HTP Crossover RGH40-75F Installation Start-Up Maintenance
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HTP Crossover RGH40-75F Installation Start-Up Maintenance

Residential hybrid floor mounted water heaters
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Installation
Start-Up
Maintenance
Parts
Warranty
RGH20-75F / RGH20-76F / RGH20-100F
RGH40-75F / RGH40-76F / RGH40-100F
RGH-75F / RGH-76F / RGH-100F Models
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.
Residential Hybrid Floor
Mounted Water Heaters
This Manual For Use With Water Heaters Manufactured Before September 4, 2018
New Bedford, MA 02745
Crossover
www.htproducts.com
LP-605 Rev. 000 Rel. 009 Date 8.16.18

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Summary of Contents for HTP Crossover RGH40-75F

  • Page 1 Crossover Residential Hybrid Floor Mounted Water Heaters Installation Start-Up Maintenance Parts Warranty RGH20-75F / RGH20-76F / RGH20-100F RGH40-75F / RGH40-76F / RGH40-100F RGH-75F / RGH-76F / RGH-100F Models This Manual For Use With Water Heaters Manufactured Before September 4, 2018 This manual must only be used by a qualified installer / service technician.
  • 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 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 literature provided with the water heater. This includes all related personnel. The qualfied installer / service technician should be guided control information.

  • Page 4: Table Of Contents

    Table of Contents B. How to Use the Control Interface Part 1 - General Safety Information C. How to Set the Water Heater for High Output Operation A. Operation and Installation Warnings D. Temperature Setting Procedure B. Improper Combustion E. Water Temperature Adjustment and Scalding C.
  • Page 5 DO NOT alter or modify the water heater or water heater controls. DO NOT use spray paint, hair spray, or any other flammable spray Altering any HTP water heater with parts not manufactured by HTP near the water heater or near the exterior fresh air intake port. DO...

  • Page 6: Improper Combustion

    Damages resulting from incorrect installation or from use • To avoid severe burns, allow water heater and associated of products not approved by HTP ARE NOT covered by warranty. equipment to cool before servicing. • Do not use petroleum-based cleaning or sealing compounds in a water heating system.

  • Page 7: High Elevation Installations

    Approximate Time / Temperature Relationships in Scalds More than 5 minutes 1 1/2 to 2 minutes About 30 seconds About 10 seconds Less than 5 seconds Less than 3 seconds About 1 1/2 seconds About 1 second Table 2 - Time and Temperature Relationship in Scalds Households with small children, disabled, or elderly persons may require a 120 F or lower temperature setting to prevent severe...

  • Page 8: Optional Equipment

    3” Pipe Clamp Condensate Trap Assembly Water Heater Stand Assembly Table 3 - Included with the Water Heater B. Optional Equipment Optional equipment available from HTP (and Part #): Optional Parts 3” Power Vent Exhaust Termination (8100P-029) 3” Exhaust Extension Adapter w/...

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

    Part 3 - Prepare the Water Heater Installation The service life of the water heater’s exposed metallic surfaces, Remove all sides of the shipping crate to allow the heater to be such as the casing, as well as internal surfaces, such as the heat moved into its installation location.

  • Page 10: Leveling

    floor shall be covered by the panel. The panel must be strong enough to carry the weight of the heater when full of water. 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. Location must also fully support the weight of the filled water heater.

  • Page 11: Exhaust Vent And Intake Pipe

    1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of E. Exhaust Vent and Intake Pipe all fuel-burning appliances installed in that space. Rooms connected The heater is rated Category IV (pressurized vent, likely to form directly to this space through openings not furnished with doors are condensate in the vent) and requires a special vent system designed considered part of the space.

  • Page 12: Prevent Combustion Air Contamination

    G. Prevent Combustion Air Contamination Install intake air piping for the heater as described in the Venting Section, this manual. Do not terminate exhaust in locations that can allow contamination of intake air. Ensure that the intake air will not contain any of the contaminants in Table 6. Contaminated air will damage the heater, resulting in possible substantial property damage, severe personal injury, or death.

  • Page 13: Technical Specifications

    I. Technical Specifications Model 100F Energy Factor (EF)* / Uniform 20 Gallon Models 0.83 EF / 0.88 UEF 96 TE 95 TE Energy Factor (UEF)* / Thermal 40 Gallon Models 0.90 UEF 0.87 UEF Efficiency (TE)* 20 Gallon Models 37,500 to 75,000 37,500 to 76,000 50,000 to 100,000 Minimum to Maximum Input...

