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Heat Transfer Gas Fired Installation & Operation Manual

Ultra high efficiency gas/solar water heater
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• Installation
• Operation
• Maintenance
© 2007 Heat Transfer Products, Inc.

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Summary of Contents for Heat Transfer Gas Fired

  • Page 1 • Installation • Operation • Maintenance © 2007 Heat Transfer Products, Inc.
  • Page 2 CONTENTS WARNING If the information in this manual is not followed exactly, a fire or explo- sion may result causing property damage, personal injury or loss of life. 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 •...

  • Page 3: Table Of Contents

    Part 2 – How The Phoenix Operates........

  • Page 4: 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 5: Part 2 - How The Phoenix Operates

    It is very important that the condensate line is sloped away from the water heater and down to a suitable inside drain. If the condensate outlet on the Phoenix is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from Heat Transfer Products, Inc.) A condensate neutralizer, if required by local authorities can be made...

  • Page 6: Part 3: Prepare Water Heater Location

    The Phoenix Solar Hot Water Heater has an internal Solar Heat Exchanger for use with solar panels. The Phoenix Solar will transfer energy from the sun and will provide hot water through the gas fired back-up when there is not sufficient solar energy. (refer to solar piping details in this manual for sug- gested piping application.)

  • Page 7: Before Locating The Phoenix

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

  • Page 8: Residential Garage Installation

    ANSI Z223.1, paragraph 5.1.9: • Place the Phoenix 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 9: When Removing A Water Heater From An Existing Common Vent System

    PART 3: PREPARE WATER HEATER LOCATION (CONTINUED) DANGER Do not install the Phoenix 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 10 PREPARATION PART 3: PREPARE WATER HEATER LOCATION (CONTINUED) 1. Water Hardness Water hardness is mainly due to the presence of calcium and magnesium salts dissolved in the water. The concentration of these salts is expressed in mg/L, ppm or grains per gallon, as a measure of relative hardness of water.

  • Page 11: Temperature And Pressure Relief Valve

    PREPARATION PART 3: PREPARE WATER HEATER LOCATION (CONTINUED) I. TEMPERATURE AND PRESSURE RELIEF VALVE WARNING Following installation of the T & P Relief Valve, the valve lever MUST be operated AT LEAST ONCE A YEAR by the water heater owner to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, blocking waterways, rendering it inoperative.
  • Page 12 The domestic water connections must be installed in accordance to all local and national plumbing codes, or any applicable standard which prevails. The inlet and outlet ports of the Phoenix are 1" on 55 gallon models. On the 80 and 119 gallon models, the inlet and outlet ports are 1 ½". On the cold inlet, (bottom left), install a 1"...

  • Page 13: Expansion Tank

    NOTES: 1. Minimum pipe size should match connection size on Phoenix. 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 backflow preventer and the cold water inlet of the Phoenix.
  • Page 14 NOTES: 1. Minimum pipe size should match connection size on Phoenix. 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.
  • Page 15 PREPARATION REVERSE MANIFOLD AND PIPING DIAGRAM FOR PHOENIX EXPANSION TANK BACKFLOW PREVENTER SHUT-OFF BALL VALVE COLD WATER COLD WATER COLD HOT WATER HOT WATER HOT WATER CHECK VALVE HOT WATER OUTLET AUXILIARY CIRCULATOR CONNECTION (SEE NOTE 4) NOTES: 1. Minimum pipe size should match connection size on Phoenix.
  • Page 16 NOTES: 1. Minimum pipe size should match connection size on Phoenix. 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.
  • Page 17 NOTES: 1. Minimum pipe size should match connection size on Phoenix. 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.

  • Page 18: Part 4: Prepare Water Heater

    Phoenix from the gas line to continue leak testing. In order to do this, you must turn off the factory and field-installed gas cocks. This will minimize the possibility of damaging the Phoenix gas valve.

  • Page 19: Gas Table

    14" WC during stand-by (static) mode and while in operating (dynamic) mode at full output. If an in- line regulator is used, it must be a minimum of 10 feet from the Phoenix. 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 20: Dungs Gas Valve

    A. INSTALLING EXHAUST VENT AND INTAKE AIR VENT DANGER The Phoenix must be vented as detailed in Venting section. 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 21: General

    VENTING PART 5: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) B. GENERAL WARNING This vent system will operate with a positive pressure in the pipe. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure.
  • Page 22 VENTING PART 5: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) any building. e. Provide a minimum of 1 foot clearance from the bottom of the exhaust above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, relief equipment, exhaust fans and inlets.
  • Page 23 VENTING PART 5: 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. 5-1 Fig. 5-2 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot Figure 5-4 Multiple Water Heater Installations Fig.

  • Page 24: Exhaust Vent And Intake Air Vent Sizing

    VENTING PART 5: 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 PH100 and PH130 and 3" for the PH199. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet.

  • Page 25: Exhaust Vent And Intake Air Pipe Installation

    VENTING PART 5: 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 5-6: Vent Run Transition Vent Reducing Vent Connection Coupling Transition 2"...

  • Page 26: Water Heater Removal From A Common Vent System

    VENTING PART 5: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) 8. A screened inlet air tee is provided with the water heater to be used as an outside intake termination. 9. The following information on Table 5-8 lists optional intake air/exhaust vent terminations available from Heat Transfer Products, Inc.
  • Page 27 The pump should have an overflow switch to prevent property damage from condensate spillage. Condensate from the Phoenix will be slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes.

