, 2021

• Lead Content: Less than 0.25% as required by the Safe Drinking
  Water Act

Product Usage Instructions

Installation

Installation must be carried out by a qualified installer or
service technician. Follow the instructions provided in this manual
carefully and in the given order to avoid any property damage or
personal injury.

Start-Up

After installation, follow the specific start-up procedures
outlined in the manual to ensure proper functioning of the water
heater.

Maintenance

Regular maintenance is essential for the efficient operation of
the water heater. Refer to the maintenance section of the manual
for detailed instructions on how to maintain your Phoenix Plus Gas
Fired Water Heater.

Parts

For information on parts and replacements, refer to the parts
section of the manual. Only use genuine parts recommended by the
manufacturer.

Warranty

Understand the warranty terms and conditions provided by the
manufacturer to ensure coverage in case of any issues with the
product.

Frequently Asked Questions (FAQ)

Q: What should I do if I smell gas?

A: If you detect a gas odor, immediately evacuate the area and
contact your gas supplier or emergency services. Do not operate any
electrical devices or create any open flames.

Q: Can I install the water heater myself?

A: No, installation must be done by a qualified and licensed
professional to ensure safety and compliance with local
regulations.

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Phoenix Plus
Gas Fired Water Heaters

Installation

Start-Up

Maintenance

Parts

Warranty

PHP Models*

• “LP” Denotes Propane Gas Operation

This Manual For Use With Water Heaters Manufactured After September 1, 2021

This manual must only be used by a qualified 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.

272 Duchaine Blvd.

New Bedford, MA 02745

www.htproducts.com LP-454 Date 10.17.23

2 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
· Do not store or use 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. 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 qualified installer, service agency, or gas supplier.
LP-454 Date 10.17.23

3

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious personal injury or death.

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 AHJ 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 reserves the right to modify product technical specifications WARNING indicates a potentially hazardous situation which, if not and components without prior notice. 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.

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 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 in the United States and the Natural Gas and Propane Installation Code – B149.1 in Canada (latest versions).
Installations Must Comply With: Local, state, provincial, and national codes, laws, regulations, and ordinances.

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 National Fuel Gas Code – ANSI Z223.1 (latest versions), be reviewed in their entirety before beginning any work.

In the United States – 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.
The latest version of the National Electrical Code, NFPA No. 70.
In Canada – The latest versions of the Natural Gas and Propane Installation Code, CSA B149.1, and the Canadian Electrical Code, C22.1, from CSA Group, 178 Rexdale Blvd, Toronto, Ontario, Canada M9W 1R3.
NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests specified in ANSI Z21.13 – latest edition.

LP-454 Date 10.17.23

4

From the Uniform Plumbing Code 2000 – Section 510 Protection From Damage

1. Water heaters generating a glow, spark or flame capable of igniting flammable vapors may be installed in a garage, provided the pilots, burners or heating elements and switches are at least eighteen (18) inches (457 mm) above the floor level.

2. Where such water heaters installed within a garage are enclosed in a separate, approved compartment having access only from outside of the garage, such water heaters may be installed at floor level provided the required combustion air is also taken from the exterior of the garage. Fuel burning water heaters having sealed combustion chambers need not be elevated.

3. All water heaters installed in areas where they may be subjected to mechanical damage shall be suitably guarded against such damage by being installed behind adequate barriers or by being elevated or located out of the normal path of a vehicle using any such garage.

4. In seismic zones 3 and 4, water heaters shall be anchored or strapped to resist horizontal displacement due to earthquake motion. Strapping shall be at points within the upper one-third (1/3) and lower one-third (1/3) of its vertical dimensions. At the lower point, a minimum distance of four (4) inches (102 mm) shall be maintained above the controls with the strapping.

5. An water heater supported from the ground shall rest on level concrete or other approved base extending not less than three (3) inches (76 mm) above the adjoining ground level.

6. When an water heater is located in an attic, attic-ceiling assembly, floor-ceiling assembly, or floor-subfloor assembly where damage may result from a leaking water heater, a watertight pan of corrosion resistant materials shall be installed beneath the water heater with a minimum three-quarter (3/4) inch (20 mm) diameter drain to an approved location.

