HTP Crossover 150 Installation Start-Up Maintenance Parts

Outdoor water heaters
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Installation
Start-Up
Maintenance
Parts
Warranty
RGH-150O / 199O* Models
O Denotes Outdoor Models; *
"LP" Denotes Propane Gas
The outdoor unit is intended for use in outdoor installations ONLY. DO NOT install the water heater indoors. Installing the
water heater indoors will result in improper water heater operation, property damage, serious personal injury, or death.
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.
Outdoor Water Heaters
New Bedford, MA 02745
Crossover
www.htproducts.com
lp-672 Rev. 000 Rel. 002 Date 10.3.18

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Summary of Contents for HTP Crossover 150

  • Page 1 Crossover Outdoor Water Heaters Installation Start-Up Maintenance Parts Warranty RGH-150O / 199O* Models O Denotes Outdoor Models; * “LP” Denotes Propane Gas The outdoor unit is intended for use in outdoor installations ONLY. DO NOT install the water heater indoors. Installing the water heater indoors will result in improper water heater operation, property damage, serious 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 The latest version of the National Electrical Code, NFPA No. 70. Foreword In the State of California: The water heater must be braced, anchored, This manual is intended to be used in conjunction with other or strapped to avoid moving during an earthquake. Contact local utili- literature provided with the water heater.
  • Page 4: Table Of Contents

    Table of Contents Part 10 - Troubleshooting Part 1 - General Safety Information A. Error Code A. Operation and Installation Warnings B. Error Tree Analysis B. Improper Combustion 1. Flame Detection 2. Air Pressure Switch Detection C. Gas 3. Recirculation / Inlet / DHW / Operating Temperature / Exhaust Sensors D.
  • Page 5 DO NOT alter or modify the water heater or water heater controls. near the water heater or near the exterior fresh air intake port. DO Altering any HTP water heater with parts not manufactured by HTP NOT place any items in or around the exhaust gas outlet port and/...
  • Page 6: Improper Combustion

    Damages resulting from incorrect installation or from use Chemical imbalance of the water supply may affect efficiency and of products not approved by HTP ARE NOT covered by warranty. cause severe damage to the appliance and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water.
  • Page 7: Water Temperature Adjustment And Scalding

    Freeze Protection Operation Stage 1 - If control detects water temperature of 46 An ASSE 1017 or ASSE 1070 temperature limiting or mixing valve is C) and below, it turns the internal and external recommended in installations servicing disabled or elderly persons, pumps On for 600 seconds and Off for 30 seconds.
  • Page 8: Optional Equipment

    Pipe the exhaust vent so that Other Optional Equipment it terminates level with or above the fence, wall, or enclosed Below is a list of other optional equipment available from HTP. These area. additional options may be purchased through your HTP distributor: •...
  • Page 9: Leveling

    • Incorrectly sized expansion tank 6. Clean and flush system when reinstalling a heater. This water heater has a condensate disposal system that may freeze if exposed to sustained temperatures below 32 F. Precautions should be taken to protect the condensate trap and drain lines Do not connect the water heater to any heating systems or from sustained freezing conditions.
  • Page 10: Exhaust Vent And Air Intake

    MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS • Hot water pipes - at least 1” from combustible materials Indoor Always take future maintenance into consideration when locating the water heater. If the water heater is located in an installation location with limited clearances, it may be necessary to remove the Indoor water heater from the space to perform maintenance.
  • Page 11: Carbon Monoxide Detectors

    appliance is located in a detached, uninhabitable structure separate Areas Likely Have Products to Avoid from the dwelling, building, or structure used in whole or in part for Contaminants residential purposes. Spray cans containing Dry cleaning / laundry areas and In addition, the installing plumber or gas fitter shall observe that a fluorocarbons establishments...
  • Page 12: Technical Specifications

