HTP PHE130-55 Installation Start-Up Maintenance Parts
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HTP PHE130-55 Installation Start-Up Maintenance Parts

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This manual must be used by a qualified installer/service technician. Read all instructions in this manual
before installing. Perform steps in the given order. Failure to comply could result in substantial property
damage, severe personal injury, or death.
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held
liable for typographical errors in literature.
120 Braley Rd. P.O. Box 429
"SNHX" indicates solar models without heat exchanger
East Freetown, MA 02717-0429
Versa-Hydro
INSTALLATION
MAINTENANCE
Versa-Hydro Water Heater Models*
PHE130-55 / 199-55
PHE130-80 / 199-80
PHE130-119 / 199-119
*A suffix of "LP" denotes propane gas
"S" indicates solar models
www.htproducts.com
START-UP
PARTS

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  • Page 1 Perform steps in the given order. Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
  • Page 2 IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
  • Page 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 death or serious injury.

  • Page 4: For The Installer

    FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. This appliance must be installed by qualified and licensed personnel.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PART 1 – GENERAL SAFETY INFORMATION ..................7 A. PRECAUTIONS ............................ 7 B. IMPROPER COMBUSTION........................8 C. GAS ............................... 8 D. WHEN SERVICING THE HEATER ...................... 8 E. HEATER WATER ..........................8 PART 2 – HOW THE HEATER OPERATES ....................8 PART 3 –...
  • Page 6 B. FIELD WIRING ............................ 30 C. LINE VOLTAGE WIRING........................30 D. LOW VOLTAGE WIRING ........................30 E. FIELD CONNECTION BOARD ......................31 F. INTERNAL WIRING ..........................32 PART 7: GAS CONNECTION ........................33 A. GAS SUPPLY ............................. 33 B. GAS PIPING ............................33 C.

  • Page 7: Part 1 - General Safety Information

    D. APPLIANCE CONTROL FAULT CODES ................... 66 PART 13: MAINTENANCE ......................... 80 MAINTENANCE NOTES ..........................83 HTP CUSTOMER INSTALLATION RECORD FORM ................ 84 PART 1 – GENERAL SAFETY INFORMATION A. PRECAUTIONS This appliance is for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back.

  • Page 8: Improper Combustion

    NOTE: If the heater is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman: 1. FIRE 2. DAMAGE 3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
  • Page 9 HTP). A condensate filter, if required by local authorities, will neutralize the condensate, and can be made up of lime crystals, marble or phosphate chips. This filter can be purchased from HTP (p/n 7450P-212) and installed in the field.

  • Page 10: Part 3 - Prepare Water Heater Location

    Spark Ignition The burner flame is ignited by applying high voltage to the system spark electrode. This causes a spark from electrode to ground. Outdoor Sensor The outdoor sensor monitors outdoor temperature and adjusts the set point to provide greater efficiency. Water temperature over 125 F can instantly cause severe burns, or death, from scalds.

  • Page 11: Clearances For Service Access

    C. CLEARANCES FOR SERVICE ACCESS Figure 1 - If you do not provide the minimum clearances shown above, it might not be possible to service the heater without removing it from the space. A water heater pan must be installed to protect the surrounding area from damage caused by leaking water.

  • Page 12: Direct Vent Installation Of Exhaust And Intake

    1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1.

  • Page 13: Prevent Combustion Air Contamination

    Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space, which could result in severe personal injury or death. NOTE: To prevent combustion air contamination, see Table 1. F. PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the heater as described in the Venting section.

  • Page 14: Water Chemistry

    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 appliance remains connected to the common venting system and other spaces in the...

  • Page 15: Part 4: Domestic Water Piping

    heater industry. Hardness expressed as mg/L or ppm may be divided by 17.1 to convert to grains per gallon. Water may be classified as very soft, slightly hard, moderately hard, or hard based on its hardness number. The minerals in the water precipitate out when the water is heated and cause accelerated lime and scale accumulation on a heat transfer surface.

  • Page 16: Domestic Hot Water Expansion Tank

    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.