Table of Contents

Part 1 – General Safety Information

5

A. Operation and Installation Warnings

5

B. Improper Combustion

6

C. Gas

6

D. When Servicing the Water Heating System

6

E. Water Chemistry Requirements

6

F. Freeze Protection

7

G. Water Temperature Adjustment

7

H. High Elevation Installations

7

Part 2 – Before You Start

8

A. What’s in the Box

8

B. How the Heater Operates

8

C. Optional Equipment

8

Part 3 – Prepare the Water Heater

8

A. Locating the Water Heater

8

B. Leveling

10

C. Clearances for Service Access

10

D. Residential Garage and Closet Installations

11

E. Exhaust Vent and Intake Pipe

11

1. Indoor Direct Vent of Exhaust and Intake

11

2. Power Venting, Indoor Combustion Air in Confined or

Unconfined Space

11

3. Outdoor Installation

12

F. Carbon Monoxide Detectors

12

G. Prevent Combustion Air Contamination

12

H. Removing a Heater from a Common Vent System

13

I. Anode Rod

13

Part 4 – Piping

15

A. General Plumbing Information

15

B. Auxiliary Connection

15

C. Backflow Preventer

15

D. Potable Expansion Tank

15

E. Temperature and Pressure Relief Valve

15

F. Scalding

16

G. Filling the Heater

16

H. Applications

17

Part 5 – Venting

18

A. General

18

B. Approved Materials for Exhaust Vent and Intake Pipe

19

C. Additional Requirements for Installation in Canada

19

D. Exhaust Vent and Intake Pipe Location

20

E. Exhaust Vent and Intake Pipe Sizing

21

F. Exhaust Vent and Intake Pipe Installation

21

G. Applications

22

1. Indoor Direct Vent Installation of Exhaust and Intake

22

2. Venting Through an Existing System

26

3. Power Venting, Indoor Combustion Air in Confined or Unconfined

Space

27

4. Outdoor Installation

28

Part 6 – Condensate Removal

29

Part 7 – Wiring

30

A. Line Voltage Input

30

B. Line Voltage Condensate Output

30

C. Internal Wiring Diagram

31

Part 8 – Gas Connections

34

A. Gas Pipe Sizing Tables

34

1. Gas Pipe Sizing

34

2. Natural Gas Pipe Sizing

34

3. LP (Liquid Propane) Gas Pipe Sizing

34

B. Gas Connection Requirements

35

C. Additional Precaution for Excess Flow Valve (EFV)

35

D. Gas Valve

36

E. Checking Gas Pressure at the Water Heater for Proper Operation

36

Part 9 – Start-Up Preparation

37

A. Check / Control Water Chemistry

37

B. Check for Gas Leaks

37

C. Fill and Test Water System

37

D. Condensate Removal

37

Part 10 – Start-Up Procedure

38

A. Operating Instructions

38

B. Overall Water Heater and Control Operation

38

C. Status Menu

38

D. Test Mode

38

E. Maintenance

39

Part 11 – Shutdown

39

A. Shutdown Procedure

39

B. Vacation Procedure

39

C. Failure to Operate

39

D. Important Notice

39

Part 12 – Troubleshooting

40

A. Error Code

40

B. Heater Error

40

C. Lockout

40

Part 13 – Installation Checklist

42

Part 14 – Maintenance

43

Part 15 – Replacement Parts

46

Limited Warranty

48

Maintenance Notes

50

Customer Installation Record Form

51

LP-454 Date 10.17.23

5

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 flooring. 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.
This appliance is rated Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting. 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. Install the water heater in a location where temperature and pressure relief valve discharge, drainage from condensate line, or a leak will not adversely affect the surrounding area or pose a hazard in freezing conditions.
Installer – Read all instructions in this manual before installing. Perform steps in the given order.
User – This manual is for use only by a qualified heating installer / service technician. Have this water heater serviced / inspected annually by a qualified 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 fire rated assembly.
A. Operation and Installation Warnings To avoid serious injury or death, read, understand, and follow all of the precautions listed here.
! DANGER
Vapors from flammable liquids will explode and cause a fire, resulting in personal injury or death. The water heater has a burner that can come on at any time and ignite vapors. DO NOT use or store flammable liquids around the water heater. Improper venting can cause a build-up of carbon monoxide. Breathing carbon monoxide can result in brain damage or death. DO NOT operate the water heater unless it is properly vented to the outside and has an adequate fresh air supply for safe operation. Inspect the exterior exhaust gas outlet port and fresh air inlet port on a regular basis to ensure they are functioning properly.
A concentration of carbon monoxide as small as .04% (400 parts per million) in the air can be fatal. When making high fire or low fire adjustments, CO levels must be monitored using a calibrated combustion analyzer such that a CO level of no more than 150 ppm is exceeded at any time during operation.

! DANGER
Adjusting the “low fire offset” or the “main flow restrictor” in small increments can result in a significant increase in CO concentration. To avoid serious injury or death, DO NOT make any adjustments to the gas valve without monitoring the exhaust gases with a fully functional and calibrated combustion analyzer.
Failure to follow these instructions will result in property damage, severe personal injury, or death.
! WARNING
This water heater must be installed by a licensed plumber, licensed gas fitter, and/or professional service technician. Improper installation and/or operation can cause a potentially hazardous situation, which, if not avoided, could result in serious injury or death, and will void the warranty.
The manufacturer cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of the qualified service technician.
Proper care of the water heater is the user’s responsibility. Ensure the user carefully reads and understands the User’s Information Manual before operating the water heater.
Make sure the user knows the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the appliance is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the appliance checked by a qualified service technician before resuming operation.
Do not power up the unit unless the gas and water supply valves are fully opened. Make sure the fresh air intake port and exhaust gas port are open and functional.
No one but a qualified service technician should attempt to install, service, or repair this water heater. There are no serviceable parts which can be changed by the user / owner.
User / Owner: Contact the original qualified service technician if the water heater needs repair / maintenance. If the original technician is unavailable, ask your gas supplier for a list of qualified service providers.
DO NOT store or place newspapers, laundry, or other combustible items near the appliance or the exterior exhaust gas outlet and/or fresh air inlet port.
The owner should inspect the system monthly for damage, water stains, signs of rust, corrosion, and exhaust vent and air intake blockage. If inspection of the unit shows signs of damage, the water heater should be shut off until the problem is repaired by a qualified technician.
After installation, all appliance safety devices should be tested.
Carefully consider installation location and the placement of critical components (circulators, condensate neutralizers, etc.) before installing the water heater.
DO NOT allow children to operate this water heater. DO NOT use this water heater if it does not appear to be operating correctly. A qualified service technician should service and inspect the water heater annually.
NOTE: If the water heater is exposed to fire or water (or is any way damaged), do not operate. Immediately call a qualified service technician. Failure to follow this information could result in property damage, severe personal injury, or death.

LP-454 Date 10.17.23

6

! WARNING
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.
DO NOT alter or modify the appliance or appliance controls. Altering any HTP water heater with parts not manufactured by HTP WILL INSTANTLY VOID the water heater warranty and could result in property damage, 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.
CAUTION
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.
NOTICE
This appliance provides an overheat shutdown limit. In the event the appliance water temperature exceeds the setpoint of the control limit, the cutoff will trip and the appliance will shut down. Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum setpoint of the limit provided with the appliance. Contact the manufacturer for additional overheat controls.
B. Improper Combustion
Do not obstruct the flow 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.
C. Gas Should overheating or gas supply fail to shut off, turn off the manual gas control valve to the water heater.

D. When Servicing the Water Heating System
Be sure to disconnect electrical power before opening water heater cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the water heater. Wiring errors can cause improper or dangerous operation. Failure to do so could result in an electrical shock, improper water heater operation, property damage, serious personal injury, or death.
· To avoid electric shock, disconnect electrical supply before performing maintenance.
· To avoid severe burns, allow water heater and associated equipment to cool before servicing.
· 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.
· Always verify proper operation after servicing the water heater.
NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the water heater rating label.
E. Water Chemistry Requirements
Chemical imbalance of the water supply may affect efficiency 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 affect 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 defined 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.

LP-454 Date 10.17.23

7

· 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 fill 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 fill 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 effect.
*NOTE: To promote appliance service life, it is strongly recommended to follow the maintenance procedures in this manual.
F. Freeze Protection NOTE: Consider piping and installation when determining heater location.

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 125oF

More than 5 minutes 1 1/2 to 2 minutes

130oF 135oF 140oF 145oF 150oF

About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 1 1/2 seconds

155oF

About 1 second

Table 1 – Approximate Time / Temperature Relationships in Scalds

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 specifically
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.
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.

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 (nonpotable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.
NOTE: HTP DOES NOT WARRANT THE APPLIANCE AGAINST FREEZERELATED DAMAGE.
G. Water Temperature Adjustment 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 1 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.

H. High Elevation Installations This water heater is designed to operate at its maximum listed capacity in installations located at 0 – 2000 ft above Sea Level. Since the density of air decreases as elevation increases, maximum specified capacity should be de-rated for elevations above 2000 ft (610 m) in accordance with the table below.

Elevations
In Canada1, de-rate by: In USA2, de-rate by:

2001 ft 3000 ft 4000 ft 4500 ft 5000 ft (610 m) (914 m) (1219 m) (1372 m) (1524 m)

10%

10%

10%

10%

may vary

–

12%

16%

18%

20%

NOTES: 1Canada: Elevations between 2000 – 4500 ft (610 – 1372 m), de-rate by 10%. Consult local authorities for de-rating for elevations above 4500 ft (1372 m). 2USA: If elevation is above 2000 ft (610 m), de-rate capacity by 4% for every 1000 ft (305 m).
Table 2 – De-Rate % for High Elevations

! WARNING
Combustion – At elevations above 2000 ft, the combustion of the water heater must be checked with a calibrated combustion analyzer to ensure safe and reliable operation. It is the Installer’s responsibility to check and adjust the combustion in accordance with this manual. Failure to follow these instructions may result in property damage, serious personal injury, or death.