    G. Technical Specifications Model Installation Outdoor, Wall Hung, Fully Condensing Minimum / Maximum Input (Btu/Hr) 15,000 / 150,000 19,900 / 199,000 F Rise 8.2 GPM 11 GPM Hot Water Capacity F Rise 6.4 GPM 8.5 GPM F Rise 3.7 GPM 5 GPM Flue System Category IV, Sealed Combustion Direct Vent, Power Vent...
  • Page 13 16.7 36.8 10.3 17.6 Figure 5 - 150 Model Dimensions 18.0 38.8 11.6 10.6 20.0 Figure 6 - 199 Model Dimensions Description Diameter Air Intake Louvers Exhaust Outlet Gas Inlet Adapter 3/4” NPT Condensate Adapter 1/2” NPT DHW Outlet Adapter 3/4”...
  • Page 14 Figure 7 - Components Number Component Description Number Component Description Number Component Description Air Intake Pipe Adapter Condensate Trap Control Panel Flue Air Pressure Sensor Gas Pipe Adapter Heat Exchanger Air Inlet Orifice Condensate Adapter Flame Detection Sensor Air Inlet Pipe Hot Water Adapter Water Level Detection Sensor Gas Outlet Pipe...
  • Page 15: Wall-Mounting

    more or less energy. The negative regulated gas valve provides only When the Master water heater receives a DHW demand, the Master the amount of fuel required to ensure clean combustion. The mixer will energize the lead water heater in the cascade system. In a new accurately regulates the combination of gas and air throughout the system start-up this will be the Master.
  • Page 16: Part 4 - Water Piping

    • Isolation (shutoff valves) should be used to ease future or death. servicing. HTP offers isolation valves (Part #7850P-090). These optional parts may be purchased separately. • All water piping should be insulated.
  • Page 17: Backflow Preventer

    B. Backflow Preventer Use a backflow preventer specifically designed for water heater installations. This valve should be installed on the cold water fill supply line per local codes. C. Potable Expansion Tank A potable hot water expansion tank is required to offset heated water expansion. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent back flowing of water into city mains.
  • Page 18 RECIRULATION COLD WATER INLET HOT WATER OUTLET COLD WATER INLET HOT WATER OUTLET Figure 11 - DHW Piping, Single Water Heater - NOTE: There is a Built-In Flow Check in the Internal Pump Loop NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2.
  • Page 19 RECIRCULATION COLD WATER INLET HOT WATER OUTLET COLD WATER INLET HOT WATER OUTLET Figure 12 - Piping with Recirculation - NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop NOTE: For installations where internal pump is not adequate for the recirculation loop, an additional pump can be installed and powered by the appliance (2A Max).
  • Page 20 HOT WATER OUTLET RECIRCULATION COLD WATER INLET HOT WATER OUTLET COLD WATER INLET Figure 13 - Water Heater with Storage Tank - NOTE: There is a Built-In Flow Check in the Internal Pump Loop HOT WATER OUTLET RECIRCULATION COLD WATER INLET HOT WATER OUTLET COLD WATER INLET Figure 14 - Water Heater with Storage Tank and Recirculation - NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop...
  • Page 21 RECIRCULATION COLD WATER INLET HOT WATER OUTLET HOT WATER OUTLET AIR HANDLER COLD WATER INLET Figure 15 - Water Heater with Air Handler without Internal or External Recirculation - NOTE: There is a Built-In Flow Check in the Internal Pump Loop RECIRCULATION COLD WATER INLET HOT WATER OUTLET...
  • Page 22 RECIRCULATION COLD WATER INLET HOT WATER OUTLET COLD WATER INLET HOT WATER OUTLET Figure 17 - Water Heater with Thermal Bypass Valve - NOTE: There is a Built-In Flow Check in the Internal Recirculation Pump Loop Using the Optional Crossover (Thermal Bypass) Valve In piping applications where a dedicated recirculation line is not available or too costly to install, the water heater can use a crossover (thermal bypass) valve as a method of recirculation.
  • Page 23 FOLLOWER FOLLOWER RECIRCULATION COLD WATER INLET HOT WATER OUTLET HOT WATER OUTLET COLD WATER INLET Figure 18 - Cascaded Water Heaters FOLLOWER FOLLOWER RECIRCULATION COLD WATER INLET HOT WATER OUTLET HOT WATER OUTLET COLD WATER INLET Figure 19 - Cascaded Water Heaters w/ Recirculation NOTE: For installations where internal pump is not adequate for the recirculation loop, an additional pump can be installed and powered by the appliance (2A Max).
  • Page 24: Circulator Sizing

    F. Circulator Sizing Figure 20 - This chart represents the internal recirculation pump performance curve taking into account valves and heat exchanger pressure losses. Figure 21 - This chart represents heat exchanger pressure drop through the heat exchanger and internal valves. NOTE: When using external recirculation mode with the built-in pump, observe the following maximum recirculation pipe lengths including fittings: •...
  • Page 25: Pressure Relief Valve