  • Page 17: Domestic Water Piping

    C. DOMESTIC WATER PIPING Domestic water connections must be installed in accordance with all local and national plumbing codes or any applicable prevailing standards. The appliance is supplied with a rated mixing valve certified to ASSE 1017. You must completely follow the instructions included with the mixing valve for proper installation. This mixing valve must be installed on the domestic outlet to assure that hot water temperature does not vary more than +/–...
  • Page 18 Differential pressure at the valve inlet should be within a 5 to 1 ratio under normal flow conditions. Inline fittings, pipe work, layout and sizing must be taken into consideration. In installations where the valve is supplied with unbalanced hot cold pressures greater than a 5 to 1 ratio, please call HTP Technical Support Department.
  • Page 19 The mixing valve is certified to ASSE 1017. It is not to be used to provide anti-scald service resulting from system pressure fluctuations, and should not be used where more sophisticated compensating temperature controls are required. Installation of the Mixing Valve 1.

  • Page 20: Auxiliary Piping

    • When checking the mixed water supply temperature, use the same faucet used in the initial installation temperature adjustment. • There may be some variation in the water temperature from the mixing valve due to seasonal temperature variations in the cold water supply. If the water supply is of poor quality, the internal components may jam, requiring an additional filter or strainer to be fitted to the system.

  • Page 21: Pressure Relief Valve For The Hydronic System

    B. PRESSURE RELIEF VALVE FOR THE HYDRONIC SYSTEM The pressure relief valve supplied with the heater is designed to relieve pressure greater than 30 psi. The hydronic heating module is designed to withstand pressure up to 150 psi. If you are changing the pressure relief valve for a higher pressure rating, you must make sure that the system components are designed for the higher pressure.

  • Page 22: Hydronic Heating Module Output

    6. Install the system circulator as shown in the piping details in this section. Make sure the circulator is properly sized for the system and friction loss. 7. Install an expansion tank on the system supply. Consult the expansion tank manufacturer’s instructions for specific information related to expansion for the required system volume and capacity.
  • Page 23 Figure 5 Figure 6...
  • Page 24 Figure 7...

  • Page 25: Hydronic Piping

    F. HYDRONIC PIPING Figure 8...
  • Page 26 Figure 9...
  • Page 27 Figure 10...
  • Page 28 Figure 11...
  • Page 29 Figure 12...

  • Page 30: Part 6: Field Wiring

    PART 6: FIELD WIRING A. FIELD WIRING COMPLIANCE REQUIREMENTS ELECTRICAL SHOCK HAZARD – For your safety, to avoid possible electrical shock hazard, turn off electrical power supply at service entrance panel before making any electrical connections. Failure to do so can result in severe personal injury or death. NOTE: Wiring must be N.E.C.

  • Page 31: Field Connection Board

    devices, the anticipator should be set to match the power requirements of those connected devices. Refer to the instruction manuals of the connected devices for further information. 3. The outdoor sensor must be connected for the unit to operate at optimum efficiency. Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs up to 150 feet.

  • Page 32: Internal Wiring

    F. INTERNAL WIRING Figure 14 – Internal connection diagram...

  • Page 33: Part 7: Gas Connection

    It is of extreme importance that this unit be properly grounded. Prior to making any electrical connections, It is very important that the building system ground is inspected by a qualified electrician. Make certain that electrical power is only turned on when the unit is completely filled with cold water. PART 7: GAS CONNECTION Failure to follow all precautions in this section could result in fire, explosion, or death! A.

  • Page 34: Gas Table

    C. GAS TABLE Refer to the following table to size the supply piping to minimize pressure drop between meter or regulator and unit. Maximum capacity of pipe in cubic feet of gas per hour for gas pressures of .5 psi or less and a pressure drop of .3”...

  • Page 35: How To Verify Combustion

    Do not do a gas conversion on this unit without an officially approved conversion kit and instructions supplied by HTP. Failure to do so could result in serious injury or death. E. HOW TO VERIFY COMBUSTION To activate service mode, press the up arrow ▲ and ENTER key together for 1 second. The unit will go through the ignition sequence.

  • Page 36: General

    A. GENERAL 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. Follow the venting instructions below carefully. Failure to do so may result in substantial property damage, severe personal injury, or death.

  • Page 37: Determine Air Intake Vent Location

    h. Do not locate the exhaust directly under roof overhangs to prevent icicles from forming. i. Provide 4 feet clearance from the inside corner of vertical walls, chimneys, etc., as well as horizontal corners created by roof overhangs. 2. DETERMINE AIR INTAKE VENT LOCATION a.
  • Page 38 Figure 17...