LP-454 Date 10.17.23

8

Part 2 – Before You Start
Remove the water heater from the packaging. Take care to place the water heater and accessories in a safe location prior to installation to prevent damage to the mechanical connections.
UNCRATING THE WATER HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
A. What’s in the Box Components included with the water heater:
· Temperature and Pressure Relief Valve · Two (2) Brass Piping Adapters · 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 efficient water heating, 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 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, 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 Outlet Tank Sensor This sensor monitors the upper portion water temperature (outlet) of the water heater. The control module adjusts burner firing 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 firing rates. Condensate Drain System This is a condensing high efficiency 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 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 Optional equipment available from HTP (and Part #):
· 3″ Stainless Steel Vent Termination Kit (3255019) · 4″ Stainless Steel Vent Termination Kit (3255015) · 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 (64980290)
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 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.

LP-454 Date 10.17.23

9

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.

· 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.

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 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.
· 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.

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 flammable liquids.
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. 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.

LP-454 Date 10.17.23

10

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 influenced 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.
All appliances eventually leak. Locate the appliance where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower floors of the building. Any appliance should be installed in such a manner that if it should leak the resulting flow of water will not cause damage to the area in which it is installed. National Plumbing codes require a drain pan for any appliance installation. This drain pan should be sized with a maximum depth of 2″, and a minimum diameter 2″ greater than the diameter of the appliance. The drain pan should empty into an open drain line. This drain line should be 3/4″ ID minimum, piped to an open drain. Leakage damages ARE NOT covered by warranty. Failure to install a drain pan is the sole responsibility of the owner and/or installer. Reference UPC 2000 (Uniform Plumbing Code) Section 510 – Protection from Damage or IPC 200 (International Plumbing code) Section 504 – Safety Devices. Leakage damages ARE NOT covered by warranty. In addition, water leak detection devices and automatic water shutoff valves are readily available at plumbing supply houses. IT IS HIGHLY RECOMMENDED BY THE MANUFACTURER TO INSTALL WATER LEAK DETECTION DEVICES AND AUTOMATIC SHUTOFF VALVES IN ANY APPLIANCE INSTALLATION WHERE A LEAKAGE OF WATER COULD RESULT IN PROPERTY DAMAGES.
Always take future maintenance into consideration when locating the water heater. If the water heater is located in an installation location with limited clearances, it may be necessary to remove the water heater from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.
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 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.

Ensure that all piping and components connected to the water heater are suitable for potable water applications. Do not use this water heater for space heating applications. Circulators suitable for DHW applications must be used. Failure to follow these instructions could result in serious personal injury or death.
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 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.
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.

Do not connect the water heater to any heating systems or components that have been previously used for non-potable applications.
Do not introduce toxic chemicals, such as antifreeze or water heater treatments, into the water heater or any piping meant for potable water purposes.

Figure 2 – Minimum Service Clearances and Drain Pan Dimensions NOTE: For closet installations, a combustible door or removable panel is acceptable front clearance. A 3″ minimum clearance must be provided from the appliance front cover to the removable panel or combustible door.
MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS
· Hot water pipes – at least 1″ from combustible materials
· Exhaust vent pipe – at least 1″ from combustible materials

LP-454 Date 10.17.23

11

Appliance Area Ventilation Air Openings – Closet Installations If the appliance is installed in a closet or alcove the appliance area/ room must be ventilated. EXCEPTION: If the appliance area/room has a volume of 150 ft3 or greater, ventilation of the appliance area/room is not required. Each ventilation air opening must meet the minimum requirements of 1 in2 per 1000 BTU/hr., but not less than 100 in2. The lower ventilation opening must be located within 6 in. of the floor, while the upper opening must be located 6 in. from the top of the space.
! WARNING

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.

If the appliance area has a volume less than 150 ft3, it is considered a Closet or Alcove. In the US/Canada, PVC vent pipe and fittings SHALL NOT BE USED within the closet or alcove. Only approved CPVC, Polypropylene, or Stainless Steel vent pipe and fittings may be used. See Table 6 for a list of approved materials. Under all circumstances proper ventilation must be provided.
The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the appliance. For power venting installations using room air for combustion, refer to the appliance venting section, this manual, for descriptions of confined and unconfined spaces. Do not install the appliance in an attic. The appliance cover must be securely fastened to prevent the appliance from drawing air from the appliance room. This is particularly important if the appliance 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.
Alcove Installations Alcove installations have the same minimum dimensions as closet installations, except the installation must be completely open to the room at a distance no greater than 18 in. (457 mm) from the front of the appliance and the room must be at least three (3) times the size of the alcove. Provided these conditions are met, the appliance requires no extra ventilation air openings to the space. If these conditions are not met, follow the requirements for Closet Installations.
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 floor of the garage. This will ensure the burner and ignition devices are well off the floor.
· When raising the water heater ensure the entire bottom and fully filled weight of the water heater are fully supported.
· Locate or protect the water heater so it cannot be damaged by a moving vehicle.
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 confined and unconfined 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.

Failure to vent the water heater properly will result in serious personal injury or death.
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 first 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. 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, 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 3.
2. Power Venting, Indoor Combustion Air 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 3. 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 3) 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/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.

LP-454 Date 10.17.23

12

Confined 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 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 of this manual.
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.

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 floor 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 certified.
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 3. 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.

· Locate the heater at least 48″ below or horizontally from any window, door, walkway, or gravity air intake.

Products to Avoid

Areas Likely to Have Contaminants

· 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 possible recirculated into the louver system, which could contaminate combustion air.
See Venting section for additional details.

Spray

cans

fluorocarbons

containing 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

Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 3.

Paint or varnish removers Hydrochloric or Muriatic acid Cements and glues

Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction

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 fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor 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 fitter 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 qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

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

Table 3 – 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.)

LP-454 Date 10.17.23

13

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 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.
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. 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 the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace 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. Anode Rod This water heater may be equipped with an anode rod. Anode rods are sacrificial components that counteract water chemistry to minimize or eliminate tank corrosion. The anode rod should be inspected at least annually and replaced as necessary to prolong tank life. Have the supply water quality professionally analyzed, as local water conditions will influence the duration for inspection and replacement of the anode rod. The use of a water softener may increase the speed of anode consumption. More frequent inspection of the anode is needed when using softened or treated water. Water with high sulfate and/or mineral content can produce a rotten egg odor in heated water. Consult a water treatment specialist for potential remedies. NOTE: Failure of a heat exchanger due to lime scale build-up on the heating surface, low pH, or other imbalance IS NOT covered by the warranty. NOTE: Do not remove the anode rod from an operating water heater. Operating the water heater without the anode rod will shorten the life of the tank and VOID the warranty. NOTE: If anode rods are rapidly consumed water chemistry should be tested by a qualified technician. Corrective action should be taken to prevent the premature failure of the water heating system. Operating the water heater with fully consumed anode rods will shorten the life of the tank and VOID the warranty.
Hydrogen gas is produced in a hot water system served by this heater that has not been used for a long period of time (two [2] weeks or more). Hydrogen gas is extremely flammable. To reduce the risk of injury under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. When hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. There should be no smoking or open flame near the faucet at the time it is open.

