HTP CGH-199* Installation Manual
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HTP CGH-199* Installation Manual

Crossover water heaters
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Installation
Start-Up
Maintenance
Parts
Warranty
CGH-199* Models
* "LP" Denotes Propane Gas
This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before installing.
Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property
damage, severe personal injury, or death.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.
The manufacturer reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.
The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required
by the Safe Drinking Water Act, Section 1417.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd.

Water Heaters

New Bedford, MA 02745
Crossover
www.htproducts.com
LP-644 Rev. 8.10.17

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Summary of Contents for HTP CGH-199*

  • Page 1: Water Heaters

    Crossover Water Heaters Installation Start-Up Maintenance Parts Warranty CGH-199* Models * “LP” Denotes Propane Gas This manual must only be used by a qualified installer / service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death. Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.
  • Page 2 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. • 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: For The Installer

    Foreword For the Installer This manual is intended to be used in conjunction with other This water heater must be installed by qualified and licensed personnel. literature provided with the water heater. This includes all related The installer should be guided by the instructions furnished with the control information.

  • Page 4: Table Of Contents

    Table of Contents Part 9 - Controls Part 1 - General Safety Information A. Control and Display Overviews A. Operation and Installation Warnings B. Start-Up Sequence B. Improper Combustion C. Changing the DHW Set-Point C. Gas D. Changing the Time D.
  • Page 5 Vapors from flammable liquids will explode and can cause a DO NOT store or place newspapers, laundry, or other combustible fire, resulting in personal injury or death. The water heater has a items near the water heater or the exterior exhaust gas outlet and/ burner that can come on at any time and ignite vapors.

  • Page 6: Improper Combustion

    DO NOT alter or modify the water heater or water heater controls. secondary maximum contaminant levels (40 CFR Part 143.3). If Altering any HTP water heater with parts not manufactured by HTP the water contains contaminants higher than outlined by the EPA,...

  • Page 7: Water Temperature Adjustment And Scalding

    Freeze Protection Operation Stage 1 - If control detects water temperature An ASSE 1017 or ASSE 1070 temperature limiting or mixing valve is of 46 F (8 C) and below, it turns the internal recommended in installations servicing disabled or elderly persons, and external pumps On for 600 seconds and or children.

  • Page 8: Part 2 - Before You Start

    One (1) (7855P-101) Cascade Communication Cable One (1) (7850P-093) Table 4 - Included with the Water Heater B. Optional Equipment Optional equipment available from HTP (and Part #): Optional Parts Flow Switch One (1) (7860P-013) System Sensor One (1) (7250P-324)

  • Page 9: Part 3 - Prepare The Water Heater Installation

    Other Optional Equipment Below is a list of other optional equipment available from HTP. These additional options may be purchased through your HTP distributor: This water heater has a condensate disposal system that may freeze • 2” PVC Concentric Vent Kit (Part # KGAVT0501CVT) if exposed to sustained temperatures below 32 F.

  • Page 10: Leveling

    NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the heater model and serial number. B. Leveling In order for the condensate to properly flow out of the collection system, the area where you locate the heater must be level.

  • Page 11: Direct Vent Of Exhaust And Intake

    Do not attempt to vent this water heater by any means other than When drawing combustion air from the outside into the mechanical those described in this manual. Doing so will void the warranty room, care must be taken to provide adequate freeze protection. and may result in severe personal injury or death.

  • Page 12: Removing A Heater From A Common Vent System

    Products to Avoid Areas Likely to Have Contaminants Spray cans containing fluorocarbons Dry cleaning / laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes / cleaners 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...