  • Page 14: Installing The Water Heater Stand, Exhaust Pipe Clamp, And Condensate Trap

    Description Diameter Description Diameter Cold Water Inlet Gas Connection 1/2” or 3/4” Female NPT 3/4” Male NPT Hot Water Outlet Drain Valve Exhaust 3” Condensate System 1/2” Male NPT Electric Cord Tank Sensor T&P Valve Display Control Thermostatic Mixing Valve Air Intake 3”...
  • Page 15 Description Diameter Description Diameter Cold Water Inlet Gas Connection 1/2” or 3/4” Female NPT 3/4” Male NPT Hot Water Outlet Drain Valve Exhaust 3” Condensate System 1/2” Male NPT Electric Cord Tank Sensor T&P Valve Display Control Thermostatic Mixing Valve Air Intake 3”...

  • Page 16: Assembling The Water Heater Stand

    1. Assembling the Water Heater Stand 40 Gallon Models NOTE: Ensure the Water Heater Stand Assembly has shipped with 20 Gallon Models all included components. See Figure 7. NOTE: Ensure the Water Heater Stand Assembly has shipped with all included components. See Figure 5. Figure 7 - 40 Gallon Model Water Heater Stand and Components Use a 5/16”...

  • Page 17: Installing The Exhaust Pipe Clamp And Condensate Trap

    3. Installing the Exhaust Pipe Clamp and Condensate Trap The factory supplied water heater stand and condensate trap must be installed with the water heater. Failure to properly install condensate trap will allow dangerous gas to contaminate the structure and result in property damage, serious personal injury, or death. DO NOT operate the water heater for any amount of time for any reason until the condensate trap is installed.

  • Page 18: Backflow Preventer

    Ensure the cold water inlet and hot water outlet pipes are not reversed. Doing so will cause the water heater to operate improperly and void warranty. Ensure the hot and cold lines are connected properly. B. Backflow Preventer Use a backflow preventer specifically designed for water heater installations.

  • Page 19: Applications

    E. Applications Figure 11 - Typical Installation LP-605 Rev. 000 Rel. 009 Date 8.16.18...
  • Page 20 Figure 12 - Single Water Heater with Recirculation Figure 13 - Two Water Heaters with 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 21 Figure 14 - Water Heater with Storage Tank 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 NOTES: 1. The Heating Application Kit (Part # 8100P-049, not included with the water heater) MUST BE installed when using an air handler. Failure to install the Heating Application Kit when using the water heater for heating applications WILL VOID product warranty. 2.

  • Page 23: Temperature And Pressure Relief Valve

    F. Temperature and Pressure Relief Valve An external pressure relief valve must be installed on this water heater. When installing, observe the following guidelines. Failure to comply with these guidelines can result in substantial property damage, personal injury, or death. This water heater must be provided with an Figure 17 - Relief Valve Installation Details approved 150 psi, ¾”...

  • Page 24: Part 5 - Venting

    Do not open the drain valve without connecting a hose so that water can be diverted to an area where water damage is not a problem. Use a flat head screwdriver to open and close the drain valve. Do not remove the drain valve from the unit without first draining the water heater.

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

    B. Approved Materials for Exhaust Vent and Intake Pipe Standards for Installation In: Item Material United States Canada Pipe and Fittings Approved ABS* ANSI/ASTM D2661 NOT PERMITTED for Intake ONLY PVC Schedule 40/80 ANSI/ASTM D1785 PVC, CPVC, and PP Venting Must PVC-DWV Schedule 40/80 ANSI/ASTM D2665 be ULC-S636 Certified.

  • Page 26: 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 19 - 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 27: Exhaust Vent And Intake Pipe Sizing

    Friction Loss Equivalent in Piping and Fittings E. Exhaust Vent and Intake Pipe Sizing 1. The exhaust vent and intake pipe adapters are 3”. Equivalent Feet Fittings or Piping 2. The total equivalent length of 3” exhaust vent and intake pipe 3”...