    ∆T = 77 ∆T = 45 ∆T = 35 Number of Flow Rate Water Pipe Dia. Flow Rate Water Velocity Pipe Dia. Flow Rate Water Pipe Dia. Units (GPM) Velocity (ft/s) (In.) (GPM) (ft/s) (In.) (GPM) Velocity (ft/s) (In.) 3.75 3.61 4.64 1 1/2...
  • Page 26: Filling The Heater

    Part 5 - Venting The heater must be vented as detailed in this section. Ensure the exhaust vent and air intake comply with these instructions regarding vent system. Inspect the installed appliance thoroughly to ensure it complies with all applicable code requirements, as well as the instructions provided in this manual.
  • Page 27: Exhaust Vent And Air Intake Location

    B. Exhaust Vent and Intake Pipe Location Vent Terminal Area Where Terminal is Not Permitted Air Supply Inlet Figure 23 - Vent Termination Clearances CANADA Description (ANSI Z223.1/NFPA 54) (CSA B149.1) Clearance above grade, veranda, porch, deck, or 12 in. balcony 4 ft.
  • Page 28: Water Heater Exhaust Vent And Air Intake Notes

    C. Water Heater Exhaust Vent and Intake Notes 1. Ensure the water heater is located where it will not be exposed to prevailing winds. 2. Do not locate water heater over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.
  • Page 29: Outdoor Installation

    Outdoor Installation CAUTION When drawing combustion air from the outdoors, care must be taken to provide adequate freeze protection. Failure to do so could result in property damage and premature product failure. Such damages and failures ARE NOT covered by product warranty. This water heater is designed to draw combustion air through the louver system in the water heater cabinet.
  • Page 30: Part 6 - Installing The Condensate Drain

    (p/n 7450P-212 (water) as a normal by-product. This condensate is acidic, with a pH available from HTP). Follow all the installation instructions included level between 3 and 4. This condensate must be drained away from with the neutralizer.
  • Page 31: Part 7 - Connecting Electrical Service

    8. Do not disconnect the power supply when the water heater is in Part 7 - Connecting Electrical Service normal operation. NOTE: For additional electrical protection, the use of a whole house surge protector is recommended. Damage caused by power surges IS NOT covered by the warranty.
  • Page 32: Wiring A Cascaded System

    Figure 32 - Wiring Detail NOTE: T/T only operates when Air Handler Application is selected in Installer Menu - 19:SU - AH. D. 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 designated Followers.
  • Page 33 Figure 38 - Electrical Wiring Diagram lp-672 Rev. 000 Rel. 002 Date 10.3.18...
  • Page 34 Figure 39 - Ladder Diagram lp-672 Rev. 000 Rel. 002 Date 10.3.18...
  • Page 35 Connector Description HT Selv No. of Location Board Silk GROUND Power Supply Line Heater Pump Power Supply (Live) Ignitor Power Supply HEAT/CP2 External Pump 65001WS-12 Gas Valve Power Supply HT (120V~) AC GROUND Power Supply (Neutral) 9-12 AC Power COM Line Solenoid Valve Power Supply (Live) CP2/3WAY LW6A4-03...
  • Page 36 Connector Description HT SELV No. of Location Board Silk Flame Sensor Outlet Operating Water Temperature OP.S Sensor DH.S DHW Temperature Sensor Inlet Water Temperature Sensor SELV (5V) LWD1140-14 BG.S Exhaust Temperature Sensor ST.S Return Water Temperature Sensor SP.S Overheat Temperature Sensor IWM Stepper Motor Coil / Y Phase IWM Stepper Motor Coil / X Phase CN10...
  • Page 37: Part 8 - Gas Connections

    Part 8 - Gas Connections FIRE AND/OR EXPLOSION HAZARD To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional. Ensure the gas on which the water heater will operate is the same type specified on the rating plate (natural gas or LP gas). This water heater must be converted into propane operation unless specifically manufactured for use with propane.
  • Page 38: Additional Precaution For Excess Flow Valve (Efv)

    C. Additional Precaution for Excess Flow Valve (EFV) If an excess flow valve (EFV) is in the gas line, check the manufacturer’s minimum and maximum flow capacity ratings. An improperly sized It is required to use a combustion analyzer to verify final adjustment EFV will not allow for a full flow of gas to the water heater and will according to the combustion chart (Table 20).
  • Page 39: Part 9 - Controls

