Heat Transfer Phoenix Evolution Installation & Operation Manual
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Heat Transfer Phoenix Evolution Installation & Operation Manual

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• Installation
• Operation
• Maintenance
Phoenix Evolution Water Heater Models*
PHE130-55 / PHE199-55
PHE130-80 / PHE199-80
PHE130-119 / PHE199-119
*A suffix of "LP" denotes propane and "S" denotes Solar Models
"SNHX" denotes Solar Models without heat exchanger
© 2009 Heat Transfer Products, Inc.

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  • Page 1 • Installation • Operation • Maintenance Phoenix Evolution Water Heater Models* PHE130-55 / PHE199-55 PHE130-80 / PHE199-80 PHE130-119 / PHE199-119 *A suffix of “LP” denotes propane and “S” denotes Solar Models “SNHX” denotes Solar Models without heat exchanger © 2009 Heat Transfer Products, Inc.
  • Page 2 WARNINGS WARNING If the information in this manual is not followed Do not store or use gasoline or other flammable exactly, a fire or explosion may result causing vapors and liquids in the vicinity of this or any property damage, personal injury or loss of life. other appliance.

  • Page 3: Table Of Contents

    Part 2 – How The Phoenix Evolution Operates ....... . .
  • Page 4 Part 9 – Control Overview ..........37-47 A. Navigation of Display B. Programming the Phoenix Evolution C. Appliance Setting Program Navigation Menu D.

  • Page 5: Part 1 - Product And Safety Information

    PRODUCT AND SAFETY INFORMATION PART 1: PRODUCT AND SAFETY INFORMATION WARNING WARNING Failure to adhere to the guidelines on this page Installer — Read all instructions in this manual, can result in severe personal injury, death or and the Venting section, before installing. substantial property damage.

  • Page 6: Part 2 - How The Phoenix Evolution Operates

    The secondary circuit then transfers the last bit of energy to the bottom of the tank where the hot gases are also converted to a water vapor giving the Phoenix Evolution a combustion efficiency of 98% with a thermal efficiency of up to 96%.

  • Page 7: Part 3: Prepare Water Heater Location

    This can be done in the field by the installer or you may purchase one from Heat Transfer Products, Inc. (P/N S7450-028). It is also very important that the condensate line is not exposed to freezing temperatures or any other type of blockage.

  • Page 8: Clearances For Service Access

    3. The Phoenix Evolution gas control system components are protected from dripping or spraying water during operation or service. 4. If the Phoenix Evolution is to replace an existing water heater, check for and correct any existing system problems such as: •...

  • Page 9: Residential Garage Installation

    ANSI Z223.1, paragraph 5.1.9: • Place the Phoenix Evolution with a minimum of 18 inches above the floor of the garage to the bottom of the heater to ensure the burner and ignition devices will be no less than 18 inches above the floor.

  • Page 10: When Removing A Water Heater From An Existing Common Vent System

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

  • Page 11: Water Chemistry For Hydronic Heating Module And Domestic Hot Water

    It is important that the water chemistry on both the domestic hot water and hydronic heating side are checked before installing the Phoenix Evolution as it will affect the reliability of the system. Outlined below are those water quality parameters which need to be met in order for the system to operate efficiently for many years.

  • Page 12: Part 4: Domestic Water Piping

    Failure of the storage tank and heat exchanger of the Phoenix Evolution will affect the warranty if the limits listed below are exceeded. You must consult a water quality company to have the water analyzed and treated.

  • Page 13: Domestic Hot Water Expansion Tank

    COPPER OR BRASS FITTINGS. TEFLON THREAD SEALANT MUST BE USED ON ALL CONNECTIONS. C. DOMESTIC WATER PIPING The domestic water connections must be installed in accordance to all local and national plumbing codes or any applicable standard which prevails. The Phoenix Evolution is supplied with a rated mix-...

  • Page 14: Phoenix Evolution Piping

    D. PHOENIX EVOLUTION PIPING The domestic inlet and outlet ports on all the Phoenix Evolution are 1” NPT connections. We rec- ommend the installation of shut-off valves and unions on both the inlet and outlet ports to isolate the Phoenix Evolution for future service.
  • Page 15 3. The mixing valve may be installed in any position. 4. Any inconsistency between these instructions and any specific instruction, bylaw or code issued by local authorities must be referred back to Heat Transfer Products Technical Support Department prior to any installation taking place.

