Versa-Hydro INSTALLATION START-UP MAINTENANCE PARTS Versa-Hydro Appliance Models* PHE130-55 / 199-55 PHE130-80 / 199-80 PHE130-119 / 199-119 *A suffix of “LP” denotes propane gas “S” indicates solar models “SNHX” indicates solar models without heat exchanger This manual must only be used by a qualified heating installer/service technician. Read and understand all instructions in this manual before installing. Perform steps in the order given.
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. 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.
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. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests specified in ANSI Z21.10.3 – latest edition. TABLE OF CONTENTS PART 1 – GENERAL SAFETY INFORMATION ..........................................................................................................................6 A. PRECAUTIONS ...................................................................................................
PART 6 - VENTING, COMBUSTION AIR AND CONDENSATE REMOVAL ............................................................................ 28 A. GENERAL ................................................................................................................................................................................. 29 B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE .................................................................................... 29 C.
B. VACATION PROCEDURE ........................................................................................................................................................ 57 C. FAILURE TO OPERATE ........................................................................................................................................................... 57 PART 12 - TROUBLESHOOTING .............................................................................................................................
D. WHEN SERVICING THE APPLIANCE To avoid electric shock, disconnect electrical supply before performing maintenance. To avoid severe burns, allow appliance to cool. E. APPLIANCE WATER Do not use petroleum-based cleaning or sealing compounds in a system serviced by this appliance. Gaskets and seals in the system may be damaged. This can result in substantial property damage. Do not use “homemade cures” or “patent medicines”.
High Efficiency Heat Exchanger The highly efficient 90/10 copper nickel heat exchanger provides direct energy transfer from the combustion gases into domestic water. Hot gases travel from the primary circuit to heat the combustion walls, which then transfer heat directly into the water.
C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP: 3” Stainless Steel Outside Termination Vent Kit (V1000) 4” Stainless Steel Outside Termination Vent Kit (V2000) 2” PVC Concentric Vent Kit (Part # KGAVT0501CVT) 3" PVC Concentric Vent Kit (Part # KGAVT0601CVT) 3” Polypro Vent Kit (Part # 8400P-001) 3” Polypro Pipe (33’ length Part # 8400P-002, 49.
This appliance is certified for indoor installations only. Do not install the appliance outdoors. Failure to install this appliance indoors could result in substantial property damage, severe personal injury, or death. 2. Check for nearby connections to: System water piping Venting connections Gas supply piping Electrical power Condensate drain 3. Check area around appliance. Remove any combustible materials, gasoline, and other flammable liquids.
The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the appliance. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death. D. RESIDENTIAL GARAGE INSTALLATION PRECAUTIONS If the appliance is located in a residential garage, per ANSI Z223.
2 should have a free area of one square inch per 1,000 Btu/hr (22cm /kW) of the total input of all appliances in the space, but not less 2 than 100 square inches (645cm ). 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, Part 6 of this manual. When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.
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 appliance, 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 the hardness of the water exceeds the maximum level of 7 grains per gallon, water should be softened to a hardness level no lower than 5 grains per gallon. Water softened as low as 0 to 1 grain per gallon may be under-saturated with respect to calcium carbonate, resulting in water that is aggressive and corrosive. pH of Water pH is a measure of relative acidity, neutrality or alkalinity. Dissolved minerals and gases affect water pH. The pH scale ranges from 0 to 14. Water with a pH of 7.
Figure 3 – Specifications and Dimensions UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. o COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0 F) before installation, handle with care until the plastic components come to room temperature. Remove all sides of the shipping crate to allow the heater to be lifted into its installation location. LP-314 REV. 3.24.
PART 4 - DOMESTIC WATER PIPING Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death. 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 product warranty. A. TEMPERATURE AND PRESSURE RELIEF VALVE FOR DHW Install a temperature and pressure relief valve into the marked port (upper right).
