HTP Versa Hydro PHE130-119, Installation Start-Up Maintenance Parts

Page 1: ...olar models SNHX indicates solar models without heat exchanger NOTICE HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature 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...

Page 2: ... 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 ...

Page 3: ...out the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage FOREWORD This manual is intended to be used in conjunction with other literature provided with the heater This includes all related control information It is important that this manual all other documents included with this system and additional publications including the Nati...

Page 4: ...ian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 Also Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Suite 100 Mississauga Ontario Canada L4W 5N6 Code for the installation of Heat Producing Appliances latest version from American Insurance Association 85 John Street New York NY 11038 The latest version of the National Electr...

Page 5: ... OR UNCONFINED SPACE 12 F PREVENT COMBUSTION AIR CONTAMINATION 13 G REMOVING A HEATER FROM A COMMON VENT SYSTEM 13 H WATER CHEMISTRY 14 PART 4 DOMESTIC WATER PIPING 15 A TEMPERATURE AND PRESSURE RELIEF VALVE FOR DHW 15 B DOMESTIC HOT WATER EXPANSION TANK 16 C DOMESTIC WATER PIPING 17 D HEATER PIPING 17 E MIXING VALVE INSTALLATION 17 F AUXILIARY PIPING 20 PART 5 HYDRONIC PIPING 20 A HYDRONIC HEATIN...

Page 6: ...T LOCATION 37 D EXHAUST AND INTAKE AIR VENT SIZING 39 E LONGER VENT RUNS 39 F EXHAUST AND INTAKE AIR VENT INSTALLATION 40 G VENTING DRAWINGS 41 1 DIRECT VENT INSTALLATION OF EXHAUST AND INTAKE 41 2 INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE 47 H CONDENSATE REMOVAL SYSTEM 49 PART 9 CONTROL OVERVIEW 50 A NAVIGATION OF THE DISPLAY 50 B PROGRAMMING THE CONTROL 50 C APPLIANCE SE...

Page 7: ...des and back Unit must have room for service 24 front and 12 sides are minimum recommended service clearances A combustible door or removable panel is acceptable front clearance This appliance has been approved for closet installation Do not install this appliance directly on carpeting For installation on combustible flooring Use only Category IV vent systems INSTALLER Read all instructions in thi...

Page 8: ...ing or sealing compounds in a heater system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or heater patent medicines Substantial property damage damage to heater and or serious personal injury may result PART 2 HOW THE HEATER OPERATES The Versa Hydro with Total System Control is truly revolutionary providing high efficiency ...

Page 9: ...rate temperature control Venting System This appliance vents in plastic pipe Use only the approved venting material outlined in the venting section Part 8 of this manual Vent size can vary from 2 to 3 depending on the appliance input rate The venting system requires an intake and exhaust vent Special attention should be taken when selecting vent location Vents can run horizontally or vertically de...

Page 10: ...uld save time and money A BEFORE LOCATING THE HEATER Check for nearby connections to System water piping Venting connections Gas supply piping Electrical power Condensate drain Check area around heater Remove any combustible materials gasoline and other flammable liquids Failure to keep heater area clear and free of combustible materials liquids and vapors can result in substantial property damage...

Page 11: ... the floor When raising the heater be certain to fully support its entire filled weight Locate or protect the heater so it cannot be damaged by a moving vehicle E EXHAUST VENT AND INTAKE AIR VENT The heater is rated ANSI Z21 10 3 Category IV pressurized vent likely to form condensate in the vent and requires a special vent system designed for pressurized venting NOTE The venting options described ...

Page 12: ...n areas where indoor air is contaminated see Table 1 it is imperative that the appliance be installed as direct vent so that all combustion air is taken directly from the outdoors into the appliance 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 ...

Page 13: ... 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 Paint or varnish removers Plastic manufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements and glues New building...

Page 14: ...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 in the National Fuel Gas Code ANSI Z 223 1 H WATER CHEMISTRY Chemical imbalance of your water can ca...

Page 15: ...lly expressed in parts per million ppm Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system Most high TDS concentrations precipitate out of the water when heated This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a water heater This scale accumulation can also impede the ability of...

Page 16: ...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 Do not under any circumstances thread a cap or plug into the relief valve Explosion serious injury or death ma...

Page 17: ...nnections on the inlet and outlet are brass or copper Never use dielectric unions or galvanized steel fittings Teflon thread sealant must be used to seal all tank connections An approved ASSE 1017 mixing valve is provided with every appliance and must be installed on the outlet to protect the user from scalding temperatures This valve reduces the point of discharge temperature by mixing the hot an...