  • Page 16: Auxiliary Piping

    DOMESTIC WATER PIPING PART 4: DOMESTIC WATER PIPING (CONTINUED) CAUTION The mixing valve is certified to ASSE 1017. It is not to be used to provide anti-scald service. Mixing valves are not designed to compensate for system pressure fluctuations and should not be used where more sophisticated compensating temperature controls are required.

  • Page 17: Part 5: Hydronic Piping

    HEATING SYSTEM RETURN HEATING SYSTEM SUPPLY directly to the Phoenix Evolution Storage Tank. The heated water inside the tank will be circulated through one side of the brazed plate heat exchanger while the heating system water flows through the other side.

  • Page 18: Hydronic Heating Module System Piping

    Normal system pressure is 15 PSI. D. HYDRONIC HEATING MODULE SYSTEM PIPING The Phoenix Evolution Hydronic Heating Module is designed to function in a closed loop hydronic system. The temperature and pressure gauge (included) will allow the user to monitor the system pressure and temperature from the Hydronic Heating Module.The gauge should be installed on the...

  • Page 19: Hydronic Heating Module Output

    Example: System Design requires 120,000 BTU at 20 Delta Step 1 Using the graphs, select the input rate of the Phoenix Evolution – In this example we would have to select a minimum input of 199K Phoenix Evolution (the 130K max. output is 100, 000 BTU which falls below our operating point).
  • Page 20 HYDRONIC PIPING PART 5: HYDRONIC PIPING (CONTINUED) Evolution Sizing Chart (130K BTU Burner Input) 140000 120000 Max Limit 100000 20 T 25 T 80000 30 T 15 T 35 T 60000 40 T 10 T 40000 20000 Heating System Flow (GPM) Fig.
  • Page 21 PHOENIX EVOLUTION AIR HANDLER APPLICATION NOTES: 1. Minimum pipe size should match connection size on Phoenix Evolution. If you require greater flow, upsize the pipe accordingly. 2. A Thermal Expansion tank suitable for potable water must be sized and installed within this piping system between the check valve and the cold water inlet of the Phoenix Evolution.
  • Page 22 PRESSURE REDUCING VALVE NOTES: 1. Minimum pipe size should match connection size on Phoenix Evolution. If you require greater flow, upsize the pipe accordingly. 2. A Thermal Expansion tank suitable for potable water must be sized and installed within this piping system between the check valve and the cold water inlet of the Phoenix Evolution.
  • Page 23 2. A Thermal Expansion tank suitable for potable water must be sized and installed within this piping system between the check valve PRESSURE and the cold water inlet of the Phoenix Evolution. TEDUCING VALVE Check with the Manufacturer of the Thermal Expansion tank for EXPANSION proper sizing.

  • Page 24: Part 6: Field Wiring

    2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes. B. FIELD WIRING All the wiring connections made to the Phoenix Evolution in the field are done on the field connec- tion board located on the right side of the cabinet. The cabinet has multiple knockouts available to route field wiring into and out of the field connection board.

  • Page 25: Field Connection Board

    FIELD WIRING PART 6: FIELD WIRING (CONTINUED) temperature accurately. Note: If the thermostat is equipped with an anticipator and it is connected directly, the anticipator should be set at.1 amps. If the thermostat is connected to other devices, the anticipator should be set to match the power requirements of the device it is connected to.

  • Page 26: Internal Wiring

    FIELD WIRING PART 6: FIELD WIRING (CONTINUED) F. INTERNAL WIRING LP-314-L Fig. 6-2 Phoenix Evolution Internal Connection Diagram 11/03/09...

  • Page 27: Part 7: Gas Connection

    National Fuel Gas Code. You must ensure that the entire gas line to the connection at the Phoenix Evolution is no smaller than ¾". Once all the inspections have been performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than the maximum gas inlet pressure, you must iso- late the Phoenix Evolution from the gas line to continue leak testing.

  • Page 28: Gas Piping

    (static) mode and while in operating (dynamic) mode at full output. If an in-line regulator is used, it must be a minimum of 10 feet from the Phoenix Evolution. It is very important that the gas line is properly purged by the gas supplier or utility. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

  • Page 29: Dungs Gas Valve

    WARNING Do not do a gas conversion on this unit without an officially approved conversion kit and instructions supplied by Heat Transfer Products, Inc. Failure to do so could result in death or serious injury. E. HOW TO VERIFY COMBUSTION Fig.