  • Page 13: Technical Specifications

    I. Technical Specifications Model Installation Indoor, Wall Hung, Fully Condensing Minimum / Maximum Input (Btu/Hr) 19,900 / 199,000 Uniform Energy Factor (UEF) / Thermal 0.92 / 95% Efficiency (TE) Flue System Sealed Combustion Direct Vent, Power Vent Vent Run 2” (50 feet), 3” (100 feet), Schedule 40 PVC, CPVC, PP Weight (lbs) 8.3 mm (0.327”) Orifice Size...
  • Page 14 Peak Hour Demand / First Hour Rating Average Gallons of Hot Water per Usage Times Used During 1 Hour Gallons Used in 1 Hour Shower Bath Shavings Hands and Face Washing Hair Shampoo Hand Dishwashing Automatic Dishwasher Food Preparation Wringer Clothes Washer Automatic Clothes Washer Total Peak Hour Demand (FHR)
  • Page 15 Figure 3 - Model Dimensions Description Diameter DHW Outlet Adapter 1 1/4” NPT DHW Inlet Adapter 1 1/4” NPT Gas Inlet Adapter 3/4” NPT Condensate Adapter 1/2” NPT Air Intake Adapter 3” Exhaust Vent Adapter 3” Model 19.7 31.9 3.75 12.5 17.5 11.1...
  • Page 16 Figure 4 - Components Number Component Description Number Component Description Number Component Description Automatic Air Vent High Voltage Terminal Block Water Inlet Pipe Top Water Outlet Adapter Gas Inlet Pipe to Gas Valve Ignition Transformer Gas Valve Water Outlet Pipe Flame Detection Sensor Intake Hose Gas Inlet Adapter...

  • Page 17: Wall-Mounting

    Condensate Trap and Hose Assembly – Each water heater has a built-in condensate trap to control the discharge of condensate produced by the water heater during normal operation. A When installing a cascaded system, it is important that the water corrugated condensate hose is also provided to ensure proper heaters are the same model.

  • Page 18: Part 4 - Water Piping

    Part 4 - Water Piping B. Backflow Preventer Use a backflow preventer specifically designed for water heater Failure to follow the instructions in this section WILL VOID the installations. This valve should be installed on the cold water fill warranty and may result in property damage, severe personal injury, supply line per local codes.

  • Page 19: Applications

    E. Applications Figure 6 - Piping Symbol Legend COLD WATER INLET HOT WATER OUTLET USED IF SENSOR CANNOT COLD WATER INLET Figure 7 - Water Heater with Storage Tank NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
  • Page 20 COLD WATER INLET HOT WATER OUTLET FLOW SWITCH COLD WATER INLET Figure 8 - Water Heater with Storage Tank and Optional Flow Switch NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
  • Page 21 COLD WATER INLET HOT WATER OUTLET FOLLOWER FOLLOWER USED IF SENSOR CANNOT COLD WATER INLET Figure 9 - Cascaded Water Heaters w/Storage Tank, Individual Pumps, and Recirculation COLD WATER INLET HOT WATER OUTLET FOLLOWER FOLLOWER USED IF SENSOR CANNOT COLD WATER INLET Figure 10 - Cascaded Water Heaters w/ Two Storage Tanks and Recirculation NOTES: 1.
  • Page 22 COLD WATER INLET HOT WATER OUTLET FOLLOWER FOLLOWER USED IF SENSOR CANNOT COLD WATER INLET Figure 11 - Cascaded Water Heaters w/ One Storage Tank, System Pump, and Recirculation NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.

  • Page 23: Circulator Sizing

    F. Circulator Sizing 199 Pressure Drop Curve 24.00 22.00 20.00 18.00 16.00 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00 Flow Rate (GPM) Figure 12 - This chart represents heat exchanger pressure losses. System Temperature Rise Chart F ∆T F ∆T F ∆T Minimum Model...

  • Page 24: Filling The Heater

    H. Filling the Heater To avoid water damage or scalding due to relief valve operation: • Discharge line must be connected to relief valve outlet and The water heater must be full of water and the system fully purged run to a safe place of disposal. Terminate the discharge line BEFORE powering the water heater.

  • Page 25: Approved Materials For Exhaust Vent And Intake Pipe

    Due to the extreme flammability of most glues, cements, solvents, and primers used to join plastic exhaust vent and intake pipes, explosive solvent vapors must be cleared from all vent piping before start-up. Avoid using excess cement or primer, as this may pool in the vent pipes.

  • Page 26: Additional Requirements For Installation In Canada

    DO NOT mix components from different venting systems. The vent system could fail, causing leakage of flue products into the living space. Use only the approved pipe and fitting materials, and primer and cement specifically designed for the material used, as listed in the above table.

  • Page 27: Exhaust Vent And Intake Pipe Location

    D. Exhaust Vent and Intake Pipe Location INSIDE CORNER DETAIL FIXED OPERABLE CLOSED FIXED CLOSED OPERABLE LP-179-CC 03/28/17 Exhaust Vent Terminal Intake Pipe Terminal Area Where Intake Terminal Is Not Permitted Figure 14 - Exit Terminals for Direct Vent Systems - ANSI Z223.1 / NFPA 54 for US and CAN/CSA B149.1 for Canada DESCRIPTION CANADA Clearance above grade, veranda, porch, deck, or balcony...

