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lp-672 Rev. 000 Rel. 002 Date 10.3.18

39

Part 9 - Controls

A. Control and Display Overviews

Figure 43 - Control Panel Detail

Figure 44 - LCD Display

B. Start-Up Sequence

After the appliance is powered ON, the LCD display shows a sequence 

of information. The icons will flash, followed by various indicators that 

describe the appliance controller and software versions. It will take the 

appliance roughly 15 seconds to cycle through the Start-Up Sequence. 

Display Items

Time for Display

Remarks

LCD Test

1 sec

All segments “ON”

0.5 sec

All segments “OFF”

Category

RGH-150 / 199

1 sec

Pdn

1 sec

0061

Software Version for 

Front Panel

1 sec

SPn

1 sec

00.xx

Software Version for 

Water Heater

1 sec

SFn

1 sec

xx.xx

Hardware Version for 

Water Heater

1 sec

Hdn

1 sec

00xx

Table 21 - Start-Up Sequence

LCD also features a backlit lamp that will illuminate:

• 

When a user action is detected (a button is pressed)

• 

The display has timed out for approximately 2 minutes

After start-up, the display appears as follows.

Figure 45 - Initial Display Screen

The Control System can operate through user and service modes 

that have specific LCD outputs and dedicated controls, including:

• 

Changing the DHW Set-Point Temperature

• 

Changing Time

• 

Status Display

• 

Installer Mode

• 

Error Mode

• 

High Elevation Mode

• 

Lock Function

NOTE: 

The Control System will not allow changes if Lock Mode is 

activated. Press and hold the 

 button is pressed for five seconds 

to unlock the control.

Summary of Contents for Crossover 150

Page 1: ...REFERENCE 272 Duchaine Blvd New Bedford MA 02745 www htproducts com lp 672 Rev 000 Rel 002 Date 10 3 18 The surfaces of these products contacted by potable consumable water contain less than 0 25 lead...

Page 2: ...ices not related to personal injury 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 stor...

Page 3: ...est version from Canadian Gas Association Laboratories 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 Also Canadian Electrical Code C 22 1 from Canadian Standards Association 5060 Spectrum Way Sui...

Page 4: ...ance 56 Part 13 Replacement Parts 59 Limited Warranty for RGH Water Heaters 65 Notes 67 Customer Installation Record Form 68 Part 1 General Safety Information This water heater is approved for outdoor...

Page 5: ...operation and service Ensure water heater cover is installed at all times when the unit is in operation Carefully consider installation location and the placement of critical components circulators co...

Page 6: ...ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger Potable water is defined as drinkable water supplied from utility or well water in compliance with...

Page 7: ...145oF Less than 3 seconds 150oF About 1 1 2 seconds 155oF About 1 second Table 3 Time and Temperature Relationship in Scalds Households with small children disabled or elderly persons may require a 1...

Page 8: ...ea Do not install heaters in locations where rain from building runoff may spill onto the heater Doing so could result in premature product failure Such failures ARE NOT covered by warranty Do not loc...

Page 9: ...to make note of the heater model and serial number To conserve water and energy insulate all water piping especially the hot and recirculation water lines Table 6 Minimum Installation and Service Clea...

Page 10: ...r death Do not attempt to vent this water heater by any means other than those described in this manual Doing so will void the warranty and may result in severe personal injury or death Failure to ven...

Page 11: ...ng Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric or Muriatic acid Furniture refinishing areas and establishments Cements...

Page 12: ...System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Ceramic Fiber Burner Gas Valve System Air Ratio Valve Minimum Flow Rate 0 5 GPM zero ac...

Page 13: ...cription Diameter A Air Intake Louvers B Exhaust Outlet C Gas Inlet Adapter 3 4 NPT D Condensate Adapter 1 2 NPT E DHW Outlet Adapter 3 4 NPT F DHW Inlet Adapter 3 4 NPT G Recirculation Return Adapter...

Page 14: ...pass it into heat transfer fluid The stainless steel construction provides protection for longer service life The heat exchanger offers greater water content providing lower system pressure and great...

Page 15: ...he connected Followers and modulates the connected units up or down to ensure the units are putting only the needed energy into the connected storage tank and also to ensure all connected units get ev...

Page 16: ...industry standards The pipe must be cleaned and without blemish before any connections are made Isolation shutoff valves should be used to ease future servicing HTP offers isolation valves Part 7850P...

Page 17: ...zed expansion tanks cause system water to be lost from the relief valve causing make up water to be added Eventual heater failure can result due to excessive make up water addition SUCH FAILURE IS NOT...

Page 18: ...y The installer is responsible for all equipment and detailing required by local codes In Massachusetts you must install a vacuum relief valve per 248 CMR 6 Mixing valve application is optional but re...

Page 19: ...t 3 All circulators should have an integral flow check 4 Drains and check valve between water heater and piping will assist in purging air from system 5 These drawings are meant to demonstrate system...

Page 20: ...install a vacuum relief valve per 248 CMR 6 Mixing valve application is optional but recommended to help prevent scalding 7 Always shut off power to the water heater or isolate the heater from the sy...