Never use dielectric unions or galvanized steel fittings on any domestic water or auxiliary connections. Use only copper or brass fittings. Thread sealant must be used on all connections. 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.
This appliance can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. By setting the thermostat on this appliance to obtain increased water temperature, you may create a higher potential for scald injury. To protect against injury, you should install an ASSE approved thermostatic mixing valve (a device to limit the temperature of water to protect against scald injury by mixing hot and cold water supply) in the system.
Setting the Mixing Valve Outlet Temperature 1. Turn both the hot and cold water supplies on. Open an outlet, preferably a sink or basin faucet rather than a shower. To calibrate, let water run for 2 minutes and measure the outlet temperature with a thermometer. Adjust the green cap counter clockwise to increase temperature and clockwise to decrease temperature, as shown in Fig. 4. Figure 4 – Adjusting the Mixing Valve 2.
PART 5 - HYDRONIC PIPING Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, serious injury, or death. A. HYDRONIC HEATING MODULE PIPING The hydronic heating module comes pre-plumbed and connected directly to the 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.
3. Install a balance and purge valve (or shut off drain valve) on the system return to purge air out of the zone at start-up. 4. Install a back flow preventer on the cold feed make–up water line. 5. Install a pressure reducing valve on the cold feed make up water line (15 psi operating pressure). Check temperature and pressure gauge when operating. It should read minimum pressure of 15 psi. 6. Install the system circulator as shown in the piping details in this section.
Figure 6 Figure 7 LP-314 REV. 3.24.
Figure 8 LP-314 REV. 3.24.
F. HYDRONIC PIPING Figure 9 – LP-314-3 NOTES: 1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance. 3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator. 4. All circulators shall have an integral flow check.
Figure 10 – LP-314-PIPING-1 NOTES: 1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance. 3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator. 4. All circulators shall have an integral flow check.
Figure 11 – LP-314-PIPING-2 NOTES: 1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance. 3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator. 4. All circulators shall have an integral flow check.
Figure 12 – LP-314-PIPING-4 NOTES: 1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance. 3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator. 4. All circulators shall have an integral flow check.
Figure 13 – LP-314-PIPING-5 NOTES: 1. Minimum pipe size should match connection size on appliance. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within the piping system between the check valve and cold water inlet of the appliance. 3. Gas line must be rated to the maximum capacity of the unit. Unit must have 10 feet of pipe after gas regulator. 4. All circulators shall have an integral flow check.
A. GENERAL This appliance 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 below carefully.
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. PVC/CPVC pipe and fittings of the same diameter are considered interchangeable. DO NOT use Foam Core Pipe in any portion of the exhaust piping from this water heating appliance. DO NOT connect PVC/CPVC to PP without an approved vent connector.
D. EXHAUST VENT AND INTAKE PIPE LOCATION Figure 14 – ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada – Exit Terminals for Direct-Vent Venting Systems DETERMINE EXHAUST VENT AND INTAKE PIPE LOCATION – FIGURE 14 NOTES: A. Provide a minimum of 1 foot clearance from the bottom of the exhaust vent and intake pipe above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. B.
The building owner is responsible for keeping the exhaust and intake terminations free of snow, ice, or other potential blockages, as well as scheduling routine maintenance. Failure to keep the vent piping terminations clear and properly maintain the appliance could result in property damage, severe personal injury, or death.
c. If the transition occurs at a distance greater than 15 equivalent feet from the water appliance, the maximum equivalent length will be reduced. Total maximum total equivalent length of increased diameter exhaust vent and intake pipe must not exceed the lengths defined in this manual. 125 maximum total equivalent feet for 2” increased to 3” diameter vent pipe; 200 maximum total equivalent feet for 3” increased to 4” diameter vent pipe.