Page 18: ...otect against scaled injury by mixing hot and cold water supply in the system This valve will reduce point of discharge temperature in branch supply lines This water heater was shipped with an ASSE approved thermostatic mixing valve Install this valve according to the directions in the mixing device container DO NOT OPERATE THIS WATER HEATER WITHOUT AN ASSE APPROVED THERMOSTATIC MIXING DEVICE If t...

Page 19: ... and gently prying up as shown in Fig 3 1 2 Set the mixing valve after the tank has heated to its set point To set the valve disconnect the outdoor sensor from the control so the domestic hot water will reach its set point temperature default setting is 160 F Once domestic hot water has reached its set point turn both the hot and cold water supplies on Open an outlet preferably a sink or basin fau...

Page 20: ...s Use only copper or brass fittings Teflon sealant must be used on all connections The top port has a dip tube that draws hot water from the dome of the unit and the bottom port dip tube returns the water to bottom of the unit 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 po...

Page 21: ...eating module The installation of an air elimination device will remove air from the system which is necessary to avoid an air lock in the central heating circulator It is recommended that all the piping is insulated to improve on the system s overall efficiency In the system piping heating coils in air handler flow control valves or other devices must be installed to prevent gravity circulation o...

Page 22: ...em circulator through the closed loop side of the brazed plate exchanger Included in this section are graphs that will help you size the appropriate circulator and output needed to meet your system design requirements Below is an example on the steps needed to determine the correct circulator for the system Example System design requires 120 000 Btu at 20 Delta Step 1 Using the graphs select the i...

Page 23: ...23 Figure 5 Figure 6 ...

Page 24: ...24 Figure 7 ...

Page 25: ...25 F HYDRONIC PIPING Figure 8 ...

Page 26: ...26 Figure 9 ...

Page 27: ...27 Figure 10 ...

Page 28: ...28 Figure 11 ...

Page 29: ...29 Figure 12 ...

Page 30: ...shown in Figure 14 A line voltage fused disconnect switch may be required to be externally mounted and connected according to local codes and standards 2 Connect the central heating pump as shown in the terminals marked CH DHW PUMP see Figure 14 The connections shown are suitable for a maximum continuous pump draw of 3 amps at 120 volts If the pump requires more current or voltage than the 120 vol...

Page 31: ...wire for runs of 100 feet or less and minimum 18 AWG wire for runs up to 150 feet Instructions are included with the outdoor sensor to correctly mount the sensor on the exterior surface of the building It is preferable to mount the sensor on the north side in an area that will not be affected by direct sunlight but will be exposed to varying weather conditions Connect the outdoor sensor to termina...

Page 32: ...32 F INTERNAL WIRING Figure 14 Internal connection diagram ...

Page 33: ... be approved by the local gas supplier or utility in addition to the governing authority Do not remove the reducing coupling attached to the gas valve Per the National Fuel Gas Code it is mandatory that this fitting be used for connection to a field fabricated drip leg as shown in the illustration at left Ensure that the entire gas line to the connection at the heater is no smaller than Once all i...

Page 34: ...removing the cap you can attach a manometer to the incoming gas drip leg The gas pressure must remain between 3 5 WC 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 Failure to prop...

Page 35: ...ow high low high Carbon Monoxide CO 0 10 ppm 0 20 ppm 0 10 ppm 0 20 ppm Carbon Dioxide CO2 8 9 8 9 9 10 9 10 Table 4 FAN SPEEDS BTU IGNITION MIN MAX 130 000 3000 2000 6950 199 000 3000 2000 8500 Table 5 PART 8 VENTING COMBUSTION AIR AND CONDENSATE REMOVAL The heater must be vented as detailed in this Venting Section Ensure exhaust and intake piping complies with these instructions regarding vent s...

Page 36: ...2564 IPEX System 636 Cements Primers CPVC ANSI ASTM F493 Table 6 Do not use Foam Core Pipe in any portion of the exhaust piping from this water heater Use of Foam Core Pipe may result in substantial property damage severe personal injury or death C EXHAUST AND INTAKE AIR VENT PIPE LOCATION 1 DETERMINE EXHAUST VENT LOCATION a The vent piping for this water heater is approved for zero clearance to c...

Page 37: ... vent and the level of maximum snow accumulation Snow removal may be necessary to maintain clearances b Do not locate intake air vent in a parking area where machinery may damage the pipe c When venting with a two pipe system maximum distance between intake air vent and exhaust vent is 6 feet 1 8 m Minimum distance between exhaust vent and intake air vent on single water heater is 10 0 255 m cente...

Page 38: ...38 Figure 17 ...

Page 39: ...g calculation applies Intake Air Vent Pipe Equivalent Length 2x5 3 10 23 ft Therefore the total combined equivalent length is 46 ft which is well below the maximum of 85 ft c The intake air and exhaust vents are intended to penetrate the same wall or roof of the building d Effort should be made to keep a minimum difference in equivalent length between the intake air and exhaust vents 3 The minimum...