Figure 3 – CO Warning Label

LP-454 Date 10.17.23

14

E AIR INLET

EXHAUST

HOT WATER OUTLET

GAS CONNECTION
D

ANODE F
ANODE

AUXILIARY J

CONDENSATE LINE
MODEL
PHP199-119 PHP260-119 PHP320-119 PHP399-119

C B A

COLD WATER INLET

G

H

A
11-3/16″ 28.42 cm

B

C

5-1/2″

7″

13.97cm 17.78cm

D
42-1/8″ 107 cm

E

F

G

H

J

77″

49″

195.58 cm

124.46 cm

32″

16″

9-3/4″

81.28 cm

40.64 cm 24.76 cm

85″

58-3/4″

SHIPPING WEIGHT LBS/KG
475 215.46 kg
555
575 260.82 kg

MODEL

COLD WATER INLET

PORT SIZES

HOT WATER OUTLET

AUXILIARY

PHP199-119

PHP260-119 PHP320-119 PHP399-119

1-1/2″ NPT 3.81 cm

1-1/2″ NPT 3.81 cm

1″ NPT 2.54 cm

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

VENTING 3″
7.62 cm
4″

GAS LINE CONDENSATE

3/4″ NPT 1.905 cm

3/4″ NPT 1.905 cm

LP-454-K 08/26/21

Performance Specifications for Phoenix Plus Models

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

BTU/Hr Efficiency (°F)

40

50

60

70

80

90

100 110 120

(°C)

22

28

33

39

44

50

56

61 67

199,000

GPH

579

463

386

331

289

257

LPH 2192 1753 1461 1253 1094 973

232 211 193 878 799 731

260,000 95%
320,000

GPH

756

605

504

432

378

336

303 275 252

LPH 2862 2290 1908 1653 1431 1272 1147 1041 954

GPH

931

745

621

532

465

414

372 339 310

LPH 3524 2820 2351 2014 1760 1567 1408 1283 1174

399,000

GPH 1161 929

774

LPH 4395 3517 2930

Table 4 – 95% Thermal Efficiency Used for Calculations

Performance Equations

Rated Input x .95

GPM =

Temp Rise (oF) x 500

663 2510

580 2196

516 1953

GPH = GPM x 60

464 1756

422 387 1597 1465

130 72 178 673 233 882 286 1083 357 1351

140 78 165 625 216 818 266 1007 332 1257

LP-454 Date 10.17.23

15

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.

B. Auxiliary Connection The auxiliary connection is provided to improve efficiency 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 fittings. Use only copper or brass fittings. 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.
Do not apply a torch within 12″ of the water heater. If sweat connections are used, sweat tubing to the adapter before fitting adapter to the water connections on the heater. Damages due to improper installation practices ARE NOT covered by warranty.
Dielectric unions or galvanized steel fittings must not be used in a system with this water heater. Doing so WILL VOID the warranty. Use only copper, brass, or stainless steel fittings. Teflon thread sealant must be used on all connections.
Plumbing of this appliance should only be done by a qualified, licensed plumber in accordance with all local plumbing codes.
A. General Plumbing Information
Use two wrenches when tightening water piping at heater. Use one wrench to prevent the heater return or supply line from turning. Failure to prevent piping connections from turning could cause damage to heater components.
The heater control module uses temperature sensors to provide both high limit protection and modulating temperature control. 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.
· Pipe material must be suitable to meet local codes and industry standards.
· The pipe must be cleaned and without blemish before any connections are made.
· All water piping should be insulated. 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 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.

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. 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.
D. Potable Expansion Tank A potable hot water expansion tank is required to offset heated water expansion. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent back flowing of water into city mains. Some local codes require back flow preventers on all incoming water supplies. The hot water expansion tank must be listed for potable water use. The expansion tank should be located on the cold inlet piping close to the water heater. Expansion Tank and Make-Up Water

1. Ensure that the expansion tank is sized to correctly handle heater and system water volume and temperature.
   ! WARNING
   Expansion tanks must be sized according to total system volume. This includes all length of pipe, all fixtures, boilers, etc. Failure to properly size for system expansion could result in wasted time, money, possible property damage, serious personal injury, or death.
   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. 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.

LP-454 Date 10.17.23

16

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 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. 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 qualified service technician to ensure that the product has not been affected 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
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 specifically
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.

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 5 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 5 – 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 filling 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-off valve in the cold water supply line.
· Open the hot water faucets to allow air to vent from the heater and piping.
· Allow sufficient time for the heater to completely fill with water.

LP-454 Date 10.17.23

17 H. Applications
Figure 5 – Reverse Manifold Piping NOTES: 1. Minimum pipe size should match 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. All circulators should have an integral flow check. 4. Drains and check valve between unit and storage tank will assist in purging air from system. 5. These drawings are 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. 6. Mixing valve application is optional, but recommended to help prevent scalding. 7. Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done. Running the water heater without water will result in dry-firing.
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.
Figure 6 – Piping with Recirculation Line and Thermostatic Mixing Valve
LP-454 Date 10.17.23

18 Part 5 – Venting

The heater must be vented as detailed in this section. Ensure exhaust vent 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 the instructions provided in this manual. Failure to properly install the vent system will result in severe personal injury or death.
A. General

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 carefully. Failure to do so will result in substantial property damage, severe personal injury, or death.
Exhaust and intake are to be piped separately. This heater cannot share a common exhaust or intake with multiple appliances. Failure to follow these instructions will result in substantial property damage, severe personal injury, or death.
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: Care must be taken to prevent condensate freezing in the exhaust vent pipe system. See local, state, provincial, and national codes for best practices to prevent condensate freezing in the exhaust vent pipe system.
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.
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 vent must be pitched a minimum of 1/4″ 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.
It is required to insert the provided exhaust and intake screens into the vent terminations to prevent blockage caused by debris or birds. Failure to keep terminations clear 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.

· Only Stainless Steel exhaust vent pipe material may be

insulated.

· DO NOT insulate the first three (3) Within First Three (3) Linear Feet of linear feet of the exhaust vent run. Appliance Exhaust Vent Adapter

· DO NOT insulate PVC, CPVC, or

Polypropylene exhaust vent pipe

Enclosed

material. Doing so will cause

Space

increased vent wall temperatures,

which could result in vent pipe failure. · CPVC, Polypropylene, or Stainless Steel pipe material MUST be used if the first three (3) linear feet of the

Exhaust

Length Greater than Six (6) Inches
LP-179-JJ 11/30/17

exhaust vent run passes through

an enclosed space greater than 6″ in length, such as a wall or

ceiling.*

· If CPVC is used to meet these requirements, the balance may be

installed with approved PVC pipe.

· If Polypropylene or Stainless Steel is used to meet these

requirements, the balance of the vent run MUST be installed

with the same material.

· Failure to comply with these requirements could result in

property damage, severe personal injury, or death.

*This rule applies when the exhaust vent passes through the enclosed

space into another interior space, i.e. through a floor or wall from the

mechanical room into another room. This rule DOES NOT apply when

the exhaust vent passes through the enclosed space immediately to the

exterior of the building.

