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HTP Hydra Smart RT-199 User Manual Download Page 5

lp-505 Rev. 000 Rel. 015 Date 1.7.20

5

Part 1 - General Safety Information

This water heater is approved for indoor installations only and is not 

intended for use as a pool heater. Clearance to combustible materials: 

0” top, bottom, sides, and back. Heater must have room for service: 

24” front, 3” left and right sides, 9” top, 12” bottom, and 0” back are 

minimum recommended service clearances. (A combustible door 

or removable panel is acceptable front clearance. A 3” minimum 

clearance must be provided from the appliance front cover to the 

removable panel or combustible door.) This water heater has been 

approved for closet installation and installation on combustible 

flooring. Do not install directly on carpeting. Install the water heater 

in a location where temperature and pressure relief valve discharge 

or a leak will not result in damage to the surrounding area. If such a 

location is not available, install an auxiliary catch pan. The appliance 

is rated Category IV (pressurized vent, likely to form condensate in 

the vent) and requires a special vent system designed for pressurized 

venting. Use only Category IV vent systems.

Installer - 

Read all instructions in this manual before installing. 

Perform steps in the given order.

User -

 This manual is for use only by a qualified installer / service 

technician. Have this water heater serviced / inspected annually 

by a qualified installer / service technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE 

CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE 

PERSONAL INJURY, OR DEATH.
NOTE: 

Obey all local codes. Obtain all applicable permits before 

installing the water heater.

NOTE: 

Install all system components and piping in such a manner 

that does not reduce the performance of any fire rated assembly.

A. Operation and Installation Warnings

To avoid serious injury or death, read, understand, and follow all of 

the precautions listed here.

Vapors from flammable liquids will explode and can cause a 

fire, resulting in personal injury or death. The water heater has a 

burner that can come on at any time and ignite vapors. DO NOT 

use or store flammable liquids around the water heater.
Improper venting can cause a build-up of carbon monoxide. 

Breathing carbon monoxide can result in brain damage or death. 

DO NOT operate the water heater unless it is properly vented to 

the outside and has an adequate fresh air supply for safe operation. 

Inspect the exterior exhaust gas outlet port and fresh air inlet port 

on a regular basis to ensure they are functioning properly.
A concentration of carbon monoxide as small as .04% (400 parts 

per million) in the air can be fatal. When making high fire or low 

fire adjustments, CO levels must be monitored using a flue gas 

analyzer such that a CO level of no more than 150 ppm is exceeded 

at any time during operation.
Adjusting the “low fire offset” or the “main flow restrictor” in small 

increments can result in a significant increase in CO concentration. 

To avoid serious injury or death, DO NOT make any adjustments to 

the gas valve without monitoring the exhaust gases with a fully 

functional and calibrated flue gas analyzer.

DO NOT allow children to operate this unit. DO NOT use this unit if 

it does not appear to be operating correctly. A qualified technician 

should service and inspect the water heater annually.

This water heater must be installed by a licensed plumber, licensed 

gas fitter, and/or qualified installer / service technician. Improper 

installation and/or operation can cause a potentially hazardous 

situation, which, if not avoided, could result in serious injury or 

death, and will void the warranty.
The manufacturer 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 

qualified installer / service technician.
Proper care of the water heater is the user’s responsibility. Ensure the 

user carefully reads and understands the User’s Information Manual 

before operating and maintaining the water heater.
Make sure the user knows the location of the gas shut-off valve 

and how to operate it. Immediately close the gas shut-off valve if 

the water heater is subjected to fire, overheating, flood, physical 

damage, or any other damaging condition that might affect the 

operation of the unit. Have the water heater checked by a qualified 

technician before resuming operation.
Do not power up the unit unless the gas and water supply valves 

are fully opened. Make sure the fresh air intake port and exhaust gas 

port are open and functional.
No one but a qualified installer / service technician should attempt 

to install, service, or repair this water heater. There are no serviceable 

parts which can be changed by the user / owner. User / Owner: 

Contact the original qualified installer / service technician if the 

water heater needs repair or maintenance. If the original technician 

is unavailable, ask your gas supplier for a list of qualified service 

providers.
Keep the area around the water heater clean and free of all materials 

that can burn. DO NOT store or place gasoline, oils, spray paint, or 

other flammable products near the water heater.
DO NOT use spray paint, hair spray, or any other flammable spray 

near the water heater or near the exterior fresh air intake port. DO 

NOT place any items in or around the exterior exhaust gas outlet 

port and/or fresh air inlet port that could restrict or block the flow in 

or out of the vent system.
DO NOT store or place newspapers, laundry, or other combustible 

items near the water heater or the exterior exhaust gas outlet and/

or fresh air inlet port.
After installation, all water heater safety devices should be tested.