  • Page 30: Part 8 - Venting, Combustion Air And Condensate Removal

    A. GENERAL DANGER The Phoenix Evolution must be vented as detailed in The Venting Section Part 8. Ensure the exhaust and intake piping comply with these instructions regarding vent system. Inspect finished combustion air intake and exhaust piping thoroughly to ensure all joints are well secured and airtight and comply with all applicable code requirements, as well as with the instructions provided in this manual.
  • Page 31 VENTING PART 8: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) WARNING Both exhaust and intake air vents must exit from the same side of the building to assure correct appliance operation. a. The vent piping for this unit is approved for zero clearance to combustible construction. b.
  • Page 32 VENTING PART 8: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Fig. 8-1 Multiple Vents Fig. 8-2 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot. There should be no more than 2 vents and 2 intakes then a space of 36” to the next set of vents.

  • Page 33: Exhaust Vent And Intake Air Vent Sizing

    VENTING PART 8: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) E. EXHAUST VENT AND INTAKE AIR VENT SIZING 1. The exhaust and intake vent size is 2" for the PHE130 and 3" for the PHE199. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet.

  • Page 34: Exhaust Vent And Intake Air Pipe Installation

    VENTING PART 8: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) b. Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe. Table 8-7: Vent Run Transition Vent Reducing Vent Connection Coupling Transition 2"...

  • Page 35: Water Heater Removal From A Common Vent System

    Inc.) A condensate filter, if required by local authorities can be made up of lime crystals, marble or phosphate chips that will neutralize the condensate. This can be done in the field by the installer or you may purchase one from Heat Transfer Products, Inc. (P/N S7450-028) It is also very important...
  • Page 36 The pump should have an overflow switch to prevent property damage from condensate spillage. Condensate from the Phoenix Evolution will be slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes.

  • Page 37: Diagrams For Venting

    VENTING J. DIAGRAMS FOR VENTING ROOF VENT WITH TEE (INTAKE) SIDEWALL VENTING WITH TEE (INTAKE) AND AND COUPLING (EXHAUST) COUPLING (EXHAUST) 1" 24'MIN EXTERIOR WALL 12" OVER MAXIMUM SNOW LEVEL OR 24" WHICHEVER INTAKE IS GREATER. 12" MIN. ROOF VENT WITH TEE (INTAKE) AND COUPLING (EXHAUST) MAINTAIN 12"MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED...

  • Page 38: Part 9 - Control Overview

    It is important to fully understand the capability of the control. This section address- es Phoenix Evolution Settings / System Settings / Maintenance Settings and System Diagnostics to help customize your control. This control is programmed to run with factory defaults that may already fit your hydronic design and may not require any adjustment at all.

  • Page 39: Appliance Setting Program Navigation Menu

    CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) ENTER MENU CODE Using the arrow keys on the display, log in the Access Code “600”. To confirm the code, press the ENTER Key to access Program Navigation Menu. ENTER MENU CODE C. APPLIANCE SETTING PROGRAM NAVIGATION MENU Once the code is confirmed, the user can now start to set the Appliance Settings.
  • Page 40 CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) TEMP DISPLAY C OR F °F Function: Allows the user to adjust the temperature measurement to either Fahrenheit to Celsius (Factory Default is F = Fahrenheit) Clock Settings (Note: The clock will reset if the boiler is powered off for more than a week). CLOCK MODE (12/24) 08/28/2009...

  • Page 41: Programming The System Setting

    CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) CLOCK DATE 08/28/2009 Fr 10:01A D. PROGRAMMING THE SYSTEM SETTING Note: Programming of the control is not possible when the unit is firing. Make sure any input such as the thermostat is turned off, so the boiler will remain idle to allow programming. To access The System Setting Program the user will need to press the ENTER Key for 4 seconds until the display shows the following: ENTER MENU CODE...
  • Page 42 CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) Function 4 Warm Weather Shutoff WARM WEATHER OFF 68 °F Description: Warm Weather Shut off will disable the heating module and the Total System Control will then optimize for domestic hot water only. Warm Weather Shut off will occur if the programmed outdoor temperature is exceeded by the current outdoor sensor temperature.
  • Page 43 CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) Function 10 CH Post Pump Time CH POST PUMP TIME 10 0 MINUTES Description: Allow the user to set the central heating pump post purge time once the thermostat is satisfied: Factory Default: 0 minutes – Range (0 – 10 minutes) . Function 11 DHW Priority DHW PRIORITY...

