HTP RT-180 Installation & Maintenance Instructions Manual
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HTP RT-180 Installation & Maintenance Instructions Manual

Hydra smart residential
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NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe
Drinking Water Act, Section 1417.
IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING
PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS
AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER WATER HEATER.
Do not try to light any water heater.
Do not touch any electrical switch.
Do not use any phone in your building.
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department. Installation and service must be provided by a qualified installer,
service agency, or the gas supplier.
120 Braley Rd. P.O. Box 429
WHAT TO DO IF YOU SMELL GAS
East Freetown, MA 02717-0429
Hydra Smart
Residential
INSTALLATION
MAINTENANCE
*A suffix of "LP" denotes propane gas
*A suffix of "N" denotes natural gas
START-UP
PARTS
Models*
RT-180 / RT-199
www.htproducts.com
LP-505 REV. 4.29.14

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Summary of Contents for HTP RT-180

  • Page 1 *A suffix of “LP” denotes propane gas *A suffix of “N” denotes natural gas NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature. NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

  • Page 2: Safety Instructions

    The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 3: For The Installer

    In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician.

  • Page 4: Table Of Contents

    INSTALLATIONS MUST COMPLY WITH: Local, state, provincial, and national codes, laws, regulations and ordinances. The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131. In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3.
  • Page 5 PART 12 – TROUBLESHOOTING ............................43 PART 13 – MAINTENANCE PROCEDURES ..........................44 REPLACEMENT PARTS ................................49 Limited Warranty for RT-180 / RT-199 Water Heaters ......................... 51 MAINTENANCE REPORT ................................53 MAINTENANCE NOTES ................................. 57 HTP CUSTOMER INSTALLATION RECORD FORM ........................58...

  • Page 6: Part 1 - Items Shipped With The Water Heater

    PART 1 – ITEMS SHIPPED WITH THE WATER HEATER ITEM DESCRIPTION QUANTITY Residential Tankless Water Heater RT-199 / RT-180 Quick Reference Guide, User, 1 Each and Installation Manuals Condensate Hose Anchors and Wall Mounting Bracket Spare Parts Kit (Gaskets and O-Rings) Vent Screens (3”)

  • Page 7: Part 2 - Safety Regulations

    HTP, Inc. cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of the professional service technician.

  • Page 8: Improper Combustion

    Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit provided with the water heater. Contact HTP, Inc. for additional overheat controls.

  • Page 9: Freeze Protection

    G. FREEZE PROTECTION Consider water heater piping and installation when determining water heater location. NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty. PART 3 – TECHNICAL SPECIFICATIONS...
  • Page 10 Figure 1 – RT-180 / RT-199 Specifications and Dimensions DESCRIPTION DIAMETER 3” Exhaust Outlet Pipe Air Intake 3” ¾” Gas Inlet ¾” DHW Outlet Adapter ¾” DHW Inlet Adapter ½” Condensate Adapter DHW Inlet Filter Table 4 – RT-199 Adapter Specifications...

  • Page 11: Part 4 - Prepare Water Heater Location

    Condensate Trap Hose Burner Case Burner Overheat Switch Table 5 – RT-180 / RT-199 Component List PART 4 – PREPARE WATER HEATER LOCATION Carefully consider installation when determining water heater location. Please read the entire manual before attempting installation. Failure to properly take factors such as water heater venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

  • Page 12: Before Locating The Water Heater

    The water heater should be located near a floor drain, or installed in proximity to an adequately drained drain pan. HTP WILL NOT be held liable for leakage damages. To conserve water and energy, insulate all water piping, especially the hot and recirculation water lines.

  • Page 13: Leveling

    Do not use this water heater for space heating applications. Circulators suitable for DHW applications must be used. 6. Clean and flush system when reinstalling a water heater. 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 water heater model and serial number.

  • Page 14: Prevent Combustion Air Contamination

    Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall. Venting methods are detailed in the Venting Section. Do not attempt installation using any other means. Be sure to locate the water heater so exhaust vent and intake piping can be routed through the building and properly terminated.

  • Page 15: Uncrating The Water Heater

    5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette. 6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use.