Page 21: ...om the system if ANY plumbing work is to be done Running the water heater without water will result in dry firing NOTES FOR AIR HANDLER APPLICATION 1 WHEN USING AN AIR HANDLER IT IS REQUIRED TO SET TH...

Page 22: ...the water heater Installer Parameter 0 RC to Preheat Mode or Internal Recirculation Mode PIPING NOTES 1 Minimum pipe size should match connection size Upsize pipe accordingly if greater flow is requir...

Page 23: ...e backflow preventer and the cold water inlet 3 All circulators should have an integral flow check 4 Drains and check valve between water heater and piping will assist in purging air from system 5 The...

Page 24: ...valves NOTE When using external recirculation mode with the built in pump observe the following maximum recirculation pipe lengths including fittings Copper Pipe 200 ft 60 m of equivalent pipe length...

Page 25: ...allowable relief valve setting for this water heater After installing the relief valve and filling and pressurizing the system test the operation of the valve by lifting the lever Make sure the valve...

Page 26: ...erious personal injury or death Such damages ARE NOT covered by water heater warranty H Filling the Heater Ensure any drain valves are completely closed Open the shut off valve in the cold water suppl...

Page 27: ...Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside...

Page 28: ...ation Avoid venting in areas that will affect neighboring buildings or be considered objectionable DO NOT locate the water heater in a parking area where it may be damaged by machinery DO NOT vent nea...

Page 29: ...re the unit exhaust extends level with or above the top of the fence to ensure flue gas does not get trapped and possibly recirculated into the louver system which could contaminate the combustion air...

Page 30: ...ate line from freezing temperatures or any type of blockage Ininstallationsthatmay encounter sustained freezing conditions the use of heat tape is recommended to avoid freezing of the condensate trap...

Page 31: ...ire 7 Low Fire Normal Low Fire Table 14 DIP Switch Group NOTE DO NOT CHANGE SWITCHES 1 3 THESE ARE FACTORY SETTINGS Internal Power Switch Maximum Flame Detecting Voltage 2 4V Pre Purge Time Tp 5 secon...

Page 32: ...ecirculation Wiring Detail MAX 2 5 FEET Connect the cascade communication cables to every unit See Figure 33 Add resistor to the end of the last follower NOTE The maximum distance between units is two...

Page 33: ...0 4 R R 12 6 P P W BK 8 2 Over Heat Temperature Sensor 7 BL 14 W Gas Valve Flow sensor 4 11 BL BL Inlet Temperature Sensor Ground G 1 Unused jumper 9 3 W W Internal Pump M 6 BL 13 W Return T24 Tempera...

Page 34: ...lp 672 Rev 000 Rel 002 Date 10 3 18 34 Figure 39 Ladder Diagram...

Page 35: ...1 RS 485 RS 485 SELV 5V DC 2 RS 485 3 4 RS 485 5 RS 485 CN4 LWD1140 06D 1 FAN NOT USED 2 3 VDD SELV 14V DC 4 Fan power start coil SELV 8 26V AC 5 Fan power end coil 6 Fan speed feedback signal SELV 1...

Page 36: ...P S Overheat Temperature Sensor 14 CN10 SMW250 08D 1 IWM Flow Control Valve IWM Stepper Motor Coil Y Phase SELV 14V 2 3 IWM Stepper Motor Coil X Phase 4 5 GND 6 IWM Stepper Motor Position 7 VDD 8 CN14...

Page 37: ...ble 18 Natural Gas Delivery Capacity Refer to ANSI Z223 1 National Fuel Gas Code Latest Edition 3 LP Liquid Propane Gas Pipe Sizing Contact gas supplier to size pipes tanks and 100 lockup gas pressure...

Page 38: ...rify final adjustment according to the combustion chart Table 20 Failure to do so could result in serious personal injury or death If the readings obtained are lower or higher than the combustion read...

Page 39: ...anel 1 sec SPn 1 sec 00 xx Software Version for Water Heater 1 sec SFn 1 sec xx xx Hardware Version for Water Heater 1 sec Hdn 1 sec 00xx Table 21 Start Up Sequence LCD also features a backlit lamp th...

Page 40: ...clockwise to lower and clockwise to raise the DHW set point After changing the temperature press the button to save the set point Hotter water increases the risk of scald injury Scalding may occur wit...

Page 41: ...layed unit M CC SELF Capacity of Master percentage N A ALL Total Cascade Capacity percentage N A F1 F19 Capacity of individual water heaters percentage N A The following recirculation settings can be...

Page 42: ...llower 1 20 follower 19 Default 0 NOTE 9 cP needs to be set with total number of units in the cascade parameter before setting 8 cn NOTE The Master water heater must always be addressed 0 9 CP 1 Casca...

Page 43: ...tivate when water heater is less than 50 of the capacity This can be used in combination with a combi appliance to increase the domestic hot water production of the system AH Air Handler Mode This mod...

Page 44: ...ange from 1 20 2 8 cn Next set the cascade address Master should always be addressed 0 range from 0 19 15 cn cannot be changed until 16 cP is set NOTE The cascade Master must be addressed 0 Followers...