  • Page 28: Applications

    The letters shall be sized equal to a minimum of the pipe diameter. However, for piping with a diameter exceeding two inches, said lettering does not need to be larger than two inches. This table lists optional exhaust/intake terminations available from HTP: Description Stock Code 3” PVC Concentric Termination Kit KGAVT0601CVT 3”...
  • Page 29 Two Pipe Roof Venting Two Pipe Sidewall 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 30 EXHAUST AIR INTAKE FRONT VIEW EXHAUST AIR INTAKE LP-325-PP 03/31/11 SIDE VIEW Figure 22 - 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 31: 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 32: 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 directly to this space, through openings not furnished with doors, and must be installed in a mechanical room where there is adequate are considered part of the space.
  • Page 33 Air Supply from Outside Building When combustion air is supplied directly through an outside wall, such as intake louver openings into the dwelling, each opening should give a minimum free area of one square inch per 4,000 BTU/ hour on the total input ratings of all appliances in the enclosed area. Figure 26 - Air Supply from Outside Building Air Supply from Inside Building When combustion air is supplied from inside the building, each...

  • Page 34: Part 6 - Installing The Condensate Drain

    Figure 29 - Power Vent Terminations Part 6 - Installing the Condensate Drain 2. Condensate line must be pitched at least ¼” per foot to properly drain. If this cannot be done, or a very long length of condensate hose This condensing high efficiency water heater has a condensate is used, increase the condensate line to a minimum of 1”...
  • Page 35 (p/n 7450P-212 available from HTP). Follow all the installation instructions included with the neutralizer. If a neutralizer is installed (2), periodic replacement of the limestone (or neutralizing agent) will be required. The rate of depletion of the limestone varies with usage of the water heater.

  • Page 36: Part 7 - Connecting Electrical Service

    Part 7 - Connecting Electrical Service Install wiring and electrically ground water heater in accordance All units come with a factory installed 3-pronged power (grounded) with the authority having jurisdiction or, in the absence of such plug. It is required to run a dedicated electrical line to the water an authority, follow the National Electrical Code, NFPA 70, and/ heater to prevent electrical interference.
  • Page 37 Maximum Flame Detecting Voltage AC200V Minimum Flame Detecting Voltage AC150V Pre-Purge Time (Tp) 5 - 10 seconds Safety Time (Igniting Time) (Ts) <5 seconds Igniting Interval Time <10 seconds Post-Purge Time (Tip) 20 seconds Over-Heating 1, 2, 3, Protection Detection Time <1 second Temperature Sensor Fault Detection Time <10 seconds...

  • Page 38: 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 39: Lp Gas Conversion

    Length of Pipe (Feet) Pipe Size (in.) BTU’s Per Hour x 1,000 (0.60 Specific Gravity, 0.5 WC 1 1/4 Pressure Drop) 1 1/2 1990 1400 1140 4640 3290 2680 2330 2080 1900 1650 1480 1210 1050 Table 21 - Liquid Propane Delivery Capacity - Corrugated Stainless Steel Pipe - Refer to ANSI Z223.1 - National Fuel Gas Code, Latest Edition Length of Pipe (Feet) Pipe Size (in.) BTU’s Per...

  • Page 40: Gas Connection Requirements

    5. Reassemble the top service panel and apply the LP label which is in the accessory kit. Figure 40 - Reassembled Top Service Panel and Applied LP Label Prior to start-up, ensure the unit is set to fire on propane. Check the rating label for the type of fuel.

  • Page 41: Setting And Verifying The Combustion Setting

    Do not fire (operate) the water heater until all connections have been completed and the heat exchanger is filled with water. Doing so will damage the water heater and void the warranty. F. Setting and Verifying the Combustion Setting 1. After the water heater has fired, flip DIP switch three (3) in Group 1 to the ON position (low fire).

  • Page 42: Part 9 - Controls

    Part 9 - Controls A. Start-Up C. How to Set the Water Heater for High Output Operation Once the unit has been properly installed, check the gas and water Press to turn OFF the water heater. If the water heater has connections for leaks.

  • Page 43: Water Temperature Adjustment And Scalding

    The temperature will change on the water heater display. Adjust to the desired temperature. Reposition knob to lock position. Households with small children, disabled, or elderly persons may Retighten screw. require a 120 F or lower temperature setting to prevent severe NOTE: To ensure proper operation, the mixing valve temperature personal injury or death due to scalding.

  • Page 44: Diagnostic Button Function

    F. Diagnostic Button Function The water heater control allows the user to review various diagnostic functions, including: Outlet Temperature, Fan RPM, and Error Code History. Press the button on the display to review various diagnostic functions. Press the buttons to scroll through the functions. Figure 46 - Press the “D”...