  • Page 16: Part 5 - Venting

    Figure 4 – Wall Mounting the Water Heater PART 5 – VENTING Vent this water heater in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death. DO NOT mix vent systems or materials unless specifically told to do so in this manual. DO NOT thermally insulate the exhaust vent or intake pipes.
  • Page 17  For sidewall venting, the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot. It is recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces.  For roof venting, minimum horizontal distance between any adjacent exhaust vent termination is 1 foot. All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.

  • Page 18: Approved Vent Materials

    Figure 5 – Vent Termination Detail DESCRIPTION CANADA Clearance above grade, veranda, porch, deck, or balcony 1 foot 1 foot Clearance to window or door that may be opened 1 foot 3 feet Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet from the center line of the terminal Clearance to unventilated soffit...

  • Page 19: Allowed Schedule 40 Vent Lengths (Pvc, Cpvc, Pp)

    When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the water heater vent connection, and at the termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

  • Page 20: Vent Termination

    Tighten the clamps using a screwdriver. Ensure the pipe is secure before continuing installation. For 2” installations, install a reducing coupling in a vertical section of pipe. See Figure 7. Figure 6 – Correct Installation into the Water heater Collar Figure 7 –...

  • Page 21: Vertical Vent Termination

    2. Vertical Vent Termination Figure 9 – Direct Vent, Vertical Termination 3. Direct Vent, Optional Horizontal and Vertical Concentric Vent Figure 10 – Direct Vent, Concentric Vent Termination (With Optional Kit) LP-505 REV. 4.29.14...

  • Page 22: Screen Installation

    4. Screen Installation After connecting the intake air and exhaust vent pipes, it is required to install the included screens into the exhaust vent and intake pipe terminations to prevent damages to the unit due to blockages. See Figure 11 for installation detail. Figure 11 –...

  • Page 23: Gas Pipe Sizing Tables

    A. GAS PIPE SIZING TABLES 1. Gas Pipe Sizing This information is for reference use only. Refer to gas pipe manufacturer specifications for actual delivery capacity. The DOE standard for Natural Gas is 1100 BTU/ft . Contact the local gas supplier for actual BTU/ft rating.
  • Page 24 2. The supply line must be sized for the maximum output of the water heater being installed. If there are additional gas appliances from the main supply line, measure the size of the supply line according to the COMBINED total maximum BTUH draw for the appliances as if they were operating at the same time.

  • Page 25: Adjusting Gas Pressure At The Water Heater

    Figure 15 – LP Gas Piping Installation – NOTE: Capacity to be Not Less than Total Capacity of Connected Appliances C. ADJUSTING GAS PRESSURE AT THE WATER HEATER NOTE: Refer Figure 16 when adjusting gas pressure. Loosen the bolts before checking the gas inlet pressure.

  • Page 26: Piping The Water Heater

    To control thermal expansion, a thermal expansion tank should be installed in systems with an installed backflow preventer. DO NOT use a closed type expansion tank. Follow expansion tank manufacturer’s specifications to properly size an expansion tank to the installation. Failure to properly accommodate thermal expansion could result in property damage, severe personal injury, or death. C.

  • Page 27: Pressure Relief Valve

    E. 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 approved 150 psi, ¾” ASME HV Valve that must be installed on the DHW outlet line (See Figure 19).