Page 45: ...Preheat Mode Internal Recirculation Mode Turns on Internal Recirculation External Recirculation Mode Turns on External Recirculation Table 24 Internal External Recirculation Mode Overview 4 When fini...

Page 46: ...m 3 Pro3 is a recirculation setting that can be completely customized for your installation Day and Time can be programmed There is no default setting Pulse In Pulse the pump runs for a set time every...

Page 47: ...restore Or go to the Installer Menu 3 In to reset the unit to factory settings and start over Figure 57 A Setting the Time B Storing the Time Setting k Press the button to store the time setting Press...

Page 48: ...al Open is Fault Press the Power button to clear the Error Code 1 Inspect the High Limit Overheat switch Ensure proper connections 2 Check High Limit Overheat switch resistance If resistance is not ze...

Page 49: ...ck APS and main controller connections Ensure all are secure 2 Check APS hose Ensure it is connected and in good condition 3 Check intake and exhaust vent for blockages 4 Check condensate line and ter...

Page 50: ...e all valves are open to the appliance and there are no leaks 2 Check wiring connections to low water level sensor Ensure all are secure 3 Check low water level sensor resistance If resistance is zero...

Page 51: ...lp 672 Rev 000 Rel 002 Date 10 3 18 51 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...

Page 52: ...es section in this manual 4 Open the gas supply valve The water temperature is not hot enough or turns cold during use 1 If recirculation or preheat modes are OFF is the faucet open enough to draw at...

Page 53: ...eater Is there 120V at the service switch Troubleshoot and correct the power supply to the manual switch Is the ON OFF switch inside the water heater cabinet is turned on Turn ON the manual power swit...

Page 54: ...e Installing Yes No Is there enough space to ensure proper installation Does installation location allow for proper service clearances Are water and gas lines properly sized and set at proper pressure...

Page 55: ...Valve properly installed and discharge line run to open drain Is the discharge line at least 3 4 in diameter and protected from freezing Wiring Yes No Has the power and control been wired per water h...

Page 56: ...causing severe personal injury or death 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 joints are properly...

Page 57: ...ter on Flushing the Water Heater Flushing the heat exchanger is a complicated procedure that should only be performed by a qualified service technician NOTE Improper maintenance WILL VOID water heater...

Page 58: ...cuit Breakers Check to see that the circuit breaker is clearly labeled Exercise circuit breaker Switch and Plug Verify ON OFF switch and convenience plug are both functional CHAMBER BURNER Combustion...

Page 59: ...55P 453 B 7 M4 X 10 TH M S 7855P 390 B 16 M4 X 9 PH PW Self Tapping 7855P 296 B 8 M4 X 10 Flat Head 7855P 391 N 1 M4 Nut 7855P 398 B 9 M4 X 12 PH M S 7855P 392 N 2 M5 Nut 7855P 399 Table 32 Replacemen...

Page 60: ...ber 1 Cabinet Assembly See Figure 66 6 Outdoor Top Cover 7855P 663 7855P 623 2 2 Outdoor Pipe Adapter 7850P 259 7 2 Exhaust Screen 7855P 667 3 2 Outdoor Exhaust Pipe 7855P 661 7855P 625 8 M4 X 10MM Sc...

Page 61: ...7855P 332 14 Display Panel Cover Plastic Washers 7850P 267 4 2 Exhaust Intake Gaskets 7850P 210 15 Control Board 150 Model 7855P 629 4 3 Exhaust Duct 7855P 333 Control Board 199 Model 7850P 272 4 4 Ex...

Page 62: ...55P 418 27 8 Burner Body 150 Model 7855P 646 26 Heat Exchanger Assembly 150 Model 7855P 631 Burner Body 199 Model 7855P 653 Heat Exchanger Assembly 199 Model 7855P 602 27 9 Burner Refractory 150 Model...

Page 63: ...38 Fan 7855P 025 LP Gas Orifice 6 2 mm 199 Model 7855P 435 39 Mixer Assembly 150 Model N A 46 Gas Valve Assembly 7855P 381 Mixer Assembly 199 Model 46 1 Gas Valve Outlet Adapter 7855P 232 39 1 Air Ga...

Page 64: ...855P 094 52 Water Outlet Pipe 150 Model 7855P 652 65 DHW Inner Block 7855P 251 Water Outlet Pipe 199 Model 7850P 276 66 Recirculation Pipe 150 Model 7855P 644 53 1 2 Pipe Clip 7855P 246 Recirculation...

Page 65: ...installations prone to vacuum related damages 3 Maintain the water heater in accordance with the maintenance procedure listed in the manufacturer s provided instructions Preventive maintenance can hel...

Page 66: ...ims process a product that must be replaced will be given a 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...

Page 67: ...lp 672 Rev 000 Rel 002 Date 10 3 18 67 Notes...

Page 68: ...e Date of Installation Installation Address Product Name Serial Number s Comments Installer s Code Name Installers Phone Number Signed by Installer Signed by Customer Installation Notes IMPORTANT Cust...

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