LP-454 Date 10.17.23

B. Approved Materials for Exhaust Vent and Intake Pipe

Item

Material

Pipe and Fittings Approved for Intake ONLY

ABS*

19

Standards for Installation In:

United States

Canada

ANSI/ASTM D2661

ANSI/ASTM D2661

Pipe Approved for Intake OR Exhaust Vent

PVC Schedule 40/80 PVC-DWV Schedule 40/80
CPVC Schedule 40/80 Polypropylene
Stainless Steel AL29-4C

UL-1738 or ANSI/ASTM D1785

UL-1738 or ANSI/ASTM D2665 UL-1738 or ANSI/ASTM F441

UL-1738 or ULC-S636

UL-1738 or ULC-S636

Certified for Category IV and Direct Vent Appliance Venting

Pipe Fittings

PVC Schedule 40
PVC Schedule 80 CPVC Schedule 40 CPVC Schedule 80

UL-1738, ANSI/ASTM D2466 or D2665
UL-1738, ANSI/ASTM D2467 or D2665
UL-1738 or ANSI/ASTM F438
UL-1738 or ANSI/ASTM F439

UL-1738 or ULC-S636

Pipe Cement Pipe Primer

ABS* PVC CPVC PVC / CPVC

ANSI/ASTM D2235 ANSI/ASTM D2564 ANSI/ASTM F493
ASTM F656

ANSI/ASTM D2235
ULC-S636 Approved Cements and Primers

· The exhaust and intake components installed with this appliance must be used for near appliance piping BEFORE transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID appliance warranty.
· In the US/Canada, PVC vent pipe and fittings SHALL NOT BE USED within the closet or alcove. Only approved CPVC, Polypropylene, or Stainless Steel vent pipe and fittings may be used.
· PVC / CPVC pipe and fittings of the same diameter are considered interchangeable.
· The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in exhaust venting systems is prohibited.
· Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. · When installing AL29-4C vent piping, DO NOT mix AL29-4C piping from different manufacturers unless using adapters specifically
designed for the purpose by the manufacturer. · DO NOT mix components from different venting systems without proper adapters. 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 the above table. · A double wall vent or insulated material may be used when using stainless steel vent material in a freezing climate. · *ABS may be used for air intake applications ONLY. · 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.
Table 6 – Approved Materials for Exhaust Vent and Intake Pipe

High heat sources (generating heat 100oF / 37oC or greater, such as boiler flue 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.
NOTE: The use of double-wall vent or insulated material for the combustion air intake pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

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.
C. Additional Requirements for Installation in Canada 1. Installations must be made with a vent pipe system certified to ULC-S636. 2. The first three (3) feet of vent pipe from the appliance 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.

LP-454 Date 10.17.23

20

D. Exhaust Vent and Intake Pipe Location

INSIDE CORNER DETAIL

G
E

A

H

B B

E

OPERABLE

FIXED

CLOSED

E

IE
K

M B

EI

A

J

C
FIXED CLOSED
OPERABLE

E
E
F
E

I

B

EB
L

D I
E
K
LP-179-CC 03/28/17

E Exhaust Vent Terminal I Intake Pipe Terminal

Area Where Intake Terminal Is Not Permitted

Figure 7 – Exit Terminals for Direct Vent Systems – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada

DESCRIPTION

US

CANADA

A Clearance above grade, veranda, porch, deck, or balcony

1 foot (30 cm)

B Clearance to window or door that may be opened

Direct Vent

1 foot

Power Vent

4 ft below or to side of opening; 1 ft above opening

3 feet (91 cm)

C Clearance to permanently closed window

D

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet (61 cm) from the center line of the terminal

E Clearance to unventilated soffit

F Clearance to outside corner

G Clearance to inside corner

H

Clearance to each side of center line extended above meter / regulator assembly

I Clearance to service regulator vent outlet

Above a regulator

within 3 feet (91 cm)

horizontally of the

vertical center line of

the regulator vent outlet

to a maximum vertical

distance of 15 ft (4.5 m)

Direct Vent

1 foot

J

Clearance to nonmechanical air supply inlet to building or

the combustion air inlet to any other appliance

Power Vent

4 ft below or to side of opening; 1 ft above opening

3 feet (91 cm)

K Clearance to mechanical air supply inlet

3 feet above if within 10 feet horizontally

6 feet (1.83 m)

L

Clearance above paved sidewalk or paved driveway located Direct Vent

on public property

Power Vent

• 7 feet (2.13 m)

7 feet (2.13 m)

M Clearance under veranda, porch deck, or balcony

1 foot (30 cm)

Table 7 – Vent Termination Clearances – *NOTE: For clearances not specified in ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada, please use clearances in accordance with local installation codes and the requirements of the gas supplier.

The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routing 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 these requirements could result in product damage, severe personal injury, or death.

LP-454 Date 10.17.23

21

E. Exhaust Vent and Intake Pipe Sizing 1. The exhaust vent and intake pipe size is 4″ for all models. 2. The maximum total equivalent length of 4″ 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.

Friction Loss Equivalent in Piping and Fittings

Fittings or Piping

Equivalent Feet

3″

4″

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 details. Failure to do so could result in property damage, serious injury, or death.

90 Degree Elbow*

5′

3′

45 Degree Elbow

3′

1′

Coupling

0′

0′

Air Inlet Tee

0′

0′

Straight Pipe

1′

1′

Concentric Kit

3′

N/A

V500 2″ Kit

N/A

N/A

V1000 3″ Kit

1′

1′

V2000 4″ Kit

1′

1′

Table 8 – *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 exhaust vent has two 90o elbows and 10 feet of

PVC pipe we will calculate:

Exhaust Vent Equivalent Length = (2×3) + 10 = 16 feet. Further, if the intake pipe has two 90o elbows, one 45o elbow,

and 10 feet of PVC pipe, the following calculation applies:

Intake Pipe Equivalent Length = (2×3) + 1 + 10 = 17 feet.

Total Equivalent Length = 16 + 17 = 33 feet.

The total equivalent length is 33 feet, well below the maximum

of 200 feet.

c. Effort should be made to keep a minimum difference in

equivalent length between the exhaust vent and intake pipe.

d. The vent size on the PHP199-119 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.

Do not reduce the vent size on any model other than the PHP199119. Doing so could result in water heater shutdown and property damage.
! WARNING
Failure to install the appliance within the minimum and maximum vent length requirements could result in improper product operation and property damage, serious personal injury, or death.
F. Exhaust Vent and Intake Pipe Installation

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space. Failure to do so could result in property damage, serious injury, or death.
NOTE: Do not block any air openings in the cabinet to ensure proper cooling and ventilation of components.

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. ABS pipe material 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. If the exhaust vent is to be terminated in a walled off area (such as a roof with a parapet wall), ensure the exhaust vent terminates a minimum of 10′ from nearest wall and extends level with or above the top of the wall. This will ensure flue gas does does not get trapped and possibly recirculated into the intake air pipe, which could contaminate the combustion air. 7. To prevent water leakage, install adequate roof flashing where the pipe enters the roof. 8. The vent for this appliance shall not be located;
a. over public walkways ; or b. near soffit vent , crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage; or c. where condensate vapor could cause damage or be detrimental to the operation of the regulators, relief valves or other equipment. 9. 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.