    Part 9 - Controls A. Control and Display Overviews Figure 43 - Control Panel Detail Figure 44 - LCD Display After start-up, the display appears as follows. LCD also features a backlit lamp that will illuminate: • When a user action is detected (a button is pressed) •...
  • Page 40: Changing The Dhw Set-Point

    C. Changing the DHW Set-Point D. Changing the Time NOTE: The setpoint cannot be changed if water is flowing through Press and hold the button for five seconds when the display the unit. Ensure there is no demand on the water heater when panel is powered ON to change the time.
  • Page 41: Status Display

    F. Status Display Status Display will activate when button is pressed and held for five seconds at Standby Mode. Figure 48 - Status Display Screen Display Display Detail Description (Main Menu) (Sub Menu) A:GA or A:LI Flow Unit Current Flow Unit (LI: Liters/min, GA: Gallons/min) b:dH DHW outlet water temperature Current DHW target temperature...
  • Page 42: Installer Mode

    G. Installer Mode To activate Installer Mode, ensure the water heater display is powered off. Then press and hold button for five seconds. Figure 49 - Installer Mode Screens Display Default Detail Description : Recirculation Pump is not used. (Recirculation and Preheat Modes are OFF.) : Title 24 Mode (Required in California, Optional in other states).
  • Page 43: Setting Up A Cascaded System

    This function sets the time to run pumps and powers the solenoid valve to purge air from AP:cP the system. Range: 1 - 30 Minutes 14:AP Pu:oF Pump Test Mode Turn this function ON to activate pump testing. Only works in installation mode. Turns off when in normal mode.
  • Page 44: Using Recirculation Modes - Step

    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. 9:cP – Set the number of units in the cascade loop [range from 1-20]. 2.
  • Page 45: Recirculation Functions - Using Recirculation Modes - Step

    Preheat or Internal Recirculation Modes – When calls for hot water are satisfied, the water heater is factory programmed to Preheat and automatically maintain the temperature set point of the water heater – 24 hours a day, 7 days a week. The differential setting can be adjusted to control the temperature set point.
  • Page 46: Smart Auto-Learn Recirculation Function

    NOTE: The optional On Demand Recirculation kit can be used to activate recirculation when unit is set to Internal or External Recirculation Modes. Hotter water increases the risk of scald injury. Scalding may occur within 5 seconds at a setting of 140 F (60 C).
  • Page 47: Part 10 - Troubleshooting

    Figure 55 - A - Selecting a Recirculation Function, B - Entering Day Setting e. The default day is displayed when the program function is selected. Press the button to remove a day. Turn the dial to select other days. See Figure 56 A. f.
  • Page 48 Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. The Code will also automatically reset after one hour (up to three (3) times. If Error happens again: 1. Monitor the gas pressure to the water heater while in operation. Ensure pressure is between 3.5 and 14” Flame has extinguished 5 Er:10 2.
  • Page 49 Error Code Error Code Description Possible Remedies This Error Code will go away when exhaust temperature decreases. If Error happens again: Exhaust (Eh) Sensor Open or 1. Check exhaust temperature sensor. Ensure connections are secure. Er:35 Short 2. Check sensor resistance. If resistance is zero, replace the sensor. 3.
  • Page 50 Error Code Error Code Description Possible Remedies Register, Ram, Rom, I/O Port, This Error Code will go away when the condition is remedied. AD Abnormal, Important If Error happens again: Er:70 EPROM Data or Safe Data 1. Turn power OFF and ON at the main power switch internal to the water heater. Abnormal 2.
  • Page 51: Error Tree Analysis

    B. Error Tree Analysis 1. Flame Detection Figure 59 - Flame Detection Error Analysis Tree 2. Air Pressure Switch Detection Figure 60 - Air Pressure Switch Analysis Tree lp-672 Rev. 000 Rel. 002 Date 10.3.18...
  • Page 52: Recirculation / Inlet / Dhw / Operating Temperature / Exhaust Sensors

    3. Recirculation / Inlet / DHW / Operating Temperature / Exhaust Sensors Figure 61 - Recirculation / 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 53 DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS The water heater control is able to record information about the water heater’s condition at the time of the ten previous faults or errors. This information is available to view in the Installer Mode under the History screen. The following screens may be displayed when reviewing the water heater history.
  • Page 54: Part 11 - Installation Checklist