  • Page 28: Exhaust Vent And Intake Pipe Sizing

    NOTE: Clean and dry the appliance connection. DO NOT use primer E. Exhaust Vent and Intake Pipe Sizing or cement on the appliance connection. 1. The exhaust vent and intake pipe size is 3”. Push the length of pipe into the connection until it touches 2.

  • Page 29: Applications

    11. In vacant chimney applications, install and seal a rain cap over This table lists optional exhaust/intake terminations available from existing chimney openings. HTP: 12. All piping must be fully supported. Use pipe hangers at a minimum Description Stock Code of 4 foot intervals to prevent sagging of the pipe where condensate 2”...

  • Page 30: Sidewall Venting

    Two Pipe Sidewall Venting Two Pipe Roof Venting EXTERIOR WALL with Elbow (Intake) with Elbow (Intake) and Coupling (Exhaust) and Coupling (Exhaust) 1" MIN. 12" MIN. EXHAUST INSERT EXHAUST SCREEN MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER (TYP) LP-505-A 06/23/15...
  • Page 31 FRONT VIEW LP-325-PP 03/03/11 SIDE VIEW FRONT VIEW SIDE VIEW Figure 19 - Horizontal (Snorkel) Venting 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]).

  • Page 32: Venting Through An Existing System

    Concentric Venting Through an Existing System NOTE: The following instructions refer only to venting through an existing vent system, and not to venting with HTP’s optional concentric vent kits. Refer to Concentric Vent Kit installation manual (LP-166) for further information on venting with the optional concentric vent kits.

  • Page 33: Power Venting, Indoor Combustion Air In Confined Or Unconfined Space

    3. Power Venting, Indoor Combustion Air in Confined or Unconfined Space This heater requires fresh, uncontaminated air for safe operation considered part of the space. Confined space is space with volume less than 50 cubic feet per and must be installed in a mechanical room where there is adequate combustion and ventilating air.

  • Page 34: Common Vent Piping

    I. Common Vent Piping 1. Vent Diameter Sizing and Lengths These units are designed for 3 inch exhaust vent and intake pipes. Common Vented units must be direct vented, with an exhaust vent The following chart outlines the maximum length of common and intake air pipe vented to the outdoors.

  • Page 35: Recommended Exhaust Pipe Transitions

    2. Recommended Exhaust Pipe Transitions Figure 25 - Recommended Exhaust Pipe Transitions 3. Two (2) Pipe Common Direct Vent Systems Common Vented units must be direct vented, with an exhaust For each floor containing bedroom(s), a carbon monoxide detector vent and intake air pipe vented to the outdoors. DO NOT power and alarm shall be placed in the living area outside the bedrooms, vent Common Vented units! Doing so will result in property as well as in the room that houses the heater.
  • Page 36 Figure 26 - Common Vented Units – Unbalanced Venting Figure 27 - Common Vented Units – Roof Venting NOTE: This drawing is meant only to demonstrate system venting. The installer is responsible for all equipment and detailing required by local codes. For sidewall applications, terminate the outlet on the All vent pipes must be glued, properly supported, and the exhaust exterior wall at least 12”...

  • Page 37: Part 6 - Installing The Condensate Drain

    (water) as a normal by-product. This condensate is acidic, with a acidic condensate (p/n 7450P-212 available from HTP). Follow all the pH level between 3 and 4. This condensate must be drained away installation instructions included with the neutralizer.

  • Page 38: Part 7 - Connecting Electrical Service

    Part 7 - Connecting Electrical Service 1. This water heater must be properly grounded. Ensure the electrical receptacle is properly grounded. Do not remove the grounding prong from the water heater plug. Install wiring and electrically ground water heater in accordance 2.

  • Page 39: Wiring A Cascaded System

    Master Follower Figure 32 - Cascade Wiring Detail C. Wiring a Cascaded System When wiring the water heater for Cascade operation, select one as the Master water heater. The remaining water heaters will be When installing a cascaded system, it is important that the water designated Followers.
  • Page 40 Figure 38 - Electrical Wiring Diagram LP-644 Rev. 8.10.17...
  • Page 41 Figure 39 - Ladder Diagram LP-644 Rev. 8.10.17...
  • Page 42 Connector Description HT Selv No. of Location Board Silk GROUND Power Supply Line Heater Pump Power Supply (Live) Ignitor Power Supply HEAT/CP2 System Pump Power Supply (Live) 65001WS-12 Gas Valve Power Supply HT (120V~) AC Heater Pump Power Supply (Neutral) 9-12 Power Supply (Neutral) NOT USED...