VENT TERMINATION KITS DESCRIPTION 2” PVC CONCENTRIC VENT TERMINATION KIT 3” PVC CONCENTRIC VENT TERMINATION KIT 2” STAINLESS STEEL VENT TERMINATION KIT 3” STAINLESS STEEL VENT TERMINATION KIT 4” STAINLESS STEEL VENT TERMINATION KIT 3” POLYPRO VENT KIT Table 7 STOCK CODE KGAVT0501CVT KGAVT0601CVT V500 V1000 V2000 8400P-001 H. VENTING DRAWINGS 1.
Figure 15 – Sidewall Venting – LP-314-C, 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. LP-314 REV. 3.24.
Figure 16 – Concentric Venting - LP-314-E, 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. LP-314 REV. 3.24.
Figure 17 – NOTE: This drawing is meant to demonstrate system venting only. The installer is responsible for all equipment and detailing required by local codes. LP-314 REV. 3.24.
Figure 18 – Horizontal Venting - NOTE: Drawing is meant to demonstrate system venting ONLY. NOTES: A. For every 1” of overhang, the exhaust vent must be located 1” vertical below overhang (overhang means top of building structure and not two adjacent walls [corner of building]). B. Typical installations require 12” minimum separation between bottom of exhaust outlet and top of air intake. C. Maintain 12” minimum clearance above highest anticipated snow level or grade (whichever is greater). D.
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.
VENT / AIR INLET SIZE 2” 3” 4” Table 8 – Minimum Vent / Chase Sizing MINIMUM EXISTING VENT / CHASE SIZE 4” 5” 7” VENTING AS A CHASE When venting as a chase, follow all instructions included in Part 6 – Venting of this manual, as well as the previous Concentric Venting section. See Figure 20 for chase venting demonstration. NOTES: A.
Figure 22 LP-314 REV. 3.24.
I. CONDENSATE REMOVAL SYSTEM NOTE: Check with your local gas company to determine if combustion condensate disposal is permitted in your area. In the state of Massachusetts, condensate must be neutralized before entering a drain. This condensing high efficiency appliance has a condensate removal system. Condensate is water vapor derived from combustion products, similar to an automobile when it is initially started.
PART 7 - FIELD WIRING To avoid electrical shock, turn off all power to the appliance prior to opening an electrical box within the unit. Ensure the power remains off while any wiring connections are being made. Failure to follow these instructions could result in component or product failure, serious injury, or death. Such product failure IS NOT covered by warranty. A.
Figure 24 – Hydronic heating module LP-314 REV. 3.24.
F. INTERNAL WIRING Figure 25 – Internal connection diagram LP-314 REV. 3.24.
Figure 26 – LP-314-R LP-314 REV. 3.24.
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 8 - GAS CONNECTION Failure to follow all precautions in this section could result in fire, explosion, or death! A.
It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to indicate a leak is present. To avoid excessive pressure drop, the gas piping must be sized for the proper flow and length of pipe. Both the gas meter and regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1” WC, the meter, regulator, and/or gas line is undersized or needs service.
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. Press ▲ to increase, or ▼ to decrease fan speed. To leave service mode, press ▲ and ▼ simultaneously.
The power must remain off until the potable water side of the appliance 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. Shut off faucet once all evidence of air is purged from the water stream. B.
D. APPLIANCE PUMP CONTROL TO ASSIST IN PURGING AIR FROM SYSTEM LOOPS Before powering up the control assure the thermostat connection is disconnected on the field connection board. Apply power to the appliance (Note: The appliance will fire the burner 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 appliance. Press the ▼ and ENTER keys simultaneously and hold for 1 second.
Figure 29 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. Press ENTER to access the System Setting Program Navigation menu. Once the code is confirmed, you can set the System Settings. Use and to navigate through the System Setting Program. 12. Press 3 times to scroll to Function 4 - “WARM WEATHER OFF”.
15. Press once to scroll to Function 7 - “MAX OUTDOOR TEMP”. This function is the third step to setting your outdoor reset curve. Enter your system’s maximum outdoor temperature value. To adjust the value, press ENTER and the factory default of 68 °F will start to blink. Use ▲ and ▼ to adjust to your designed temperature. To store the new value press ENTER. 16. Press once to scroll to Function 8 - “MIN SUPPLY TEMP”. This function is the final step to setting your outdoor reset curve.