This water heater is certified for indoor installations only. The water 

heater consists of gas ignition system components which must be 

protected from water (dripping, spraying, etc.) during operation and 

service. Carefully consider installation location and the placement 

of critical components (circulators, condensate neutralizers, etc.) 

before installing the water heater.
The water heater temperature is factory set to 125

o

F (51.7

o

C). 

To avoid scalding, always check the temperature of the hot water 

before bathing, showering, washing, etc. DO NOT adjust the water 

temperature while the water heater is being used by other persons.

The owner should inspect the system monthly for damage, water 

stains, signs of rust, corrosion, and exhaust vent and air intake 

blockage. If inspection of the unit shows signs of damage, the water 

heater should be shut off until the problem is repaired by a qualified 

technician.

Summary of Contents for Hydra Smart RT-199

Page 1: ... held liable for typographical errors in literature NOTETO CONSUMER PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE 272 Duchaine Blvd New Bedford MA 02745 www htproducts com lp 505 Rev 000 Rel 015 Date 1 7 20 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 Improper installation adju...

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 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 Do not try to light any appliance Do not touch any electrical switch ...

Page 3: ...cer or departmental official may be the AHJ NOTE The manufacturer reserves the right to modify product technical specifications and components without prior notice For the Installer Thiswaterheatermustbeinstalledbyqualifiedandlicensedpersonnel The installer should be guided by the instructions furnished with the water heater and by local codes and utility company requirements In the absence of loc...

Page 4: ...E Setting and Verifying the Combustion Setting 47 Part 9 Controls 48 A Control and Display Overviews 48 B Start Up Sequence 48 C Changing the DHW Set Point 49 D Changing the Temperature Indicator 49 E Status Display 50 F Installer Mode 51 G Setting Up a Cascaded System 52 Part 10 Troubleshooting 53 A Error Code 53 B Error Tree Analysis 56 1 Flame Detection 56 2 Air Pressure Switch Detection 56 3 I...

Page 5: ...the water heater annually This water heater must be installed by a licensed plumber licensed gas fitter and or qualified installer service technician Improper installation and or operation can cause a potentially hazardous situation which if not avoided could result in serious injury or death and will void the warranty The manufacturer cannot anticipate every circumstance that might involve a pote...

Page 6: ...eating or gas supply fail to shut off turn off the manual gas control valve to the water heater This water heater has been designed to heat potable water ONLY Using this water heater to heat non potable fluid WILL VOID product warranty and could result in property damage personal injury or death D When Servicing the Water Heating System To avoid electric shock disconnect electrical supply before p...

Page 7: ...stat on this heater to obtain the increased water temperature required by these appliances you may create the potential for scald injury To protect against injury install a mixing valve in the water system This valve will reduce point of use discharge temperatures by mixing cold and hot water in branch supply lines Such valves are available from your local plumbing supplier Table 3 details the rel...

Page 8: ...3 Mesh 7855P 085 2 screens Table 5 Optional Equipment Other Optional Equipment Below is a list of other optional equipment available from HTP These additional options may be purchased through your HTP distributor 2 PVC Concentric Vent Kit Part KGAVT0501CVT 3 PVC Concentric Vent Kit Part KGAVT0601CVT 2 Stainless Steel Outside Termination Vent Kit Part V500 3 Stainless Steel Outside Termination Vent...

Page 9: ...recautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions Failure to take precautions could result in property damage severe personal injury or death The service life of the water heater s exposed metallic surfaces such as the casing as well as internal surfaces such as the heat exchanger are directly influenced by proximity to damp and salty mari...