  • Page 39: Exhaust And Intake Air Vent Sizing

    D. EXHAUST 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 and intake air vents should not exceed 85 ft. a.

  • Page 40: Exhaust And Intake Air Vent Installation

    7. A screened straight coupling is provided with the unit for use as an outside exhaust termination. 8. A screened inlet air tee is provided with the water heater to be used as an outside intake termination. 9. The following table lists optional intake air/exhaust vent terminations available from HTP. VENT TERMINATION KITS...

  • Page 41: Venting Drawings

    G. VENTING DRAWINGS 1. DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE If installing a direct vent option, combustion air must be drawn from the outdoors directly into the appliance intake, and exhaust must terminate outside. There are three basic direct vent options detailed in this manual: 1.
  • Page 42 Figure 19 – LP-314-D NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 43 Figure 20 – LP-314-E NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 44 Figure 21 – LP-314-F NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 45 Figure 22 – LP-314-J NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.
  • Page 46 Figure 23 – LP-179-AA NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes.

  • Page 47: Indoor Combustion Air Installation In Confined Or Unconfined Space

    2. INDOOR COMBUSTION AIR INSTALLATION 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 1 on page Error! Bookmark not defined..
  • Page 48 Figure 25...

  • Page 49: Condensate Removal System

    If the heater condensate outlet is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP). If required by local authorities, a condensate filter of lime crystals, marble, or phosphate chips will neutralize slightly acidic condensate. This can be installed in the field and purchased from HTP (p/n 7450P-212).

  • Page 50: Part 9: Control Overview

    PART 9: CONTROL OVERVIEW The control monitors the safety sensors of the heater to assure safe and efficient operation. It has many features to address configurations associated with hydronic design. This section addresses the programming features of the control. It is important to fully understand its capabilities.

  • Page 51: Appliance Setting Program Navigation Menu

    To access the Program, the user will need to press the ENTER key for 4 seconds until the display shows the following: Use the arrow keys on the display to log in Access Code “600”. To confirm the code, press ENTER to access the Program navigation menu.
  • Page 52 Function: Allows the user to adjust the temperature measurement to either Fahrenheit or Celsius (Factory default is F = Fahrenheit). Clock Settings (Note: The clock will reset if the boiler is powered off for more than a week.) Function: Changes the clock from 12 hour mode (8:45 PM) to 24 hour mode (20:45). To change to 24 hour mode when this screen is displayed, press the ENTER key.

  • Page 53: Programming The System Setting

    D. PROGRAMMING THE SYSTEM SETTING NOTE: Programming 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, press the ENTER Key for 4 seconds until the display shows the following: Next, use the arrow keys on the display to log in the System Menu Access Code “925”.
  • Page 54 Function 4 Warm Weather Shutoff Description: Warm Weather Shutoff disables the heating module and the Total System Control will then optimize for domestic hot water only. Warm Weather Shutoff will occur if the programmed outdoor temperature is exceeded by the current outdoor sensor temperature. Factory default 68 F (Range 41 F to Function 5...
  • Page 55 Function 11 DHW Priority Description: Allows the user to set DHW priority time, which is the amount of time to shut down the hydronic heating module when the system control senses a large domestic hot water usage. Factory default 30 minutes (Range 0 to 60 minutes). Function 12 Error Outdoor Sensor Description: Allows the user to set the control to display an error message if an outdoor sensor is open or...

  • Page 56: Control Status Menu

    Description: This parameter sets the 2 middle digits of the amount of run hours until the next service reminder. Function 17 Description: Sets the day in the date function. Description: Sets the 2 right digits of the amount of run hours until the next service reminder. Function 18 Description: Allows the user to input a telephone number that will be displayed when maintenance is required.
  • Page 57 Press the ▼ key once. The top line of this screen displays the current domestic hot water temperature set point entered in the Appliance Settings. The bottom line displays the current tank target temperature. NOTE: This target tank temperature set point will vary due to the total system control that is based on environment and system conditions.
  • Page 58 Press the ▼ key once. This screen displays the second oldest lockout fault the heater control had. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred. Press the ▼...

  • Page 59: Part 10: Start-Up Procedure

    Press the ▼ key once. This screen displays the eighth oldest lockout fault the heater control had. The top line will alternate between the words “FAULT HISTORY” and the fault encountered. The bottom line will display the date and time the fault occurred. Press the ▼...