  • Page 44: Phoenix Evolution Control Status Menu

    F. PHOENIX EVOLUTION CONTROL STATUS MENU: The Phoenix Evolution Controller also has the ability to review the status of the system. To access the status screens simply press the right arrow key . Once the first value is displayed than press...
  • Page 45 CONTROL OVERVIEW PART 9: CONTROL OVERVIEW (CONTINUED) Press the key once CH TARGET 140°F CH SUPPLY 122°F This screen displays the current central heating temperature set point on the top line. Note: That this temperature set point may vary from what was set in the Appliance Settings screen if an outdoor sensor is used.
  • Page 46 CONTROL OVERVIEW / START-UP PROCEDURE PART 9: CONTROL OVERVIEW (CONTINUED) Press the key once DHW USE CH USE The top line of this display indicates the percentage of energy used for domestic hot water over the appliance lifetime. The bottom line of this display indicates the percentage of energy used for cen- tral heating over the appliance lifetime.

  • Page 47: Part 10 - Start-Up Procedure

    START-UP PROCEDURE PART 9: CONTROL OVERVIEW (CONTINUED) the bottom line will display the date and time that the fault occurred. Press the key once FAULT HISTORY 08/28/2009 5:19A This screen displays the fifth oldest lockout fault the boiler controller had. The top line will alternate between the words ‘FAULT HISTORY’...

  • Page 48: Fill And Purge Dhw

    A. FILL AND PURGE DHW The power must remain off until the potable water side of the Phoenix Evolution is fully purged of air. To purge the tank, turn on the cold water feed and open a faucet at the highest point of the sys- tem.

  • Page 49: Fill And Purge Hydronic Heating Loop

    START-UP PROCEDURE PART 10. START-UP PROCEDURE (CONTINUED) B. FILL AND PURGE HYDRONIC HEATING LOOP Freeze Protection (When Used) WARNING Never use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems. Use only freeze – prevention fluids certified by fluid manufacturer as specified for use with Stainless Steel Hydronic Heating Module Heat Exchanger and verified in fluid manufacturer’s literature.

  • Page 50: Purge Air From Hydronic Heating Module

    Before powering up the control assure the thermostat connection is disconnected on the field con- nection board. Apply power to the Phoenix Evolution (Note: The Phoenix Evolution will fire the burn- er and heat the water inside the storage tank to the domestic hot water temperature set point). Press The display can show the temperature set point of the Phoenix Evolution.
  • Page 51 START-UP PROCEDURE PART 10. START-UP PROCEDURE (CONTINUED) • Turn down thermostats, making sure that they are set so there is no call for heat while programming. This section discusses how to program your control for optimum system performance. This sec- tion will walk you through a few of the major sections of the control parameters.
  • Page 52 START-UP PROCEDURE PART 10. START-UP PROCEDURE (CONTINUED) return to the home screen on the display. This completes the essential programming in Appliance Setting Programs. If other values need to be changed in this section such as the display time, refer to the Control Overview section Part 9. 10) To further optimize the system performance and efficiency a proper outdoor reset curve should be set.
  • Page 53 START-UP PROCEDURE PART 10. START-UP PROCEDURE (CONTINUED) 13) Use the right arrow button 3 times to scroll to Function 4 “WARM WEATHER OFF”. This is the warm weather shut down. This function determines at which outdoor temperature to turn off the hydronic heating module, and operate only as a water heater for the warmer weather.

  • Page 54: Maintenance

    If any of the sensors detect an abnormal condition or an internal component fails during the opera- tion of the Phoenix Evolution, the display may show an error message and error code. This message and code may either be the result of a temporary condition in which case the display will revert to...