Page 10: ... in the space with the water heater For power venting installations using room air for combustion refer to the venting section this manual for descriptions of confined and unconfined spaces Do not install the water heater in an attic Failure to comply with these warnings could result in substantial property damage severe personal injury or death E Exhaust Vent and Intake Pipe The heater is rated C...

Page 11: ... less than 100 square inches 645cm2 If the confined space is within a building of tight construction air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual When drawing combustion air from the outside into the mechanical room care must be taken to provide adequate freeze protection Failure to provide an adequate supply of fresh combustion air can ca...

Page 12: ...s and doors between the space in which the water heater remains connected to the common venting system and other spaces in the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum speed Do not operate a summer exhaust fan Close all fireplace dampers 4 Place in operation the applia...

Page 13: ...6oF 20 80oC Power Supply and Communication CN4 14V DC Product Approvals and Requirements EMC 89 336 EEC LVD 73 23 EEC Ignition System Direct Electronic Ignition Automatic Flame Sensing Burner System Single Orifice Premixed Fuel Modulation Metal Fiber Burner Gas Valve System Air Ratio Valve Minimum Flow Rate 0 5 GPM Internal Pipe Material Stainless Steel Dimensions W 17 3 H 27 6 D 12 6 W 17 3 H 27 ...

Page 14: ...and reliability Control The integrated control system monitors the system and responds to internal and external signals to regulate fan speed and control output This allows the water heater to deliver only the amount of hot water required and nothing more The control can regulate the output of multiple water heaters through its cascade system function by establishing one water heater as the master...

Page 15: ...s provided with many safety features to ensure reliable and safe operation Each safety is connected to the water heater control The water heater will alert the user if an unsafe condition occurs and needs to be addressed The following are provided safeties Flue Pressure Switch monitors flue pressure Burner High Limit monitors burner plate temperature High Limit Water Switch monitors water heater w...

Page 16: ...e installed on any suitable internal wall suitable sound proofing may be required when installing onto a stud partition wall The water heater must be installed on a wall that can bear its weight more than 88 lbs when fully plumbed and full of water Installing the water heater on a wall which cannot support its weight could result in property damage personal injury or death This water heater is too...

Page 17: ...ormer 16 Gas Inlet Pipe 1 28 Cold Water Inlet Adapter 5 Igniter 17 Flame Sight Glass 29 Cold Water Inlet Filter 6 Flame Detection Sensor 18 Burner Case 30 Control Panel 7 Primary Heat Exchanger Assembly 19 Exhaust Duct 31 Operating Temperature Sensor 8 Hot Water Outlet 20 Gas Valve 32 High Limit Overheat Switch 9 Mixing Valve 21 Gas Inlet Pipe 2 33 Ceramic Heater 10 Air Pressure Switch 22 BLDC Fan...

Page 18: ...onal external controls The domestic water connections must be installed in accordance with all local and national plumbing codes or any applicable standard which prevails The inlet cold and outlet hot ports are 3 4 on all models Pipe material must be suitable to meet local codes and industry standards The pipe must be cleaned and without blemish before any connections are made B Backflow Preventer...

Page 19: ...INIMUM pipe size for all water heater loop piping This is to avoid the possibility of inadequate flow through the water heater Using less than the required minimum pipe size and piping could result in system problems property damage and premature water heater failure Such problems ARE NOT covered by product warranty E Applications Figure 7 Piping Symbol Legend DO NOT use this water heater for high...

Page 20: ...uum 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 system if ANY plumbing work is to be done Running the water heater without water will result in dry firing 8 When using unit with storage tank the setpoint of the water heater needs to be at least 20oF higher than th...

Page 21: ...ant to demonstrate system piping only 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 recommended to help prevent scalding 7 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done Running the ...

Page 22: ... 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 recommended to help prevent scalding 7 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done Running the water heater without water will result in dry firing 8 When using unit wit...

Page 23: ...9 3 1 2 11 57 3 72 97 4 42 125 4 17 12 62 4 05 106 4 82 136 4 55 13 67 4 39 115 3 83 3 1 2 148 4 93 14 72 4 73 124 4 13 159 4 06 4 15 78 3 52 3 133 4 42 171 4 35 16 83 3 75 142 4 72 182 4 64 17 88 3 99 150 3 84 4 193 4 94 18 93 4 22 159 4 06 205 5 23 Table 13 Recommended Water Pipe Size G Pressure Relief Valve An external pressure relief valve must be installed on this water heater When installing...

