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HTP CGH-199O Series Installation, Start-Up, Maintenance, Parts And Warranty

Crossover outdoor water heaters
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Installation
Start-Up
Maintenance
Parts
Warranty
CGH-199O* Models
*O Denotes Outdoor Models; "LP" Denotes Propane Gas;
"F" Denotes Floor Models with Built-In Pump
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-673 Rev. 000 Rel. 001 Date 8.30.18

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Yonus
April 27, 2025

Err-11 reset it a month ago and work now went to lockdown after few times resetting

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Summary of Contents for HTP CGH-199O Series

  • Page 1 Crossover Outdoor Water Heaters Installation Start-Up Maintenance Parts Warranty CGH-199O* Models *O Denotes Outdoor Models; “LP” Denotes Propane Gas; “F” Denotes Floor Models with Built-In Pump 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: Improper Combustion

    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: Gas

    Damages resulting from incorrect installation or from use or other chemical imbalance IS NOT covered by the warranty. of products not approved by HTP ARE NOT covered by warranty. The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates.

  • 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

    • Heater must be placed in an area where the exhaust plume Below is a list of other optional equipment available from HTP. These will not be recirculated into the louver system located on the additional options may be purchased through your HTP distributor: front access panel.

  • Page 9: Leveling

    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 Do not connect the water heater to any heating systems or should be taken to protect the condensate trap and drain lines components that have been previously used for non-potable from sustained freezing conditions.

  • Page 10: Exhaust Vent And Air Intake

    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 water heater from the space to perform maintenance. Failure to consider maintenance when determining installation location could Indoor result in property damage.

  • Page 11: Prevent Combustion Air Contamination

    appliance is located in a detached, uninhabitable structure separate Areas Likely Have from the dwelling, building, or structure used in whole or in part for Products to Avoid Contaminants residential purposes. In addition, the installing plumber or gas fitter shall observe that a Spray cans containing...

  • Page 12: Technical Specifications

    G. Technical Specifications Model Installation Outdoor, Wall Mounted Model or Floor Model, Fully Condensing Minimum / Maximum Input (Btu/Hr) 19,900 / 199,000 Uniform Energy Factor (UEF) / Thermal 0.92 / 95% Efficiency (TE) Flue System Category IV, Sealed Combustion Direct Vent, Power Vent Wall Mount Weight (lbs) Floor Model...
  • Page 13 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 14 Figure 5 - Wall Model Dimensions Figure 6 - Floor Model Dimensions Description Diameter Air Intake Exhaust Vent 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 (3/4” PVC Socket on Floor Models) Table 13 - Adapter Specifications lp-673 Rev.
  • Page 15 Figure 7 - 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 16: Wall-Mounting

    Electronic LCD Display – The high resolution display allows the user heater reaches 80% of its firing rate, the Master will modulate down to monitor water heater functions. The display also provides the means and split the load in half with the next unit in the system service to program the system parameters to maximize the efficiency of the rotation.

  • Page 17: Part 4 - Water Piping

    the plumbing system. A thermal trap or heat trap loop may be installed here to provide additional energy savings and prevent the thermal Align the heater bracket grooves on the back of the water siphoning of domestic hot water. heater with the tongues on the wall bracket and hang the water heater on the bracket.
  • Page 18 COLD WATER INLET HOT WATER OUTLET USED IF SENSOR CANNOT COLD WATER INLET COLD WATER INLET HOT WATER OUTLET USED IF SENSOR CANNOT HEATER PUMP WITH INTERNAL CHECK COLD WATER INLET Figure 10 - Water Heater with Storage Tank - NOTE: Floor Models are supplied with a Built-In Pump NOTES: 1.
  • Page 19 COLD WATER INLET HOT WATER OUTLET FLOW SWITCH COLD WATER INLET Figure 11 - 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 20 Figure 12 - Cascaded Water Heaters w/Storage Tank, Individual Pumps, and Recirculation - NOTE: Floor Models are supplied with a Built-In Pump NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet.
  • Page 21 Figure 13 - 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. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet.

  • Page 22: 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 14 - This chart represents heat exchanger pressure losses. System Temperature Rise Chart F ∆T F ∆T F ∆T Minimum Model...

  • Page 23: 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 24 B. Exhaust Vent and Intake Pipe Location Vent Terminal Area Where Terminal is Not Permitted Air Supply Inlet Figure 16 - 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 25: Water Heater Exhaust Vent And Air Intake Notes

    D. Application Combustion air must be drawn from the outdoors directly into the The outdoor enclosure is not designed to carry heavy weight. Do water heater intake, and exhaust must terminate safely outside. DO not stack anything on the water heater. Doing so could result in NOT INSTALL THIS WATER HEATER INDOORS.