LP-454 Date 10.17.23

22

10. Horizontal lengths of exhaust vent must slope back towards the appliance not less than ¼” per foot to allow condensate to drain from the vent pipe. 11. Do not terminate vent where vapors can accumulate and harm people or pets. 12. When it can be avoided, do not terminate vent where vapors can damage shrubs or plants. Such damages are not covered by product warranty. 13. Moisture in the exhaust gas will condense as it leaves the vent terminal. In cold weather this condensate can freeze on the exterior wall, under the eaves, and on surrounding objects, including shrubs. Some discoloration to the exterior of the building is to be expected. However, improper location or installation can result in severe damage to the structure or exterior finish of the building, and increase the opportunity for vent blockages and nuisance shutdowns. 14. In vacant chimney applications, install and seal a rain cap over existing chimney openings. 15. 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. 16. Do not use the heater to support any piping. 17. A screened straight coupling is provided with the heater for use as an outside exhaust termination. 18. A screened inlet air tee is provided with the heater to be used as an outside intake termination. 19. Maximum Snow Level Determination: These installation instructions reference snow levels in establishing a minimum height for the installation of exhaust vent or air intake terminations. Snow levels shall be determined as follows:
a. The installation location may, by ordinance, designate how snow levels are calculated in that location; or b. In the absence of specific ordinances, snow levels shall be calculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service’s 10 year statistics for the installation location/geographical area. 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 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 vent near soffit vents, crawl space vents, or other areas where condensate or vapor could create a nuisance or hazard or cause property damage. · DO NOT vent where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valve, or other equipment. In the Commonwealth of Massachusetts and as Required by State and Local Codes: The vented gas fueled appliance shall not be installed so its combustion, ventilation, or dilution air is obtained from a bedroom or bathroom. Signage: Whenever any through-the-wall (horizontal or sidewall) vent is installed less than seven feet above the finished grade, a metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight feet above grade directly in line with the exhaust vent terminal. The sign shall read, in print no less than 0.5 inches in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

Marking of Exhaust Vent and Intake Pipe: Piping used for ventilation, make-up, or combustion air intake shall be labeled as follows:
a. Throughout the entire developed length: i. Labels must be placed every ten feet for exposed/visible piping; or ii. Labels must be placed every three feet for concealed piping.
b. At all changes of direction; c. On each side of a penetration through a partition, wall or ceiling; and d. The labels shall be black lettering that:
i. Indicates that the piping is used for ventilation, make-up, or combustion air intake, and ii. The letters shall be sized equal to a minimum of the pipe diameter. However, for piping with a diameter exceeding two inches, said lettering does not need to be larger than two inches. The following table lists optional exhaust/intake terminations available from HTP:

Description 3″ PVC Concentric Termination Kit 3″ Stainless Steel Termination Kit

Stock Code KGAVT0601CVT
V1000

4″ Stainless Steel Termination Kit

V2000

3″ Polypro Vent Kit Table 9 – Optional Vent Kits

8400P-001

G. Applications
1. Indoor Direct Vent Installation 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 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 pipe 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 pipe 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. NOTE: To prevent combustion air contamination, see Table 3.

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

LP-454 Date 10.17.23

TWO PIPE ROOF VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST)

STRAIGHT COUPLING

24″ MIN.

INSERT INLET/EXHAUST SCREEN INTO
STRAIGHT COUPLING

TEE
INSERT INLET/EXHAUST SCREENS INTO
EACH END OF TEE

12″ OVER MAXIMUM SNOW LEVEL OR 24″ WHICHEVER IS GREATER

Sidewall Venting

with Kit

VENT KIT

23
EXTERIOR WALL
EXHAUST

EXHAUST VENT

RIGHT SIDE VIEW

INTAKE AIR VENT

Sidewall Venting with Tee (Intake) and Exhaust

12″ MIN.

1″ MIN.

LP-445-G 06/23/15

MAINTAIN 12″ MINIMUM CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS
GREATER (TYP)
LP-505-A
Sidewall Venting with Concentric Kit
1″ MIN.
CONCENTRIC VENT KIT

MAINTAIN 12″ MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW
LEVEL OR GRADE, WHICHEVER IS GREATER (TYP.)

EXHAUST
MAINTAIN 12″ MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR 12″
GRADE, WHICHEVER IS GREATER (TYP)
2″ Pipe
INSERT INLET/OUTLET SCREEN INTO EACH END OF TEE
INSERT INLET/OUTLET SCREEN INTO ELBOW
( 90 ELBOW for 2″ PIPE – FACING UPWARD)

INTAKE

LP-179-GG 12/13/16
3″ Pipe
INSERT INLET/OUTLET SCREEN INTO EACH END OF TEE

INSERT INLET/OUTLET SCREEN INTO ELBOW (45 ELBOW FOR 3″ PIPE – FACING DOWNWARD)

CONCENTRIC VENT KIT
Roof Venting with Concentric Vent Kit

IMPORTANT: INTAKE LEG MUST BE FACING UP
EXHAUST
INTAKE

12″ OVER MAXIMUM SNOW LEVEL OR 24″ – WHICHEVER IS GREATER

LP-505-C 05/26/15

Figure 9 – Two Pipe Roof and Sidewall Venting with Included Equipment (Tee and Coupling)
NOTE: When installing two pipe sidewall venting, terminate 2″ exhaust vent pipe with a 90o elbow, and 3″ exhaust vent pipe with a 45o elbow. Failure to do so will result in improper appliance
operation.

LP-505-C 05/26/15

NOTE: EXTENDED VENT RUNS WHEN TRANSITIONING TO A LARGER DIAMETER MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE

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.

All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4″ 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 of 4 foot intervals on the vent pipe. Venting must be readily accessible for visual inspection from the first three feet from the heater.

LP-454 Date 10.17.23

24
Snorkel Venting (Two Pipe Sidewall Venting Terminations Beneath an Overhang)

D

A

Venting Below Grade For installations that exit the wall below grade: 1. Excavate the site to a point where the pipes are to exit as shown
in Figure 12. 2. Ensure the wall is fully sealed where the pipes penetrate. 3. The exhaust vent / air intake piping MUST be secured to the side
of the building above grade, as shown, to provide rigidity. 4. Ensure that the exhaust vent / air intake clearances are maintained.
Exhaust
Air-inlet

Exhaust

Wall Brackets
B

Intake

Figure 12 – Venting Below Grade

Outdoor Venting

Vent piping outside the building is permitted under the following con-

ditions:

1. The maximum length outside the building is 20 feet (6.1 m). Note

that outdoor length must be included in the overall vent length

calculation.

2. All normal termination clearances are maintained.

C

3. The pipe is supported every 24″ (610 mm).

4. The exhaust and air intake are sloped back to the appliance 1/2″

elevation for every linear foot (13 mm for every linear 305 mm).

LP-700-C 05/30/19
Figure 11 – Two Pipe Sidewall (Horizontal Snorkel) Venting NOTES: A. For every 1″ of overhang, the exhaust vent must be located 1″
vertical below the overhang (12″ minimum). Overhang means top of building structure (roof ) and not two adjacent walls (corner of building). B. Maintain minimum separation between exhaust vent and air intake sidewall terminations, as required by local codes. C. Maintain 12″ minimum clearance above highest anticipated snow level or grade (whichever is greater). D. The exhaust vent must extend a minimum of 12″ to a maximum of 24″ beyond the building. NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

Gas Vent Directly Below Keep Free of Obstructions
Exhaust Vent
Maximum of 20 ft [6.1 m] is permitted for piping outside a building.
Figure 13 – Outdoor Venting

LP-454 Date 10.17.23

25
Figure 14 – Unbalanced Venting – Roof Exhaust and Sidewall Intake NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. All vent pipes must be glued, properly supported, and the exhaust pitched a minimum of 1/4″ 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 of 4 foot intervals on the vent pipe. Venting must be readily accessible for visual inspection from the first three feet from the heater.
LP-454 Date 10.17.23

26

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.