Page 24: ...ATURE AND OR PRESSURE BUILD UP WHICHCANRESULTINPROPERTYDAMAGE SERIOUSPERSONAL INJURY OR DEATH The water heater must be full of water and the system fully purged BEFORE powering the water heater When filling the water heater open a hot water tap to release air in the water heater and piping All air has been purged from the system when water runs freely from the faucets Applying power to the water h...

Page 25: ...to the flue adapter Failure to do so could result in property damage severe personal injury or death The exhaust and intake components installed with this appliance must be used for near appliance piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed components Doing so WILL VOID appliance warranty PVC CPVC pipe and fittings of the same diameter are consi...

Page 26: ...u may use AL29 4C stainless steel venting to comply with Canadian requirements 2 The first three 3 feet of vent pipe from the water heater flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings You must not use B vent in an exhaust application B vent is for intake applicat...

Page 27: ...t may be opened Direct Vent 1 foot 3 feet 91 cm Power Vent 4 ft below or to side of opening 1 ft above opening C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner H Clea...

Page 28: ...iance vent Figure 19 Correct Installation into the Appliance Collar Figure 20 Transitioning from 3 to 2 Vent Pipe G Exhaust Vent and Intake Pipe Installation All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space Failure to do so could result in property damage serious injury or death 1 UseonlysolidPVC CPVC orstainlesssteelp...

Page 29: ...on location may by ordinance designate how snow levels are calculated in that location or b Intheabsenceofspecificordinances snowlevelsshallbecalculated from the average monthly maximum depth of snow accumulation as indicated by the National Weather Service s 10 year statistics for the installation location geographical area In addition Total length of vent piping shall not exceed the limits speci...

Page 30: ...t GREATER TYP MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST OR GRADE WHICHEVER IS VENT KIT EXHAUST ANTICIPATED SNOW LEVEL EXTERIOR WALL 06 23 15 LP 505 A Sidewall Venting with Kit 05 26 15 LP 505 C INTAKE IMPORTANT EXHAUST INTAKE LEG MUST BE FACING UP CONCENTRIC VENT KIT MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP 1 MIN Sidewall Venting with C...

Page 31: ...t Screen installation ONLY 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 B Typical installations require 12 minimum separation between bottom of exhaust outlet and top of air intake C Maintain 12 minimum clearance above highest anticipated snow level or grade whicheve...

Page 32: ... Concentric Vent Kit installation manual LP 166 for further information on venting with the optional concentric vent kits Concentric venting through an existing system must run vertically through the roof See Table 19 for proper minimum vent sizing Use only the approved venting materials specified in Table 14 for piping the system All instructions listed in this Venting section apply See Figures 2...

Page 33: ...from the outdoors into the water heater intake connection Unconfined space is space with volume greater than 50 cubic feet per 1 000 Btu hour 4 8 cubic meters per kW of the total input rating of all fuel burning appliances installed in that space Rooms connected directly to this space through openings not furnished with doors are considered part of the space Confined space is space with volume les...

Page 34: ... and vertical and then adding the equivalent lengths of each fitting used in the system A vent system s length must not exceed the maximum length outlined in the chart below Maximum Vent Length in Ft for Direct Vent 2 Pipe Number of Units Common Vented Load BTU Hr Pipe Size 3 4 6 8 10 12 1 199 000 100 100 N A N A N A N A 2 398 000 50 83 3 597 000 N A 58 133 4 796 000 N A 101 5 995 000 75 6 1 194 0...

Page 35: ...damage severe personal injury or death 3 Two 2 Pipe Common Direct Vent Systems For each floor containing bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedrooms as well as in the room that houses the heater Detectors and alarms shall comply with NFPA 720 latest edition Failure to comply with these requirements could result in product damage severe per...

Page 36: ...ons from blockage by installing at least 12 above the maximum anticipated snowfall accumulation Figure 29 Common Vented Units Unbalanced Venting Figure 30 Common Vented Units Roof Venting All vent pipes must be glued properly supported and the exhaust pitched a minimum of 1 4 per foot back to the heater to allow drainage of condensate When placing support brackets on vent piping the first bracket ...