  • Page 60: Fill And Purge Dhw

    A. FILL AND PURGE DHW The power must remain off until the potable water side of the heater 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 system. Observe filling of the tank and inspect for any leaks in the system which may occur and need to be repaired.

  • Page 61: Purge Air From Hydronic Heating Module

    C. PURGE AIR FROM HYDRONIC HEATING MODULE a. Connect to a purge and drain valve location (shown in piping details) and route hose to an area where water can drain and be seen. b. Close the ball valves below the purge and drain valve. c.
  • Page 62 2. Press and hold ENTER for 4 seconds until you see the screen to enter the log in access code shown below. 3. Use the  key to move the blinking zero to the left most zero. Next, use ▲ and ▼ to log in 600, the access code.
  • Page 63 Figure 27 10. Press and hold ENTER for 4 seconds until you see the screen to log in the access code. 11. Use the  and  arrow keys to move the blinking zero to the left and right. Next, use the ▲ and ▼ arrow keys on to log in the access code of 925.

  • Page 64: Part 11: Shutdown And Maintenance

    14. Press  once to scroll to Function 6 - “MAX SUPPLY TEMP”. This function is the second step to setting your outdoor reset curve. Enter your system’s hydronic heating module maximum supply temperature value. To adjust the value, press ENTER and the factory default of 140 °F will start to blink. Use ▲...

  • Page 65: Vacation Procedure

    B. VACATION PROCEDURE If there is danger of freezing, change the set point to 70 F. DO NOT turn off electrical power! If there is no danger of freezing, follow Shutdown Procedure, Part 11, Section A. C. MAINTENANCE In unusually dirty or dusty conditions, care must be taken to keep appliance burner and door in place at all times.

  • Page 66: Appliance Error

    B. APPLIANCE ERROR When an error condition occurs, the controller will display a description and code on the display readout. These error messages and their recommended corrective actions are described in Section D, Appliance Control Fault Codes. C. APPLIANCE FAULT 1.
  • Page 67 Table 11 Fault Code FOU This display indicates that the outdoor sensor is defective, either shorted or open, or the outdoor temperature is below –40 F. NOTE: The installer must choose YES for Function 12 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.
  • Page 68 Fault Code E07 This display indicates that one or both of the clip-on temperature sensors in the hydronic heating module has been disconnected. This error allows the tank portion of the unit to still operate, but will not allow the hydronic heating module to operate until the error is cleared.
  • Page 69 Fault Code E19 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 overloaded. Remedy: Inspect power wiring to unit and repair as necessary. If connected to line voltage, notify electric utility company.
  • Page 70 2. Disconnect TT wiring. If error clears, there is an issue in the thermostat wiring. Review external wiring. 3. If available, connect PC and use HTP service software to check the 24v supply display in the lower left corner of the screen. The number displayed here must be greater than 128 and should be at least 250.
  • Page 71 Fault Code F01 This display indicates that the flue temperature limit switch of the unit has tripped. This is a serious safety issue, as indicated by the red fault light and the word LOCKOUT flashing on the display. The unit will not restart until the flue cools down sufficiently and a technician repairs the cause of the problem and pushes the RESET button on both the device and the display.
  • Page 72 Fault Code F05 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 F and a serious safety issue exists.
  • Page 73 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 check gap spacing (see Figure 28). 3. Remove any corrosion from the spark electrode and flame rectifier probe. 4.
  • Page 74 Fault Code F11 There is flame when the control is not telling the unit to run. The red fault light and the word LOCKOUT flashing on the display indicate that this code is serious safety issue. The unit will not restart until a technician repairs the cause of the lockout and resets the unit.
  • Page 75 Fault Code PP The control has been programmed by a technician or the factory. After programming, the control was left in a locked out mode. Press RESET to begin use of the control. Remedy: Press RESET for at least one second.
  • Page 76 Figure 29...
  • Page 77 Figure 30...
  • Page 78 Figure 31 – LP-314-G...
  • Page 79 Figure 32...

  • Page 80: Part 13: Maintenance

    PART 13: MAINTENANCE Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.

  • Page 83: Maintenance Notes

    MAINTENANCE NOTES...

  • Page 84: Htp Customer Installation Record Form

    Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative. Distributor/Dealer: Please insert contact details.

This manual is also suitable for:

Phe130-80Phe199-55Phe199-80Phe130-119Phe199-119

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