  • Page 28: Diagrams For Venting

    VENTING J. DIAGRAMS FOR VENTING SIDEWALL VENTING WITH TEE (INTAKE) AND SIDEWALL VENTING WITH KIT COUPLING (EXHAUST) EXTERIOR WALL EXTERIOR WALL VENT KIT PART# V500 - 2" V1000 - 3" V2000 - 4" EXHAUST 1" MIN. 12" MIN. EXHAUST INTAKE SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL...

  • Page 29: Part 6. Start-Up Procedure

    1. Turn on all electric power to appliance. Make sure tank is full with cold water and purge all piping. To assure adequate purging, open all hot water faucets. 2. Adjust the temperature setpoint of the Phoenix if desired. The factory default setting is 119°. If changes are ncessary follow “Overall Appliance and Control Operation” in this section.

  • Page 30: Status Menu

    2 minutes. C. STATUS MENU Installers are also able to check the current status of the Phoenix parameters by pressing { S 4/RESET} key for 3 seconds. Once activated, the display will show |d1| alternating value of the actual upper supply tank temperature.

  • Page 31: Maintenance

    VENTING PART 6. START-UP PROCEDURE (CONTINUED) Fig. 6-1 COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS Natural Gas Propane LP high high Carbon Monoxide 0–20 ppm 20 ppm–30 ppm 0–20 ppm 40 ppm–60 ppm (CO%) Carbon Dioxide 8½% –...

  • Page 32: Internal Wiring

    WIRING PART 6. START-UP PROCEDURE (CONTINUED) F. INTERNAL WIRING Phoenix Connector Diagram...

  • Page 33: Part 7: Shutdown

    PART 8: TROUBLESHOOTING A. PHOENIX ERROR CODE An error code may occur in the installation of the Phoenix. This condition may lead to a lock out condition of { S 4/RESET} the controller, which will need to be manually reset through the button.
  • Page 34 TROUBLESHOOTING PART 8: TROUBLESHOOTING (CONTINUED) WARNING When servicing or replacing any components of this water heater be certain that: • The gas is off. • All electrical power is disconnected DANGER When servicing or replacing components that are in direct contact with the heater water, be certain that: •...
  • Page 35 Table for Supply Temperature Code Description Duration Corrective Action Sensor 1. Try reset, if F00 repeats, Phoenix Resistance Table for create a demand for hot Supply Temperature Sensor water (n DANGER: use caution to prevent burn High/Low Temp. Resistance injury) If water is above Sensor Temp.
  • Page 36 (194°) 2. If unit did reset successfully, let the PHOENIX run and go into the status menu to check the upper and lower temperature sensor. If either reading displayed does not make sense, check appropriate sensor with ohmmeter.
  • Page 37 LOW WATER CUT-OFF UPPER TEMP SENSOR LOWER TEMP SENSOR LINE INTAKE COLD WATER EXHAUST INLET VENT AUXILIARY CONNECTION CONDENSATE LINE PHOENIX WATER HEATER DIMENSIONS MODEL GALLONS PH-55 23" 52" 45" 5" 13-1/4" 9-3/4" 6" 3-7/8" 45" 36" 13" 45" PH-80 23"...
  • Page 38 SENSOR CONTROL WELL COLD WATER INLET AUXILIARY HEAT EXHANGER HEAT EXHANGER CONNECTION COLD INLET HOT OUTLET PHOENIX SOLAR WATER HEATER DIMENSIONS MODEL GALLONS A PH-80S 23" 72" 64" 5-1/4" 32" 29" 25-1/2" 5-3/4" 9-3/4" 27-3/4" 64" 36" 32" 64" PH-119S 27"...
  • Page 39 TROUBLESHOOTING ITEM DESCRIPTION PART # Temperature and Pressure Relief Valve TP1400 PVC 1/2" Plug 7100P-080 PVC 1/2" Tee 7100P-079 1/2" NPT x 1/2 Hose Barb 7100P-044 Condensate Hose 7100P-043 Cable Clamp 7250P-649 Spring Clamp (Condensate Hose) 7250P-302 Thermodisc Flue ECO 210 7250P-089 Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154...
  • Page 40 TROUBLESHOOTING ITEM # DESCRIPTION PART # Temperature and Pressure Relief Valve TP1400 PVC 1/2" Plug 7100P-080 PVC 1/2" Tee 7100P-079 1/2" NPT x 1/2 Hose Barb 7100P-044 Condensate Hose 7100P-043 Cable Clamp 7250P-649 Spring Clamp (Condensate Hose) 7250P-302 Thermodisc Flue ECO 210 7250P-089 Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154...
  • Page 41 TROUBLESHOOTING ITEM ITEM DESCRIPTION PART # DESCRIPTION PART # Combustion Blower 7100P-015 16 Control Board Display (w/Ribbon Cable) 7100P-041 Gas Valve Adapter Plate 7250P-644 17 Sight Glass Gasket 7100P-021 Screws M5 x 10 Slotted Countersunk (Gas 7100P-045 18 Sight Glass 7100P-022 Valve Adapter Plate) Housing Cover - Swirl Plate...
  • Page 42 TROUBLESHOOTING...
  • Page 43 TROUBLESHOOTING...
  • Page 44 © 2007 Heat Transfer Products, Inc. LP-179 REV. 7/11/07...

This manual is also suitable for:

SolarPhoenix ph-55Phoenix ph-80Phoenix ph-119Phoenix ph-80sPhoenix ph-119s

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