  • Page 28: Wiring Information

    A. WIRING INFORMATION 1. This water heater must be properly grounded. Ensure the electrical receptacle that the water heater will be plugged into is properly grounded. 2. Do not attach the ground wire to either the gas or water piping. Figure 20 –...
  • Page 29 SYSTEM CONTROL SETTINGS MAXIMUM FLAME DETECTING VOLTAGE 2.5V PRE-PURGE TIME (Tp) Maximum 10 seconds, minimum 1 second SAFETY TIME (IGNITING TIME) (Ts) 3.5 seconds IGNITING INTERVAL TIME <10 seconds POST-PURGE TIME (Tip) 3 minutes OVER-HEATING 1,2,3 PROTECTION DETECTION TIME <1 seconds TEMPERATURE SENSOR FAULT DETECTION TIME <2 seconds # OF IGNITION ATTEMPTS (Ntl)
  • Page 30 Figure 22 – Electrical Wiring Diagram LP-505 REV. 4.29.14...
  • Page 31 Figure 23 – Ladder Diagram LP-505 REV. 4.29.14...
  • Page 32 CONNECTOR DESCRIPTION HT SELV NO. OF LOCATION BOARD SILK UNUSED Power Supply Line UNUSED Ignitor L(HT) Ceramic Heater (Freeze Protection) 65001WS-12 HT (120V~) Gas Valve EARTH GROUND Power Supply Neutral 9-12 AC Power COM Line RS485 + RS-485 SELV (5V) SMW250-03 RS485 - Unused...
  • Page 33 CONNECTOR DESCRIPTION HT SELV NO. OF LOCATION BOARD SILK Flame Detect Sensor OP.S Operating Water Temperature Sensor DH.S DHW Temperature Sensor Inlet Water Temperature Sensor SELV (5V) LWD1140-14 BG.S Exhaust Temperature Sensor ST.S Unused SP.S Unused AGM Stepper Motor Coil / Y Phase SELV (24V) CN12 AGM Stepper Motor Coil / X Phase...

  • Page 34: Part 10 - Operating System Instructions

    PART 10 – OPERATING SYSTEM INSTRUCTIONS A. CONTROL PANEL Figure 24 – Water heater Control Panel Detail B. LCD DISPLAY DESCRIPTIONS Figure 25 – LCD Display Detail LCD also features a backlit lamp that will illuminate:  When a user action is detected (a button is pressed) ...

  • Page 35: Changing The Dhw Set-Point

    The Control System can operate through user and service modes that have specific LCD outputs and dedicated controls, including:  Changing the Set-Point Temperature  Error Mode  Status Display Mode  Installer Mode NOTE: The Control System will not allow changes if Lock Mode is activated unless the B button is pressed for more than 5 seconds. D.

  • Page 36: Installer Mode

    Figure 28 – Status Mode Screens Parameter Detail Description A: Li or A: GA Flow 1 Current Flow Value (Li: Liters/min, GA: Gallons/min) b: Fr Fan rpm Current Fan RPM Value Lock Mode is In Use (ON) or Unused (OFF) C: Lc Lock Mode Allows user to lock out any temperature change.

  • Page 37: Error Mode

    Figure 29 – Installer Mode Screens Index Default Parameter Description Most Recent History Error Codes (H0 – H9) 1: EH E0:00 History 2: cE Clear Error History Clears Error History Restores System to Default Settings (Burner operation time, Ignition cycles, and Supply 3: In System Reset power time will not be reset)
  • Page 38 Error Code Error Code Description Possible Remedies Press the Power button to clear the Error Code. If Error happens again: 1. Monitor the gas pressure to the water heater while in operation. Ensure pressure is between 3.5 and 14” WC. Flame has Extinguished 8 2.
  • Page 39 Error Code Error Code Description Possible Remedies IMPORTANT: If you smell gas, STOP! Follow the instructions on page 2, this manual, and call a qualified service technician or the fuel gas utility. Gas Leakage is Detected Press the Power button to clear the Error Code. in 10 Minutes, or three If Error happens again: Er:40...

  • Page 40: Error Tree Analysis

    Error Code Error Code Description Possible Remedies This Error Code will go away when the condition is remedied. If Error happens again: 1. Check if dip switch High Fire setting is ON. Switches 6 and 7 should be OFF for normal operation. Exhaust NTC detects Vent 2.

  • Page 41: Gas Detection

    2. GAS DETECTION Figure 32 – Gas Detection Error Analysis Tree 3. AIR PRESSURE SWITCH Figure 33 – Air Pressure Switch Analysis Tree 4. Inlet / DHW / Operating Temperature SENSORS Figure 34 – Inlet / DHW / Operating Temperature Sensors Error Analysis Tree LP-505 REV.

  • Page 42: Part 11 - Final Installation Checklist

    PART 11 – FINAL INSTALLATION CHECKLIST Is there enough space to ensure proper installation? Does installation location allow for proper service clearances? BEFORE Are water and gas lines properly sized and set at proper pressures for the installation? INSTALLING Is water heater location as near the exhaust vent / intake pipe terminations as possible? Have combustible materials been cleared from the installation location? Is there a drain close to the water heater? Does water heater loop piping meet the minimum sizing requirements listed?