Vent / Air Inlet Size Minimum Existing Vent / Chase Size

3″

5″

4″

7″

Table 10 – Minimum Existing Vent / Chase Sizing

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. Use only the approved venting materials specified in Table 6 for piping the system. All instructions listed in this Venting section apply. See Figures 15-1 and 15-2 for venting demonstrations.

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, serious personal injury, or death.

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, serious 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.

ting through an Existing Sy

1

EXHAUST

2

SEAL

EXHAUST SEAL

Chase Venting Through an Existing System When venting as a chase, follow all instructions included in this Venting section, including those in the previous Concentric Venting Through an Existing System section. See Figure 15-3 for chase venting demonstration.
3 EXHAUST

24″ INTAKE

EXISTING

COMBUSTION AIR EXISTING
SEAL

COMBUSTION AIR
AIR INTAKE w/SCREEN 12″ MIN.

EXISTING VENT

SEAL

Exhaust Intake

Exhaust Intake

Exhaust Intake

Exhaust Intake

AIR INTAKE (w/SCREEN)

SEAL

SEALED CAP

SEAL

SEALED CAP

CAP

LP-325-MM

SEAL

03/15/12

Figure 15 – 1, 2 – Concentric Venting ThrLPo-3u25g-LhL an Existing System, 3, Chase Venting Through an Existing System

LP-325-NN 07/22/13

NOTE: These drawings are meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required

by local codes.

LP-454 Date 10.17.23

27

3. Power Venting, Indoor Combustion Air 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 3. 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 16) 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 of this manual. See Figure 17.

DO NOT INSTALL WATER HEATER,
BOILER, OR APPLIANCE NEAR DRYER

Figure 16 – Do Not Place Appliance Near Dryer

Indoor Combustion Air (Single Pipe)

EXHAUST

Outdoor Combustion Air (Single Pipe)

6″
ROOM OPENING
ROOM OPENING
6″

UPPER AIR DUCT

Boiler, Water Heater, or Appliance

LP-325-S 09/29/11

LOWER AIR DUCT

Figure 17 – Indoor and Outdoor Combustion Air – Single Pipe

EXHAUST

Boiler, Water Heater, or Appliance

LP-325-T 8/5/2010

LP-454 Date 10.17.23

28
4. Outdoor Installation
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. This water heater is designed to draw combustion air through the louver system in the front of the heater cabinet. Before 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 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 19 – Recommended Outdoor Enclosure

Figure 18 – Recommended Outdoor Installation Clearances
LP-454 Date 10.17.23

Figure 20 – Outdoor Enclosure with Overhang

29

Part 6 – Condensate Removal
This condensing high efficiency appliance 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 appliance and to a suitable drain. The condensate line must remain unobstructed. If allowed to freeze in the line or obstructed in any other manner, condensate can exit from the appliance tee, resulting in potential water damage to property. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The condensate pump should have an overflow switch to prevent property damage from spillage. Condensate from the appliance will be slightly acidic (pH from 3.2 to 4.5). Check with your local gas company to determine if combustion condensate disposal is permitted in your area. Install a neutralizing filter if required by local codes.

be required. The rate of depletion of the limestone varies with usage of the appliance. During the first year of appliance operation, check the neutralizer every few months for depletion. 9. Route the drain line to a nearby floor drain, laundry tub, or condensate pump. If the appliance condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP). NOTE: If a nearby laundry tub is used as a disposal for waste water from the washing machine, draining the condensate into this tub allows the soapy water discharge to neutralize the acidic condensate. 10. An error will appear on the appliance display if condensate line is blocked. The appliance will not operate with a blocked condensate line. It is extremely important to have this condition repaired by a qualified service technician. 11. Damages due to frozen or blocked condensate lines or leaks ARE NOT covered by warranty.

Power to the optional condensate pump is continuous. When the water heater is powered off the condensate pump will remain on. It is important to remember to turn off the condensate pump when powering down the water heater. Failure to do so could result in property damage, severe personal injury, or death.
NOTES: 1. Due to its efficient design, the appliance produces condensate (water) as a normal by-product. This condensate is acidic, with a pH level between 2 and 4.5. This condensate must be drained away from the appliance and disposed in accordance with all local regulations. 2. The condensate line should be as short as possible and must be pitched at least ¼” per foot to properly drain. If this cannot be done, increase the condensate line and place a tee in the line to properly reduce vacuum lock in the drain line. Tees should be placed after the condensate neutralizer (if used). 3. Use corrosion- resistant materials to drain condensate. Use flexible plastic hose or tube, PVC, or CPVC pipe. PVC or CPVC pipe must comply with ASTM D1785, F441, or D2665. Cement must comply with ASTM D2564 for PVC pipe or F493 for CPVC pipe. For Canadian applications, use CSA or ULC certified flexible tube, PVC or CPVC pipe, fittings, and cement. 4. If using flexible tube, place an overflow tee in the tube line to prevent condensate backing up into the appliance if the tube should kink. Ensure the overflow tee is positioned near a drain or in a location that will not damage the surrounding area. 5. Do not reduce the size of the condensate line. The line must at minimum equal the diameter of the line included with the appliance. 6. 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. Longer condensate runs are more prone to freezing. 7. Support of the condensate line may be necessary to avoid blockage of the condensate flow. 8. Local building codes may require an in- line neutralizer to be installed (not included) to treat the condensate. See Figure 21. If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate (p/n 7450P-212 available from HTP). Follow all the installation Figure 21 – Condensate Piping instructions included with the neutralizer. If a neutralizer is installed, periodic replacement of the limestone (or neutralizing agent) will

LP-454 Date 10.17.23

30
Part 7 – Wiring
Install wiring and electrically ground water heater in accordance with the authority having jurisdiction or, in the absence of such an authority, follow the National Electrical Code, NFPA 70, and/or CSA C22.1 Electrical Code-Part 1 in Canada. Failure to follow all applicable local, state, and national regulations, mandates, and building supply codes for guidelines to install the electrical power supply could result in property damage, serious personal injury, or death. ELECTRICAL SHOCK HAZARD ­ To ensure safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so could result in property damage, serious personal injury, or death. 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. Failure to follow these instructions could result in component or product failure, serious injury, or death.
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. 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 clauses. 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 22 – Line Voltage Wiring
LP-454 Date 10.17.23

31 C. Internal Wiring Diagram

Figure 23 – Stage 1 Wiring Diagram

LP-454 Date 10.17.23

32
Figure 24 – Stage 2 Wiring Diagram – Not Applicable to 199kBTU Models
LP-454 Date 10.17.23

33

Figure 25 – Control Board Wiring

LP-454 Date 10.17.23

34

Part 8 – Gas Connections

! WARNING
FIRE AND/OR EXPLOSION HAZARD To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional.
Ensure the gas on which the boiler will operate is the same type specified on the rating plate (natural gas or LP gas). This boiler must be converted to propane operation. Follow Gas Conversion Manual instructions (separate document). Failure to follow these instructions could result in property damage, personal injury, or death.
Make sure the gas line pressures are within normal limits. Pressures outside normal limits can result in poor performance and hazardous operating conditions, property damage, personal injury, or death.
NOTICE
Do not operate the boiler on Natural Gas or LP gas with average sulfur rates greater than 30 mg/m3. Doing so could result in improper product operation and failure, and WILL VOID the boiler warranty.