  • Page 26: 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 27: Part 6 - Installing The Condensate Drain

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

  • Page 28: 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 29: Wiring A Cascaded System

    Master Follower Figure 25 - Cascade Wiring Detail D. Wiring a Cascaded System When wiring the water heater for Cascade operation, select one as the When installing a cascaded system, it is important that the water Master water heater. The remaining water heaters will be designated heaters are the same model.
  • Page 30 Figure 31 - Electrical Wiring Diagram lp-673 Rev. 000 Rel. 001 Date 8.30.18...
  • Page 31 Figure 32 - Ladder Diagram lp-673 Rev. 000 Rel. 001 Date 8.30.18...
  • Page 32 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 33: 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 34: 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 Operation pressure regulator. Adjust propane supply regulator provided NOTE: Refer to Figure 42 when checking gas pressure. Loosen the by the gas supplier for 14 inches w.c.

  • Page 35: 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 36: 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 37: 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 41 - Status Display Screen Display Display Detail Description (Main Menu) (Sub Menu) Current Voltage of 0-10V Input A:In 0-10V Display...

  • Page 38: 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 42 - 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 39: 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 40 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 41: 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 42 Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. Outlet Water Temperature If Error happens again: (OP) 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 43 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 44: Error Tree Analysis

    B. Error Tree Analysis 1. Flame Detection Figure 45 - Flame Detection Error Analysis Tree 2. Air Pressure Switch Detection Figure 46 - Air Pressure Switch Analysis Tree 3. Inlet / DHW / Operating Temperature / Exhaust Sensors Figure 47 - Inlet / DHW / Operating Temperature Sensors Error Analysis Tree lp-673 Rev.

  • Page 45: Suggested Corrective Actions

    C. Suggested Corrective Actions Problem Possible Causes Possible Remedies 1. Is the plug on the power supply cord unplugged 1. Reset the plug. from the electrical outlet? 2. Reset the circuit breaker. No electrical power to the water 2. Is the circuit breaker tripped? 3.
  • Page 46 Display Condition Diagnostic Possible Corrective Actions Check for loose connections and proper pin Check for continuity on the wire harness from Nothing appears Occurs when alignment / engagement on the control’s the display to the control. See repair parts sec- on the display communication is plug...

  • Page 47: Part 11 - Installation Checklist

    If the condensate outlet on the appliance is lower than the drain, you must use a condensate removal pump, available from HTP (554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert the user of a condensate overflow, which, if not corrected, could cause property damage.
  • Page 48 Water Piping Does water heater loop piping meet the minimum sizing requirements listed? NOTE: Smaller piping will cause performance problems. Has water chemistry been checked? Does water chemistry meet requirements? If water chemistry does not meet requirements, have treatment measures been put in place? Has the system been cleaned and flushed? Has water piping been insulated for freeze protection? Exhaust Vent and Combustion Air Intake...

  • Page 49: Part 12 - Maintenance

    Part 13 - Maintenance The water heater must be inspected and serviced annually, Failure to inspect the venting system and have it repaired by a preferably at the start of the heating season, by a qualified service qualified service technician can result in vent system failure, causing technician.
  • Page 50 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 51 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 52: 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-12 M4 X 15 PW + M/S 7855P-395 M4 X 8 PH + Self Tapping 7855P-385 B-13 M4 X 20 TH + Self Tapping 7855P-396 M4 X 8 TH + Self Tapping 7855P-386...
  • Page 53 Figure 51 - Replacement Parts - Outdoor Floor Model Number Description Part Number Number Description Part Number Cabinet Assembly See Figure 66 3/4” ID SS Gas Flex - 18” Long 7865P-016 1 1/4” FIP 304 SS Cap 7860P-004 Handle, Front Cover 7600P-033 2”...
  • Page 54 B-10 B-13 Figure 52 - Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Cabinet Assembly 7860P-005 Display Panel Bracket 7855P-413 Top Wall Mount Bracket 7850P-068 Terminal Blocks Bracket 7855P-434 Bottom Wall Mount Bracket 7850P-092 Control Board 7855P-408 Air Vent 7855P-063 Display Panel...
  • Page 55 Figure 53 - Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Exhaust Pipe Assembly 7855P-415 HX Dual (OP/OH) 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...
  • Page 56 Figure 54 - 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 57: Limited Warranty For Rgh Water Heaters

    COVERAGE regulations. A. During the first year after the original date of installation, HTP warrants 4. The workmanship of any installer. The manufacturer disclaims and does that it will repair or replace, at its option, any defective or malfunctioning...
  • Page 58 During the claims process a product that must be replaced will be given a Aluminum 0.05 to 0.2 mg/l designation of either a) field scrap, or b) return to HTP. If the product must be returned to HTP, the returned product must arrive at HTP within thirty Chloride 100 mg/l (30) days of the date of our request to return the product.
  • Page 59 Notes lp-673 Rev. 000 Rel. 001 Date 8.30.18...
  • Page 60 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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