    DHW Inlet Temperature (In) Sensor DHW Outlet Temperature (dH) Sensor (7850P-015) (7850P-019) Exhaust Temperature (Eh) Sensor HX (OP) Temperature Sensor (7850P-070) (7850P-081) Temperature ( Resistance (Ω) Temperature ( Resistance (Ω) 62162 28409 48440 22152 38045 17408 30107 13782 23998 10990 19261 8824 15562...
  • Page 55 Install Condensate Piping / Tubing and Components Have all condensate components included with the water heater been installed? Is the condensate line piped with the approved materials listed in this manual? Has the condensate line been routed to a laundry tub or other drain? Has condensate line been protected from freezing with heat tape? Has the installer ensured that the condensate does not drain onto a finished surface? Install Gas Piping...
  • Page 56: Part 12 - Maintenance

    Part 12 - Maintenance Visually inspect the intake piping for any signs of blockage. Inspect the entire length of the intake pipe to ensure piping is intact and all The water heater must be inspected and serviced annually, joints are properly sealed. Inspect the intake pipe bracing. Ensure preferably at the start of the heating season, by a qualified service bracing is undamaged and in good condition.
  • Page 57 Immediately shut the water heater down per instructions on Do not open shutoff valve V1. page 2 and call a qualified service technician to inspect the d. Allow water to flow through the water heater for 5 minutes. valve and system. Close shutoff valve V2.
  • Page 58 INSPECTION ACTIVITIES DATE LAST COMPLETED 1 st YEAR 2 nd YEAR 4 th YEAR* 3 rd YEAR PIPING 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 59: Part 13 - Replacement Parts

    Part 13 - 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 60 Figure 65 - Replacement Parts 150 Model 199 Model 150 Model 199 Model Number Description Number Description Part Number Part Number Part Number Part Number Cabinet Assembly See Figure 66 Outdoor Top Cover 7855P-663 7855P-623 2” Outdoor Pipe Adapter 7850P-259 2”...
  • Page 61 B-16 B-13 Figure 66 - Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Bottom Wall Mount Bracket 7850P-092 Manual Power Switch 7855P-014 Cabinet Assembly - 150 Model 7855P-626 Condensate Block APS 7855P-017 Cabinet Assembly - 199 Model 7850P-263 Display Panel Bracket - 150 Model 7855P-628...
  • Page 62 Figure 67 - Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Exhaust Temperature Sensor Clip 7855P-349 Ceramic Fiber Burner - 150 Model 7855P-635 27-4 Exhaust Temperature (Eh) Sensor 7855P-092 Ceramic Fiber Burner - 199 Model 7855P-420 Exhaust Pipe Assembly - 150 Model 7855P-630 27-5...
  • Page 63 Figure 68 - Combustion System Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Burner Inlet Channel (w/ Damper) 7855P-424 Gas Pipe (to Mixer) - 150 Model 7855P-638 Air Damper - 150 Model 7855P-637 Gas Pipe (to Mixer) - 199 Model 7855P-650 Air Damper - 199 Model 7855P-618...
  • Page 64 64 65 O-12 B-16 O-11 O-10 O-11 O-11 B-15 O-10 O-11 B-16 O-10 Figure 69 - Water Side Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER OP Temperature Sensor 7850P-081 Mixing Block 7855P-603 3/4” Pipe Gasket 7855P-073 DHW Outlet Adapter 7855P-225 Overheat Switch (Heat Exchanger) 7850P-051...
  • Page 65: Limited Warranty For Rgh Water Heaters

    COVERAGE 4. The workmanship of any installer. The manufacturer disclaims and does A. During the first year after the original date of installation, HTP warrants not assume any liability of any nature caused by improper installation, that it will repair or replace, at its option, any defective or malfunctioning repair, or maintenance.
  • Page 66 During the claims process a product that must be replaced will be given a Total Hardness 200 mg/l designation of either a) field scrap, or b) return to HTP. If the product must (Residential Use - Below 140 F water...
  • Page 67: Notes

    Notes lp-672 Rev. 000 Rel. 002 Date 10.3.18...
  • Page 68: 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...

This manual is also suitable for:

Crossover 199

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