A. Gas Pipe Sizing Tables 1. Gas Pipe Sizing This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard for Natural Gas is 1100 BTU/ft3. Contact the local gas supplier for actual BTU/ft3 rating.
2. Natural Gas Pipe Sizing The following table lists maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 14″ or less and a pressure drop of 0.5 inches water column, based on a 0.60 specific gravity for natural gas.
3. LP (Liquid Propane) Gas Pipe Sizing Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

Pipe Size (in.)

10

20

30

3/4

360

247

199

Length of Pipe (Feet)

40

50

60

80

100

150 200

BTU’s Per

Hour x 1,000

1 1 1/4

678

466

374

320

284

257 220

Schedule 40

1390

957

768

657

583

528 452

400

322

275

Metallic Pipe

1 1/2

2090 1430 1150

985

873

2

4020

2760

2220

1900

1680

3

11300 7780

6250

5350

4740

4

23100 15900

Table 11 – Source – ANSI Z223.1

12700

10900

9660

The gas supply shall have a minimum of no less than 3.5″water column, a maximum inlet pressure of no greater than 14″ water column (350 mm), and ½ pound pressure (3.5 kPa). The entire piping system, gas meter, and regulator must be sized properly to prevent excessive 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 the water heater is connected to the gas type 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 26! 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 appliance is no smaller than 3/4″. If the water heater experiences a pressure drop greater than 1″ WC, the meter, regulator, or gas line is undersized or in need of service. A manometer can be attached to the incoming gas drip leg by removing the cap. The gas pressure must remain between 3.5″ and 14″ WC during stand-by (static) mode and while in operating (dynamic) mode at full output. If an in-line regulator is used, it must be installed a minimum of 10 feet from the heater. It is very important that the gas line is properly purged by the gas supplier or utility. Improper line sizing or failure to

791 1520 4290 8760

677 1300 3670 7490

600 1160 3260 6640

482 928 2610 5330

412 794 2240 4560

(0.60 Specific Gravity, 0.5 WC
Pressure Drop)

properly purge the lines will result in ignition failure. This problem is especially noticeable in NEW LP installations, in empty tank situations, or when a utility company shuts off service to an area to maintain supply lines. 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, isolate the heater from the gas line to continue leak testing. To do this, turn off the factory and fieldinstalled gas cocks. 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. 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.

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.

LP-454 Date 10.17.23

35 B. Gas Connection Requirements

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, 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, fire, explosion, property damage, severe personal injury, or death.
1. The gas adapter fitting on the water heater is 3/4″ NPT. NOTE: The gas supply pipe size must not be less than 3/4″.
2. The supply line must be sized for the maximum output of the water heater being installed. If there are additional gas appliances on the main supply line, size the supply line for the maximum total COMBINED BTU/Hr draw of the appliances. This will ensure the supply line is sized to allow all the appliances to operate at the same time.
3. Measure the length of the gas supply line from the gas meter to the water heater. The water heater must be installed downstream of the gas meter to ensure adequate gas supply.
4. Use the table in this manual or refer to the gas line manufacturer’s sizing information to determine the correct supply pipe size. Run the gas supply line in accordance with all applicable codes.
5. The National Fuel Gas Code (NFPA 54) requires that a sediment trap (drip leg) be installed in the gas line on appliances not so equipped. The drip leg must be accessible, a minimum of 3″ in length, and not subject to freezing conditions. See Figure 26.
6. A manual gas shut-off valve should be installed in the gas supply line close to the water heater. Locate and install manual shutoff valves in accordance with local and state requirements.
7. To facilitate any future maintenance, it is also recommended that an approved gas union fitting be installed in the supply line between the shut- off valve and the 1/2″ NPT connection on the water heater.
8. Use a manometer to test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the water heater.
9. Leak test the gas line pipe before placing the water heater in operation. Only use approved leak detector liquid solutions to check for leaks. Never use an open flame to check for leaks.
C. Additional Precaution for Excess Flow Valve (EFV) If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and maximum flow capacity ratings. An improperly sized EFV will not allow for a full flow of gas to the appliance and will cause the appliance to malfunction. See Figure 27.
! WARNING
When performing a pressure test on the gas line piping, be sure the appliance is disconnected or isolated if the test pressure is expected to exceed 1/2 PSI (14″ WC), as damage to the gas valve could occur. Such damage could result in fire, property damage, serious personal injury, or death.

Figure 26 – Gas Connection Figure 27 – Excess Flow Valve (EFV)

LP-454 Date 10.17.23

36

D. Gas Valve
Do not do a gas conversion on this appliance without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the appliance to fire on Natural or Propane gas will result in extremely dangerous burner operation, leading to fire, explosion, severe personal 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.

E. Checking Gas Pressure at the Water Heater for Proper Operation
NOTE: Refer to Figure 28 when checking gas pressure. 1. The water heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at pressures greater than ½ psi (3.5 kPa). 2. The water heater must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa). Loosen the screw on the pressure tap inlet to attach a manometer and check the gas inlet pressure. The minimum and maximum inlet gas line pressures must meet the requirements shown in Table 12.

Natural or LP Gas Minimum Pressure

3.5″ WC

Maximum Pressure Table 12 – Gas Pressure Requirements

14″WC

LP-454 Date 10.17.23

Figure 28 – Gas Valve

37

Part 9 – Start-Up Preparation
Thoroughly clean and flush any system before installing the water heater. A. Check / Control Water Chemistry

· If using softened water to fill 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 effect.
*NOTE:To promote appliance service life, it is strongly recommended to follow the maintenance procedures in this manual.
B. Check for Gas Leaks

Chemical imbalance of the water supply may affect efficiency 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 affect 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 defined 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 fill 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.

Before starting the appliance, and during initial operation, smell near the floor and around the appliance for gas odorant or any unusual odor. Remove appliance front door and smell interior of appliance enclosure. Do not proceed with startup if there is any indication of a gas leak. Repair any leaks at once.
PROPANE ONLY ­ The propane supplier mixes an odorant with the propane to make its presence detectable. In some instances the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas. If you discover any evidence of a gas leak shut down the appliance at once. Find the leak source with a bubble test and repair immediately. Do not start the appliance again until the leak is repaired. Failure to comply could result in substantial property damage, severe personal injury, or death.
C. Fill and Test Water System
The water heater must be full of water and the system fully purged BEFORE powering the water heater. When filling the water heater, open a hot water tap to release air in the water heater 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.
· Ensure any drain valves are completely closed.
· Open the shut-off valve in the cold water supply line.
· Open the hot water faucets to allow air to vent from the heater and piping.
· Allow sufficient time for the heater to completely fill with water.
D. Condensate Removal 1. The water heater is a high efficiency condensing water heater. Therefore, the unit has a condensate drain. Condensate fluid is nothing more than water vapor, derived from combustion products, similar to that produced by an automo

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