  • Page 55: Appliance Error

    FAULT Light will be lit steadily and the message “LOCKOUT” will be displayed on the readout on the lower line. The Phoenix Evolution will not start until a qualified technician has repaired the boiler and pressed the RESET button for more than 1 second. If there is an error mes- sage displayed on the readout and the message “LOCKOUT”...
  • Page 56 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) CAUTION This appliance has wire function labels on all internal wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing. Table 12-1: Resistance Tables Outdoor Sensor (7250P-319) Temperature Sensors...
  • Page 57 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) to enable this feature. The unit will continue to operate when this error is displayed but the control will ignore the outdoor reset feature and run at the programmed temperature. The bottom line of the display will indicate the status of the pump.
  • Page 58 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) temperature rises. Fault Code E19 LINE VOLTAGE PUMP OFF Description: This display indicates that the line voltage frequency is out of range. This could happen if the unit is being powered from a small gasoline powered generator that is not functioning correctly or over- loaded.
  • Page 59 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) Fault Code LOU 24 VOLT LOW PUMP ON Description: This display indicates that the 24 volt power supply on the control is damaged or overloaded. This code will reset automatically if it is the result of an overload and that overload condition is removed. The second line indicates the status of the pump.
  • Page 60 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) Fault Code F01 FLUE TEMP PUMP ON Description: This display indicates that the flue temperature limit switch of the unit has tripped. This code indi- cates a serious safety issue. The unit will not restart until the flue cools down sufficiently and a tech- nician repairs the cause of the problem and pushes the RESET button on both the device and the display.
  • Page 61 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) Fault Code F05 TOP TEMP HIGH PUMP ON Description: This display indicates that the top temperature of the tank is excessive. If this code is accompanied by the illuminated red ‘FAULT’ light and ‘LOCKOUT’ flashing on the display then this code indicates that the temperature on the top sensor has exceeded 230 deg.
  • Page 62 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) will be on as indicated on the second line of the display Remedy: 1. Watch the igniter through the observation window provided. 2. If there is no spark, for natural gas units check the spark electrode for the proper gap. Use 2 quarters together as a gauge to hold ignitor against to check gap distance.
  • Page 63 24 to 40 volts. If it is lower than 24 volts, check for excessive external loads connected to the Phoenix Evolution sensor terminals. Disconnect the 5 pin plug from the fan and check the voltage on the red wire again. If it is now between 24-40 volts, replace the fan.
  • Page 64 TROUBLESHOOTING PART 12: TROUBLESHOOTING (CONTINUED) this error occurs at any time other than when a technician is servicing the unit, the control has failed and must be replaced by a qualified technician. Remedy: Control must be re-programmed. If programming does not solve problem, control must be replaced. Fault Code PP CONTROL PROGRAMED Description:...
  • Page 65 LOWER TEMP SENSOR AIR INTAKE EXHAUST VENT AUXILIARY ELECTRICAL CONNECTION CONNECTIONS COLD WATER INLET CONDENSATE DRAIN FRONT HEAT PACK PHOENIX EVOLUTION WATER HEATER DIMENSIONS MODEL #* GALLONS PHE130-55 / 23" 34" 53" 46" 19-1/2" 7-3/8" 14-1/2" 5" 14" 46" 46" PHE199-55 LINE PHE130-80 / 23"...
  • Page 66 38-1/2" 26" 37" 24" 31-1/4" 64-1/2” 64-1/2" 10-1/4” 10-1/4” PHE199-80S PHE130-119S / 27" 37" 74" 65-3/4" 38-1/2" 26" 37" 24" 33" 64-1/2” 66-1/2" 5-3/4” 5-3/4” PHE199-119S PHOENIX EVOLUTION SOLAR WATER HEATER SPECIFICATIONS AIR INTAKE/ WATER INLET/ AUXILIARY GAS LINE SYSTEM RELIEF SHIPPING...
  • Page 67 TROUBLESHOOTING REPLACEMENT ITEM # PART # DESCRIPTION QTY. PART # TP1400 TP1400 TEMPERATURE AND PRESSURE RELIEF VALVE 7100-006 7100P-006 HIGH LIMIT SAFETY 7100-852-1 7100P-852-1 LOW WATER CUT-OFF SENSOR 7100-004 7100P-004 UPPER TEMPERATURE SENSOR 7100-005 7100P-005 LOWER TEMPERATURE SENSOR 7100-172 7100P-172 CLIP-ON PIPE TEMPERATURE SENSOR 7100-132 7100P-132...
  • Page 68 TROUBLESHOOTING LP-314-H REV. 12/14/09 LP-314-G REV. 11/19/09...
  • Page 69 TROUBLESHOOTING...
  • Page 70 TROUBLESHOOTING...
  • Page 73 MAINTENANCE NOTES...
  • Page 74 MAINTENANCE NOTES...
  • Page 75 MAINTENANCE NOTES...
  • Page 76 © 2009 Heat Transfer Products, Inc. www.htproducts.com LP-314 REV. 12/21/09...

This manual is also suitable for:

Phoenix evolution phe130-55Phoenix evolution phe199-55Phoenix evolution phe130-80Phoenix evolution phe199-80Phoenix evolution phe130-119Phoenix evolution phe199-119

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