Page 37: ...tions use CSA or ULC certified PVC or CPVC pipe fittings and cement 4 A frozen condensate line could result in a blocked vent condition It is very important to protect the condensate line from freezing temperatures or any type of blockage In installations that may encounter sustained freezing conditions the use of heat tape is recommended to avoid freezing of the condensate line It is also recomme...

Page 38: ...is properly grounded Do not remove the grounding prong from the water heater plug 2 Do not attach the ground wire to either the gas or water piping If the water heater display does not turn on first check the plug Then check the electrical panel circuit breaker and reset if necessary Ifthecircuitbreakertripsagain donotreset Disconnect the plug and have a qualified technician diagnose the problem B...

Page 39: ...36 Installed Resistor NOTE The maximum distance between units is two and a half feet See Figure 37 This maximum distance can be increased by connecting additional wire harnesses together However the number of units that can be cascaded will be reduced by one for every additional harness used 3 Add a resistor to the cascade communication cable of the last unit See Figure 36 NOTE Every cable comes w...

Page 40: ...lp 505 Rev 000 Rel 015 Date 1 7 20 40 Figure 38 150 Model Electrical Wiring Diagram ...

Page 41: ...lp 505 Rev 000 Rel 015 Date 1 7 20 41 Figure 39 150 Model Ladder Diagram ...

Page 42: ...lp 505 Rev 000 Rel 015 Date 1 7 20 42 Figure 40 199 Model Electrical Wiring Diagram ...

Page 43: ...lp 505 Rev 000 Rel 015 Date 1 7 20 43 Figure 41 199 Model Ladder Diagram ...

Page 44: ... RS 485 CN4 LWD1140 06 1 FAN UNUSED 2 GND SELV 30V 3 VDD SELV 14V 4 Fan power start coil SELV 30V 5 Fan power end coil 6 Fan speed feedback signal SELV 14V CN8 LWD250 04 1 MCU ISP GND SELV 5V DC 2 ISP Reset Port 3 ISP TOOL0 Data Port 4 VCC CN11 1 HWL UNUSED 8 2 LWL Water Leak Sensor 150 Model Only 10 3 HD UNUSED 11 4 TH Connect to the Display Control Thermostat SELV 14V DC 12 5 Condensate APS Cond...

Page 45: ...r Coil X Phase 4 5 GND 6 AGM Stepper Motor Position SELV 14V 7 VDD SELV 24V CN10 SMW250 08 1 DHM Mixing Valve DHM Stepper Motor Coil Y Phase SELV 14V 2 3 DHM Stepper Motor Coil X Phase 4 5 GND 6 DHM Stepper Motor Position 7 UNUSED 8 VDD CN14 SMW250 09 1 IWM Flow Control Valve GND 2 IWM Stepper Motor Position 3 VDD 4 IWM Stepper Motor Coil X Phase 5 IWM Stepper Motor Coil Y Phase 6 VDD 7 IWM Steppe...

Page 46: ...ble 25 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 regulator Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure B Gas Connection Requirements 1 The gas connection fitting on the water heater is NPT NOTE Th...

Page 47: ...4mm Allen key to adjust the offset screw in a clockwise positive or counterclockwise negative direction approximately 1 4 turn See Figures 44 and 45 Check your It is required to use a calibrated combustion analyzer to verify final adjustment according to the combustion chart Table 27 Failure to do so could result in serious personal injury or death combustion values Repeat this procedure until the...

Page 48: ... 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 28 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 48 Initial Display Sc...

Page 49: ...hen the display panel is powered ON The DHW icon and current set point will display and flash Then press and hold the button for five seconds The scald warning symbol H high temperature will display High temperature DHW Set Point range is 121 140oF 49 5 60oC Turn the dial counterclockwise to lower and clockwise to raise the DHW set point After changing the temperature press the button to save the ...

Page 50: ...er operating time Time burner has operated in 1 hour units 3 rH Burner operating time Time burner has operated in 1000 hour units 4 It Ignition attempts Number of ignition attempts 10 times the displayed unit 5 IH Ignition attempts Number of ignition attempts 10 000 times the displayed unit J AG AGM Value Correction AGM Value Correction Range 50 to 50 Default 00 Table 29 Status Display Screen Desc...