  • Page 43: Part 8 - Gas Connections

    Connector Description HT SELV No. of Location Board Silk Flame Sensor Outlet Operating Water Temperature OP.S Sensor DH.S Exhaust Temperature Sensor Inlet Water Temperature Sensor LWD1140-14 External DHW Temperature Sensor / BG.S Aquastat SELV (5V) ST.S Outlet Temperature Sensor SP.S Overheat Temperature Sensor CN14 1 - 9...

  • Page 44: Lp (Liquid Propane) Gas Pipe Sizing

    3. LP (Liquid Propane) Gas Pipe Sizing D. Checking Gas Pressure at the Water Heater for Proper Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure Operation regulator. Adjust propane supply regulator provided by the gas NOTE: Refer Figure 42 when checking gas pressure. Loosen the bolts supplier for 14 inches w.c.

  • Page 45: Part 9 - Controls

    2. When low fire settings have been obtained, flip DIP switch seven (7) to its original (OFF) position. This will return the heater to normal operation. 3. Flip DIP switch six (6) to ON (high fire). Again check combustion readings with a combustion analyzer. NOTE: DO NOT adjust the gas valve offset screw at high fire.

  • Page 46: Start-Up Sequence

    Factory DHW Set-Point is 120 F (48.8 C). Initial DHW Set-Point range The LCD display also features a backlit lamp that will illuminate: is 95 – 140 F (35 – 60 • When a user action is detected (a button is pressed) •...

  • Page 47: Status Display

    E. Status Display Status Display will activate when button is pressed and held for five seconds at Standby Mode when the display panel is powered ON. Figure 48 - Status Display Screen Display Display Detail Description (Main Menu) (Sub Menu) Current Voltage of 0-10V Input A:In 0-10V Display...

  • Page 48: Installer Mode

    F. Installer Mode Installer Mode will activate when button is pressed and held for five seconds while the water heater display is powered Off. Figure 49 - Installer Mode Screens Display Default Detail Description 1:EH E0.00 Error history up to 10 Check ten most recent Error Codes (E0 - E9) 2:cE Clear Error History...

  • Page 49: Setting Up A Cascaded System

    Display Default Detail Description This water heater may be installed at elevations up to 10,000 feet and operate on either Natural or LP. The appliance will de-rate by 4% for each 1000 feet above sea level. Select the appropriate installation location as described below. Selects Installation Location for Proper Water Heater Operation at Altitude: 0-2 for installation locations from sea level to 1999 feet 2-5 for locations from 2000 to 4999 feet...

  • Page 50: 0-10 Volt Input

    Program the Master and Follower Water Heaters in a Cascade System: To program the cascade system, first enter the Installer Mode. Scroll down to and select the following parameters on each water heater in the system: 1. 16:cP – Set the number of units in the cascade loop [range from 1-20]. 2.

  • Page 51: Part 10 - Troubleshooting

    Part 10 - Troubleshooting A. Error Code When the water heater encounters an error, the display will flash “Er” followed by a numerical code. The water heater shall enter a soft lockout condition if the error is such that it can return to normal operation once the condition relieves itself (overheat conditions, NTC open or shorts, etc.).
  • Page 52 Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. Outlet Water Temperature If Error happens again: Sensor Detects Water 1. Ensure the pump is connected properly and operational. Replace pump if it is not operational. Er:26 Temperature Greater Than 2.
  • Page 53 Press the Power button to clear the Error Code. If Error happens again: Low Water Cut-Off circuit is 1. Ensure that the LWCO jumper is installed if low water cut off is not use. Er:42 open 2. Ensure that the water LWCO wires are properly installed (if in use). 3.

  • Page 54: Error Tree Analysis

    B. Error Tree Analysis 1. Flame Detection Figure 52 - Flame Detection Error Analysis Tree 2. Air Pressure Switch Detection Figure 53 - Air Pressure Switch Analysis Tree LP-644 Rev. 8.10.17...

  • Page 55: Inlet / Dhw / Operating Temperature / Exhaust Sensors

    3. Inlet / DHW / Operating Temperature / Exhaust Sensors Figure 54 - Inlet / DHW / Operating Temperature Sensors Error Analysis Tree C. Suggested Corrective Actions Problem Possible Causes Possible Remedies 1. Is the plug on the power supply cord unplugged 1.