Page 40: ...eater not less than per ft to allow condensate to drain from the vent pipe If the exhaust pipe must be piped around an obstacle that results in the creation of a low point condensate will collect and form a blockage This condensate must be drained away using a field installed condensate drain assembly see Figure 26 5 All piping must be fully supported Use pipe hangers at a minimum of 4 ft interval...

Page 41: ... terminated Different vent terminals can be used to simplify and eliminate multiple penetrations in the building structure see Optional Equipment in Venting Section The air intake and exhaust vent piping lengths routing and termination methods must all comply with the methods and limits given in the Venting section Part 8 of this manual When installing a combustion air intake from outdoors care mu...

Page 42: ...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: ...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: ...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: ...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: ...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: ...c 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...

Page 48: ...48 Figure 25 ...

Page 49: ...ndensate line Steel brass copper or other materials will be subject to corrosion or deterioration A second vent may be necessary to prevent a condensate line vacuum lock if a long horizontal run is used An increase in condensate line diameter may be necessary to allow condensate to drain properly Support of the condensate line may be necessary to avoid blockage of the condensate flow Figure 26 The...

Page 50: ...and again use the keys to change the value Repeat until the correct code is entered Press the ENTER key to accept the code If the code is correct the readout will change to the appropriate screen If the programming code is not accepted the readout will continue to display as shown above The ENTER key is also used to enable a parameter for editing After navigating to the desired parameter hold down...

Page 51: ... correctly in order for the total system control to operate the appliance at optimum efficiency Function Allows the user to adjust the central heating designed supply set point from 50 o F to 170 o F Factory default 140 o F Function Allows the user to adjust the heating system designed delta T set point from 5 o F to 30 o F Factory default 20 o F Function Allows the user to adjust the DHW set poin...

Page 52: ...een is displayed press the ENTER key The letter A or P after the time will blink Press or once and the letter will disappear Press the ENTER key to save the new setting Function Allows the user to adjust the hour setting Function Allows the user to adjust the minute setting Function Allows the user to adjust the day of week displayed Function Allows the user to switch to European date format 2009 ...

Page 53: ...ROGRAM NAVIGATION Once the System Menu Access Code is confirmed the user can start to set the System Parameters Menu Use the arrow keys on the display to navigate through the different program settings To change an appliance setting press ENTER Increase system settings by pressing and decrease by pressing on the display Listed below are the system settings that can be programmed into the control F...

Page 54: ...ply temperature based on the minimum outdoor design temperature Factory default 140 o F Range 77 o F to 170 o F Function 7 Max Outdoor Temp Description Allows the user to set the maximum outdoor design temperature for the system Factory default 68 o F Range 32 o F to 95 o F Function 8 Min Supply Temp Description Allows the user to set the design supply water temperature based on the maximum outdoo...

Page 55: ...ystem sensor is open or shorted NOTE This error does not stop the appliance from running Factory default ON Selection ON OFF NOTE Press ENTER to store system parameters Function 14 Service Schedule Description Allows the user to program the heater maintenance schedule by selecting a service date or time based on the heater run hours Factory default OFF Selection Date or Run Hours NOTE Without sett...

Page 56: ...after pressing the key as described above This screen displays the actual temperature that the top and bottom tank sensors are measuring Press the key once This screen displays the current central heating temperature set point on the top line NOTE If an outdoor sensor is used this temperature set point may vary from what was set in the Appliance Settings Screen The bottom line is the actual temper...

Page 57: ... how much energy input in thousand BTU from the burner into the storage tank Press the key once The top line of this display indicates the percentage of energy used for domestic hot water over the appliance lifetime The bottom line indicates the percentage of energy used for central heating over the appliance lifetime Press the key once The top line of this display indicates the number of times th...

Page 58: ...LT HISTORY and the fault encountered The bottom line will display the date and time the fault occurred Press the key once This screen displays the fifth 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 key once This screen displays the sixth o...

Page 59: ...ition device that automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call...

Page 60: ...e expansion tank water content and follow fluid manufacturer s instructions 4 When using freeze protection fluid with automatic fill install a water meter to monitor water make up Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 5 Close manual any automatic air vents and any drain valves in the hydronic system loop ...

Page 61: ... 1 second The display will read The central heating pump will come on Run pump until all the air has been purged through each circuit If you press the keys simultaneously the central heating pump will shut off The display will read Once the system has been purged of air the installer can now proceed to program the control and system design parameters E PROGRAMMING THE TOTAL SYSTEM CONTROL Before p...