  • Page 45: Suggested Corrective Actions

    Error Code Description Cause Possible Remedies 1. Unplug the water heater. 2. Check wire connections of the gas valve, thermostat, and air pressure switches. Gas Valve, ECO Hot Water 3. Use an ohmmeter to check for continuity of the following Outlet, ECO Burner Plate, or items: The gas valve has lost power.
  • Page 46 Problem Possible Causes Possible Remedies 1. Allow time for the cold water already in the pipes to flow from the faucet. It takes a long time before hot Is the faucet some distance from the water heater? 2. Have recirculation valves and/or plumbing water flows from the faucet return line(s) installed and program the unit for recirculation.

  • Page 47: Part 11 - Installation Checklist

    DHW Outlet (Ot) Temperature Sensor (8100P-016) HX (Ht) Temperature Sensor (8100P-014) Temperature ( Resistance (Ω) 61353 48126 37979 30153 24085 19354 15645 12721 10403 8555 7075 5882 4915 Figure 47 - Flame Sight Glass 4129 3485 2956 2518 2155 1852 1599 1385 1205...
  • Page 48 Install Exhaust Vent and Intake Piping 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? Has the exhaust vent line been pitched back to the water heater at a rate of 1/4” per foot? Have the exhaust vent and intake pipes been properly installed to the water heater? Install Condensate Piping / Tubing and Components Have all condensate components included with the water heater been installed?

  • Page 49: Part 12 - Maintenance

    Part 12 - Maintenance is undamaged and in good condition. Notify a qualified service technician if any problems are found. The water heater must be inspected and serviced annually, Check the Condensate Drain System preferably at the start of the heating season, by a qualified service •...
  • Page 50 Do not open the drain valve without connecting a hose so that water To avoid water damage or scalding due to relief valve operation, a can be diverted to an area where water damage is not a problem. discharge line must be connected to the valve outlet and directed Use a flat head screwdriver to open and close the drain valve.
  • Page 51 The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1). ” •...
  • Page 52 COMBUSTION CO/CO2 Levels Check CO and CO2 levels in Exhaust. Record at high and low fire. FINAL INSPECTION Check list Verify that you have completed entire check list. WARNING: FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. Homeowner Review what you have done with the homeowner.

  • Page 53: Part 13 - Replacement Parts

    Part 13 - Replacement Parts Figure 51 - 20 Gallon Model Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Pour Form (PU) Controller Cover 8100P-034 Top Service Panel 8100P-031 T&P Relief Valve 8100P-015 Top Cover Drain Valve 8100P-005 Air Intake 8100P-032...
  • Page 54 Ignition Flame Plug Sensing Figure 52 - 20 Gallon Model Combustion System Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Hot Outlet Water Pipe 8100P-021 Exhaust Chamber T&P Relief Valve 8100P-015 Burner Assembly 8100P-004 Tempering Valve 8100P-018 Water Tank Exhaust Adaptor 8100P-039 H/E Thermistor...
  • Page 55 Figure 53 - 40 Gallon Model Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Pour Form (PU) Controller Cover 8100P-034 Top Service Panel 8100P-031 T&P Relief Valve 8100P-015 Top Cover Drain Valve 8100P-005 Air Intake 8100P-032 Main Power Cord 8100P-009 Mesh Screen 8100P-033...
  • Page 56 Ignition Flame Plug Sensing Figure 54 - 40 Gallon Model Combustion System Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER Hot Outlet Water Pipe 8100P-021 Pipe Clamp 8100P-045 T&P Relief Valve 8100P-015 Exhaust Chamber Tempering Valve 8100P-018 Burner Assembly 8100P-004 Exhaust Adaptor 8100P-039...

  • Page 57: Limited Warranty For Rgh Floor Mounted Water Heaters

    Owner. 15. Damages, malfunctions, or failures caused by operating an empty H. HTP will not accept claims from the Owner for labor costs incurred by any person as a result of the repair, replacement, removal, or reinstallation of a or partially empty water heater (“dry firing”), or failures caused by...
  • Page 58 During the claims process a product that must be replaced will be Corrosivity Non-corrosive given a designation of either a) field scrap, or b) return to HTP. If the Fluoride 2.0 mg/l product must be returned to HTP, the returned product must arrive Foaming Agents 0.5 mg/l...

  • Page 59: Notes

    Notes LP-605 Rev. 000 Rel. 009 Date 8.16.18...

  • Page 60: Customer Installation Record Form

    Customer Installation Record Form The following form should be completed by the qualfied installer / service technician 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 rgh20-76fCrossover rgh20-100fCrossover rgh20-75fCrossover rgh40-76fCrossover rgh40-100fCrossover rgh-75f ... Show all

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