  • Page 43: Part 12 - Troubleshooting

    Figure 35 – Flame Sight Glass PART 12 – TROUBLESHOOTING TROUBLESHOOTING CHART 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 2.

  • Page 44: Part 13 - Maintenance Procedures

    PROBLEM POSSIBLE CAUSES POSSIBLE REMEDIES White “smoke” can be seen coming out Depending on the outside temperature, water vapor This is normal operation – no action is required. of the exterior can be produced as the exhaust is vented. exhaust gas vent. Table 24 –...
  • Page 45 Combustible/Flammable Materials Do not store combustible materials, gasoline, or other flammable vapors or liquids near the water heater. If found, remove these materials immediately. Air Contaminates If allowed to contaminate combustion air, products containing chlorine or fluorine will produce acidic condensate that will cause significant damage to the water heater.
  • Page 46 Figure 36 – Cleaning the Air Intake Filter 7. Dry the filter completely. Then reinsert the filter into the plastic assembly. 8. Replace the front cover of the water heater cabinet. Reconnect power supply to the water heater. 9. Press the Power button on the control panel to turn on the water heater. Check Primary and Gas Piping ...
  • Page 47  If relief valve seats properly, restore power to the water heater. Observe operation for five minutes and ensure it operates properly. Check the Burner Clean the exterior of the burner. Cleaning the Cold Water Inlet Filter (Draining the Water Heater) 1.
  • Page 48 5. Open service valves (V3 and V4) on the hot water outlet and cold water inlet lines. 6. Turn on the circulation pump. Operate the pump and allow the cleaning solution to circulate through the water heater for at least 1 hour at a rate of 4 gallons per minute.

  • Page 49: Replacement Parts

    REPLACEMENT PARTS Figure 39 – Cabinet Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER EXHAUST ASSY 7850P-021 AIR PRESSURE SWITCH 7850P-047 CASE 7850P-044 DISPLAY BRACKET 7850P-065 DOOR ASSY 7850P-025 DISPLAY 7850P-057 FRONT COVER 7850P-062 CONTROL 7850P-058 DISPLAY PANEL BRACKET 7850P-024 CONTROL BRACKET 7850P-066...
  • Page 50 Figure 40 – Heat Exchanger Replacement Parts NUMBER DESCRIPTION PART NUMBER NUMBER DESCRIPTION PART NUMBER HEAT EXCHANGER ASSY 7850P-032 35-6 METAL FIBER 7850P-075 31-1 EXHAUST PIPE ASSY (UP) 7850P-033 FLAME DETECTOR SENSOR 7850P-031 31-2 EXHAUST TEMPERATURE SENSOR 7850P-070 MIXING VALVE 7850P-054 7850P-071 WATER TEMPERATURE...

  • Page 51: Limited Warranty For Rt-180 / Rt-199 Water Heaters

    B. If HTP is unable to repair or replace the water heater or part(s) so as to conform to this warranty after a reasonable number of attempts, HTP will then provide, at its option, a replacement water heater.
  • Page 52 NO OTHER WARRANTIES This HTP Warranty gives you specific legal rights, and you may also have other rights that vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you.

  • Page 53: Maintenance Report

    MAINTENANCE REPORT In unusually dirty or dusty conditions, care must be taken to keep water heater cabinet door in place at all times. Failure to do so VOIDS WARRANTY! Allowing the water heater to operate with a dirty combustion chamber will hurt operation. Failure to clean the heat exchanger as needed by the installation location could result in water heater failure, property damage, personal injury, or death.
  • Page 54 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. TECH SIGN OFF Table 28 - *Continue annual maintenance beyond the 4 year as required.
  • Page 55 LP-505 REV. 4.29.14...
  • Page 56 LP-505 REV. 4.29.14...

  • Page 57: Maintenance Notes

    MAINTENANCE NOTES LP-505 REV. 4.29.14...

  • Page 58: Htp Customer Installation Record Form

    HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.

This manual is also suitable for:

Rt-199

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