Page 51: ...OTE Use a calibrated combustion analyzer to ensure CO and CO2 are within the ranges shown in this manual Adjust the offset screw in the clockwise positive or counterclockwise negative directions approximately 1 8 turn if the measured CO2 value on LOW FIRE is out of range 10 Cn 00 Cascade Address Chooses water heater cascade address Range 01 Master 02 follower 1 17 follower 18 Default 00 NOTE The M...

Page 52: ...amage severe personal injury or death A maximum of eighteen 18 199 models may be installed in a cascaded system A maximum of four 4 150 models may be installed in a cascaded system Installing more than the maximum amount of water heaters in a cascaded system will result in system problems property damage and premature water heater failure Such problems ARE NOT covered by product warranty When inst...

Page 53: ...n 2 5DC after ignition 4 Check igniter transformer for proper connection 5 Clean the spark igniter with steel wool to remove oxides Ensure proper separation 3 4 mm 6 Replace the spark igniter if damaged 7 Assure that the flame is stable when lit 8 If the problem persists replace the main control Er 16 Operating Temperature Sensor or DHW Sensor Detects Water Temperature Greater than 199oF 93oC This...

Page 54: ...ly but RPMs are too low or too high replace the fan 4 If the problem persists replace the main control Er 42 Flue APS Closed is Normal Open is Fault Condensate Drain Trap Press the Power button to clear the Error Code 1 Check FLUE APS and main controller connections Ensure all are secure 2 Check FLUE APS resistance If resistance is zero replace the switch 3 Check FLUE APS hose Ensure it is connect...

Page 55: ... Cascade Communication Error NOTE This error will only appear in a cascaded system 1 Turn power OFF and ON at the appliance display panel 2 If error reappears ensure all cascaded appliances are powered ON 3 If error reappears check Installer Mode parameter 13 at the Master appliance Ensure the number of cas caded units chosen in this parameter matches the number of cascaded units in the system 4 I...

Page 56: ...lp 505 Rev 000 Rel 015 Date 1 7 20 56 B Error Tree Analysis 1 Flame Detection Figure 53 Flame Detection Error Analysis Tree 2 Air Pressure Switch Detection Figure 54 Air Pressure Switch Analysis Tree ...

Page 57: ... Press and hold the Power button to turn the unit ON 3 Refer to the Diagnostic and Error Codes section in this manual 4 Open the gas supply valve The water temperature is not hot enough or turns cold during use 1 Is the faucet open enough to draw at least 0 5 gallons 2 2L per minute through the water heater 2 Is an error code flashing on the display panel 3 Is the outlet water temperature set too ...

Page 58: ...heater 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 switch inside the water heater cabinet Check for 120V at the line voltage terminal block located inside the water heater cabinet Correct wiring inside the water heater cabinet using the wiring diagram in...

Page 59: ...re proper installation Does installation location allow for proper service clearances Are water and gas lines properly sized and set at proper pressures for the installation 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 Water Piping Yes No Does ...

Page 60: ...ly line pressure been measured Does the gas type match the type indicated on the water heater rating plate Has a union and shut off valve been installed Relief Valve Yes No Is the Pressure Relief 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 heater...

Page 61: ...ent and Intake Pipe Terminations Verify that the water heater exhaust vent and intake pipe terminations are clean and free of obstructions Remove any debris from the exhaust vent or intake pipe openings If removing the debris does not allow the water heater to operate correctly contact your qualified installer service technician to inspect the water heater and the vent system Check Exhaust Vent an...

Page 62: ...e control panel to turn on the water heater Check Primary and Gas Piping Remove the water heater cover and perform a gas leak inspection following Operating Instructions page 2 this manual If gas odor or leak is detected follow procedures on page 2 Call a qualified installer service technician Visually inspect for leaks around the internal water heater water connections and around the heat exchang...

Page 63: ...ument was written Other types of respirators may be needed depending on job site conditions Current NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lini...

Page 64: ...rcuit breaker is clearly labeled Exercise circuit breaker Switch and Plug Verify ON OFF switch and convenience plug are both functional CHAMBER BURNER Combustion Chamber Check burner tube and combustion chamber coils Clean according to maintenance section of manual Vacuum combustion chamber Spark Electrode Clean Set gap at 1 8 CONDENSATE Condensate Trap Clean debris from the condensate trap Fill w...