  • Page 56: Part 11 - Start-Up

    Display Condition Diagnostic Possible Corrective Actions Correct wiring per wiring diagram Check wiring for short circuit or incorrect including connection of transformer to wiring Nothing appears on the the control. Control is not display control panel but receiving power Check transformer connection to the the fan runs at full speed Push the Power button on the control control per wiring diagram.

  • Page 57: Check For Gas Leaks

    Do not start the water heater again until the leak is available from HTP (554200). This pump is equipped with two leads repaired. Failure to comply could result in substantial property that can be connected to an alarm or another type of warning device damage, severe personal injury, or death.

  • Page 58: Part 12 - Installation Checklist

    DHW Inlet / Outlet Temperature Sensor HX (OP) Temperature Sensor (7850P-015) (7850P-081) Exhaust Temperature Sensor (7850P-070) Temperature ( Resistance (Ω) Temperature ( Resistance (Ω) 62162 28409 48440 22152 Visual Check Hole 38045 17408 Ensure Flame is Blue 30107 13782 23998 10990 19261 8824...
  • Page 59 Install Exhaust Vent and Intake Piping Have venting lengths been minimized? Are terminations properly spaced from windows, doors, and other intake vents? Have all vent terminations been installed at least one foot above exterior grade and one foot above normal snow accumulation level? Is vent piping properly supported? Has vent piping been checked for leaks?

  • Page 60: Part 13 - Maintenance

    Part 13 - Maintenance The water heater must be inspected and serviced annually, Failure to inspect the venting system and have it repaired by preferably at the start of the heating season, by a qualified service a qualified service technician can result in vent system failure, technician.
  • Page 61 Maintenance Report • Lift the relief valve lever. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve discharge pipe to ensure that the valve does not weep after the line has had time to drain. If the valve weeps, lift In unusually dirty or dusty conditions, care must be taken to keep the lever again to attempt to clean the valve seat.
  • Page 62 INSPECTION ACTIVITIES DATE LAST COMPLETED 1 st YEAR 2 nd YEAR 4 th YEAR* PIPING 3 rd YEAR Near water heater Check water heater and system piping for any sign of leakage. piping Leaking pipes could cause property damage. Make sure all piping is properly supported.

  • Page 63: Part 14 - Replacement Parts

    Part 14 - Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER M3 X 6 PH + M/S 7855P-384 B-10 M4 X 12 TH + M/S 7855P-393 M4 X 8 PH + Self Tapping 7855P-385 B-11 M4 X 14 PH + Self Tapping 7855P-394 M4 X 8 TH + Self Tapping 7855P-386...
  • Page 64 Figure 57 - Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Cabinet Assembly 7860P-005 Air Vent Adapter 7855P-454 Top Wall Mount Bracket 7850P-068 Control Board Bracket 7855P-412 Bottom Wall Mount Bracket 7850P-092 Air Pressure Switch 7855P-262 Exhaust Adapter Gasket 7850P-041 Ignition Transformer 7855P-007...
  • Page 65 Figure 58 - Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Exhaust Pipe Assembly 7855P-415 Outlet Temperature Sensor 7855P-030 30-1 Exhaust Temperature Sensor Clip 7855P-349 Water Level Detection Sensor 7855P-029 30-2 Exhaust Temperature Sensor Flame Sensor 7855P-031 7855P-092 Exhaust Temperature Sensor...
  • Page 66 Figure 59 - Combustion System Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Burner Inlet Channel (w/ Damper) 7855P-424 APS Hose Fitting 7855P-375 Air Damper 7855P-618 Gas Valve Assembly 7855P-431 Air Damper Guide 7855P-369 55-1 Gas Valve Outlet Adapter 7855P-232 Fan Outlet Gasket 7855P-425...

  • Page 67: Limited Warranty For Cgh-199 Water Heaters

    1. Any water heater purchased from an unauthorized dealer or online COVERAGE retailer. A. During the first year after the original date of installation, HTP 2. Any water heater not installed by a qualified heating installer/ warrants that it will repair or replace, at its option, any defective or...
  • Page 68 NOTE: Any parts or heaters returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied. If all warranty conditions are satisfied, HTP will provide replacement...

  • Page 69: Notes

    Notes LP-644 Rev. 8.10.17...

  • Page 70: Customer Installation Record Form

    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. Customer’s Name Date of Installation Installation Address...

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