Page 62: ...al Heating value press once The second screen adjusts the heating system Heating Delta T value The factory default is 20 o F 7 After you have entered and stored the Heating Delta T value press once The third screen adjusts the DHW Set Point Adjust the value to the desired Domestic Hot Water temperature The factory default is 119 o F IMPORTANT NOTE This value sets the tank temperature when the appl...

Page 63: ...m weather shutdown This function determines the outdoor temperature that will turn off the hydronic heating module and operate the appliance only as a water heater for the warmer weather To adjust this value press ENTER and the factory default of 68 F starts to blink Use and to adjust this value to your system needs To store the new value press ENTER 13 Next press once to scroll to Function 5 MIN ...

Page 64: ...o air lock or blockage in the tank side loop of the hydronic heating module To do this press and hold and ENTER This will bring you into the pump service mode Press 3 times until SERVICE PUMP RS 5 is on the screen This puts the hydronic heating module pump at 5 volts 50 Press until the value is increased to 10 putting the pump at full speed Once flow is confirmed press and at the same time to retu...

Page 65: ...lem exists with the appliance the controls or the gas supply Under such circumstances a qualified service technician should be contacted immediately to properly service the appliance and correct the problem If a technician is not available pressing RESET once will remove the lockout state so additional trials for ignition can be performed PART 12 TROUBLESHOOTING A APPLIANCE ERROR CODE If any of th...

Page 66: ...he unit for a period of time to assure correct operation and no recurrence of the fault message D APPLIANCE CONTROL FAULT CODES When servicing or replacing any components of this appliance be certain that The gas is off All electrical power is disconnected When servicing or replacing components that are in direct contact with this appliance be certain that There is no pressure in the appliance Pul...

Page 67: ...ll 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 Remedy Inspect wiring from outside sensor for damage or shorted connections and repair as necessary Measure resistance of outdoor sensor and compare to resistance chart If not within range...

Page 68: ...esistance Tables in Section 12 3 Replace themistor if necessary Fault Code ECS NOT CONNECTED This display indicates that the main control board and the smaller ECS control board are not com municating properly 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 The second line indicates the status of t...

Page 69: ...the flue is not blocked 2 Check the switch wiring by applying a jumper in place of the switch If the code clears with the jumper in place REPLACE the flue switch and connect the wires to the new switch BEFORE running unit Do not use a jumper to remedy this error A faulty switch MUST be replaced Failure to do so could result in serious injury or death Fault Code LEO This display indicates that ther...

Page 70: ...e the 20 pin Molex from the ECS board If the message clears examine the wiring to the heating module and fan for shorts or grounds and repair as necessary 6 If message only occurs when the burner tries to light check gas valve for excessive current draw 7 If message is present with the low voltage harness disconnected from the 926 control board replace the 926 control board Fault Code F00 This dis...

Page 71: ...2 This display indicates that the top temperature sensor of the tank has failed This code indicates a serious safety issue by the red fault light and the word LOCKOUT flashing on the display The unit will not restart until a technician replaces the sensor and resets the unit During this lockout fault the circulator pump will be on as indicated on the second line of the display Remedy 1 Check the e...

Page 72: ...minated red fault light and LOCKOUT flashing on the display then the temperature on the bottom sensor has exceeded 230 o F and a serious safety issue exists The boiler will not restart until a technician repairs the cause of the excessive temperature and resets the unit If the red fault light is not illuminated and this message is displayed then the bottom temperature of the tank is at or above 21...

Page 73: ...ame loss and resets the unit During this lockout fault the pump will be on as indicated on the bottom line of the display Remedy 1 Monitor the gas pressure to the unit while in operation 2 Assure that the flame is stable when lit 3 Check to see if the display readout changes from GAS VALVE ON to RUN within a few seconds after the boiler ignites 4 Check the FLAME signal on the status display It sho...

Page 74: ... 30 faster or slower than the control commanded speed for more than 10 seconds The red fault light and flashing LOCKOUT on the display indicates a serious safety issue The unit will not restart until the technician repairs and resets the unit During this lockout fault the pump will be on as indicated on the second line of the display Remedy 1 Check the combustion air fan wiring 2 Measure the DC vo...

Page 75: ...ode 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: ...76 Figure 29 ...

Page 77: ...77 Figure 30 ...

Page 78: ...78 Figure 31 LP 314 G ...

Page 79: ...79 Figure 32 ...

Page 80: ...ly labeled Exercise circuit breaker CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Spark Electrode Clean Set gap at Flame Probe Clean Check ionization in uA d7 on status menu in Start up Procedures Record high fire and low fire CONDENSATE Neutralizer Check condensate neutralizer Replace if ...

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Page 83: ...83 MAINTENANCE NOTES ...

Page 84: ... Date of Installation Installer s Code Name Product Serial Number s Comments Installer s Phone Number 1 Signed by Installer Signed by Customer 2 IMPORTANT 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 con...