ARROW Keys – The right and left arrow keys ( ) are used to navigate between the default Display and Status Display. The keys are also used in programming modes to change between programmable parameters. It is recommended you use the Menu Maps in the back of this manual and the detailed menu instructions printed in this section to help in menu navigation. ARROW Keys – The up and down (▲▼) arrow keys are used to navigate between the various parameters displayed in the menu.
CLOCK YEAR 08/28/2009 Function: Adjusts the year setting. Fr 10:01A CLOCK MONTH 08/28/2009 Fr 10:01A Function: Adjusts the month setting. CLOCK DATE 08/28/2009 Fr 10:01A Table 14 – Clock Settings The clock is set. NOTE: The clock does not automatically adjust for Daylight Savings Time, and requires manual adjustment. D. PROGRAMMING THE SYSTEM SETTING NOTE: Programming the control is not possible when the unit is firing.
Function 11 DHW Priority DHW PRIORITY 30 MINUTES 11 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 ERROR OUTD SENSOR 12 Allows the user to set the control to display an error message if an outdoor sensor is open or shorted. NOTE: This error does not stop the appliance from running.
POWER ON 0h INPUT 0kBTU Press the ▼ key once. DHW USE 0% CH USE 1% Press the ▼ key once. GOOD IGNIT 0x CH CYCLE 0x Press the ▼ key once. FAULT HISTORY 1 07/27/2009 Mo 5:19A Press the ▼ key once. The top line indicates the amount of hours the appliance has power applied to its lifetime. The bottom line indicates how much energy input (in thousand BTU) from the burner into the storage tank. FAULT HISTORY 2 08/28/2009 Fr 5:19A This screen displays the second oldest lockout fault of the appliance control.
during any one of these three ignition trials, normal operation will resume. If the burner lights, and goes off in about 4 seconds, check the polarity of the wiring. See Electrical Connection Section in Part 7. If the burner does not light after the third ignition trial, the control will enter a lockout state. This lockout indicates that a problem exists with the appliance, the controls, or the gas supply.
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 18 SCREEN Fault Code FOU Outdoor Sensor Failure OUTDOOR SENSOR FOU PUMP ON DESCRIPTION POSSIBLE REMEDY This indicates that the outdoor sensor is defective, shorted or open, or the outdoor temperature is below –40oF.
Fault Code ECS NOT CONNECTED ECS NOT CONNECTED PUMP OFF This indicates the main control board and the smaller ECS control board are not communicating 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 the pump. 1. Ensure both ends of the ribbon cable are connected properly and securely in place. 2. Next, check the ribbon cable for damage or wear.
Fault Code F01 FLUE TEMP PUMP ON 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.
Fault Code F10 FLAME LOSS F10 The flame was lost while the unit was lit 3 times during 1 demand call. The red fault light and the word LOCKOUT flashing on the display indicate a serious safety issue. The unit will not restart until the technician repairs the cause of flame loss and resets the unit. During this lockout fault, the pump will be on as indicated on the bottom line of the display. 1. Monitor gas pressure to the unit while in operation. 2. Assure that the flame is stable when lit. 3.
Figure 30 LP-314 REV. 3.24.
Figure 31 – LP-314-G LP-314 REV. 3.24.
Figure 32 LP-314 REV. 3.24.
PART 13 – MAINTENANCE In unusually dirty or dusty conditions, care must be taken to keep appliance cabinet door in place at all times. Failure to do so VOIDS WARRANTY! Allowing the appliance to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in appliance failure, property damage, personal injury, or death. Such product failures ARE NOT covered under warranty.
LP-314 REV. 3.24.
LP-314 REV. 3.24.
MAINTENANCE NOTES LP-314 REV. 3.24.
HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