Page 65: ...t Filter Cap 7850P 016 16 Power Switch 7850P 059 4 3 Cold Water Filter 7850P 017 17 Control Panel 7850P 057 5 Bracket Igniter Air Pressure Switch 7850P 214 18 Front Cover Assembly 7850P 025 6 Hot Water Pipe Assembly 7850P 121 18 1 Control Panel Window 7850P 023 6 1 Hot Water Plug 7850P 202 19 Case Bracket 7850P 127 6 2 Hot Water Temperature Sensor 7850P 019 20 Flow Control Valve 7850P 053 7 Ignite...

Page 66: ... Head Packing 7850P 135 6 HX Water Temperature OP 7850P 081 3 5 Burner Head Gasket 7850P 136 7 Overheat Sensor 7850P 147 4 Heat Exchanger Assembly 7850P 137 8 3 4 Pipe Gasket 7855P 073 4 1 Heat Exchanger Semi Assembly 7850P 138 9 Mixing Valve 7850P 054 4 2 Condensate Bay 7850P 140 10 O Ring P15 7855P 044 4 3 Exhaust Temperature Sensor 7850P 070 11 Condensate Outlet O Ring P16 7855P 075 4 4 Seconda...

Page 67: ... Gasket 15A 7855P 072 1 2 O Ring 7850P 003 4 15A Packing Non Asbestos 7855P 221 1 3 N A N A 5 Gas Mixer Bracket 7850P 242 6 Gas Valve Bracket 7850P 158 1 4 AGM Actuator 7850P 152 7 Silencer Elbow 7850P 159 1 5 Silencer Body 7850P 155 8 Gas Pipe Upper 7850P 160 2 Gas Valve Assembly 7850P 156 9 Gas Pipe Lower 7850P 161 2 1 Gas Valve 7850P 034 10 O Ring P18 7850P 047 Table 42 150 Model Combustion Sys...

Page 68: ... Flow Control Valve 7850P 053 4 Ignition Transformer 7850P 045 17 Water Inlet Valve Assembly 7850P 018 5 Gas Inlet Nipple 7850P 043 17 1 Water Inlet Valve Body 7850P 067 6 Overheat Sensor 7850P 050 17 2 Water Inlet Sensor 7850P 015 7 DHW Supply Pipe Assembly 7850P 020 17 3 Water Inlet Filter 7850P 017 7 1 DHW Supply Pipe 7850P 063 17 4 Water Inlet Filter Cap 7850P 016 7 2 Water Outlet Sensor 7850P...

Page 69: ...40 32 2 Blower O Ring 7850P 003 46 Gas Valve Adapter Straight 7850P 077 32 3 AGM Actuator 7850P 004 47 Gas Valve Assembly w Plug 7850P 078 33 Silencer Elbow 7850P 036 47 1 Gas Valve 7850P 012 34 Silencer Body 7850P 035 47 2 Gas Valve Plug 7850P 013 35 Burner Assembly 7850P 011 48 Gas Valve Adapter 90 Degree 7850P 079 35 1 Burner Head 7850P 007 49 Gas Valve Bracket 7850P 080 35 2 Ignition Rod Brack...

Page 70: ...anufacturer s provided instructions Preventive maintenance can help avoid any unnecessary breakdown of the water heater and keep it running at optimum efficiency 4 Maintain all related system components in good operating condition 5 Use the water heater in an open system or in a closed system with a properly sized and installed thermal expansion tank 6 Use the water heater at water pressures not e...

Page 71: ...returned to HTP the returned product must arrive at HTP within thirty 30 days of the date of our request to return the product After receipt of the returned product HTP may require as many as thirty 30 additional days for product testing NOTE Any components or heaters returned to HTP for warranty analysis will become the property of HTP and will not be returned even if credit is denied If you have...

Page 72: ...lp 505 Rev 000 Rel 015 Date 1 7 20 72 Notes ...

Page 73: ...me 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 Customer Please only sign after the installer has fully reviewed the installation safety proper operation and maintenance of the system If the system has any problems please call the installer If you are...

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