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Crossover

Water Heaters

Installation

Start-Up

Maintenance

Parts

Warranty

CGH-199* Models

* “LP” Denotes Propane Gas

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.

The manufacturer 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.

272 Duchaine Blvd.

New Bedford, MA 02745

www.htproducts.com

LP-644 Rev. 8.10.17

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, 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.

Содержание CGH-199*

Страница 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 644 Rev 8 10 17 The s...

Страница 2: ...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...

Страница 3: ...The manufacturer reserves the right to modify product technical specifications and components without prior notice For the Installer Thiswaterheatermustbeinstalledbyqualifiedandlicensedpersonnel The i...

Страница 4: ...ay Overviews 45 B Start Up Sequence 46 C Changing the DHW Set Point 46 D Changing the Time 46 E Status Display 47 F Installer Mode 48 G Setting Up a Cascaded System 49 H 0 10 Volt Input 50 Part 10 Tro...

Страница 5: ...er 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 rest...

Страница 6: ...rvice life Failure of an appliance due to lime scale build up low pH or other chemical imbalance IS NOT covered by the warranty The water must be potable free of corrosive chemicals sand dirt and othe...

Страница 7: ...er Table 3 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications ApproximateTi...

Страница 8: ...103 One 1 1 1 4 FIP X 3 4 FIP 304 S S Reducing Coupling 7860P 003 One 1 1 1 4 FIP 304 SS Cap 7860P 004 One 1 3 CPVC 7855P 101 One 1 Cascade Communication Cable 7850P 093 One 1 Table 4 Included with th...

Страница 9: ...g contaminated by the products places and conditions listed in this manual Avoid continuously high levels of humidity Never close existing ventilation openings Ensure a minimum 1 clearance around hot...

Страница 10: ...ns could result in property damage Such damages ARE NOT covered by product warranty MINIMUM CLEARANCES FROM COMBUSTIBLE MATERIALS Hot water pipes at least 1 from combustible materials Exhaust vent pip...

Страница 11: ...When drawing combustion air from inside a conventionally constructed building to a confined space such space should be provided with two permanent openings one located 6 15cm below the space ceiling t...

Страница 12: ...rs 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 ven...

Страница 13: ...D 73 23 EEC Ignition 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...

Страница 14: ...mixing valve and increasing tank setpoint temperature Example If installation requires 120F from Mixing Valve set tank at 140F to increase First Hour Rating Peak Hour Demand First Hour Rating Use Ave...

Страница 15: ...water heaters through its cascade system function by establishing one water heater as the master and the other connected water heaters as followers The master water heater requires a sensor to provide...

Страница 16: ...temperature Low Water Sensor monitors water level in the heat exchanger optic flame sensor monitors flame quality Flue Sensor monitors flue temperature CondensatePressureSwitch monitorspressuretoensur...

Страница 17: ...r has an adequate water level to eliminate overheating and damge to the heat exchanger Pump Service Mode Allows manual operation of pumps to commission system and check pump operation Cascade Operatio...

Страница 18: ...returnvalveinthesystem install an additional tee here suitable for a potable hot water expansion tank In the hot outlet install a suitable adapter to match the tubing of the plumbing system A thermal...

Страница 19: ...des 6 In Massachusetts you must install a vacuum relief valve per 248 CMR 7 Mixing valve application is optional but recommended to help prevent scalding 8 Always shut off power to the water heater or...

Страница 20: ...MR 7 Mixing valve application is optional but recommended to help prevent scalding 8 Always shut off power to the water heater or isolate the heater from the system if ANY plumbing work is to be done...

Страница 21: ...all a vacuum relief valve per 248 CMR 7 Mixing valve application is optional but recommended to help prevent scalding 8 Always shut off power to the water heater or isolate the heater from the system...

Страница 22: ...lp prevent scalding 8 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 firin...

Страница 23: ...possible No other valves should be placed between the pressure relief valve and the appliance DO NOT install a relief valve with a pressure rating greater than 150 psi This is the maximum allowable re...

Страница 24: ...LVE AS DIRECTED COULD RESULT IN UNSAFETEMPERATURE AND OR PRESSURE BUILD UP WHICHCANRESULTINPROPERTYDAMAGE SERIOUSPERSONAL INJURY OR DEATH The water heater must be full of water and the system fully pu...

Страница 25: ...Intake Pipe The exhaust and intake components installed with this heater must be used for near heater piping BEFORE transitioning to the approved materials listed above DO NOT REMOVE these installed c...

Страница 26: ...insulated material for the combustion air intake pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air C Additional Requirements for Ins...

Страница 27: ...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 t...

Страница 28: ...x 2 reducing coupling not included Follow the steps below to install 3 vent pipe into the appliance vent collar See Figure 15 for additional details Figure 15 Correct Installation into the Appliance C...

Страница 29: ...s an outside exhaust termination 15 A screened inlet air tee is provided with the heater to be used as an outside intake termination 16 Maximum Snow Level Determination These installation instructions...

Страница 30: ...ST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER TYP EXTERIOR WALL EXHAUST INTAKE 1 MIN 06 23 15 LP 505 A Two Pipe Sidewall Venting with Elbow Intake and Coupling Exhaust INSERT EXHAUST SCREEN...

Страница 31: ...nstrate proper Vent 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 wa...

Страница 32: ...n 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 concentr...

Страница 33: ...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 burni...

Страница 34: ...ht pieces used both horizontal 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 be...

Страница 35: ...ommon venting multiple heaters Common Vented units must be direct vented with an exhaust vent and intake air pipe vented to the outdoors DO NOT power vent Common Vented units Doing so will result in p...

Страница 36: ...blockage by installing at least 12 above the maximum anticipated snowfall accumulation Figure 26 Common Vented Units Unbalanced Venting Figure 27 Common Vented Units Roof Venting All vent pipes must b...

Страница 37: ...ified 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 typ...

Страница 38: ...nal Manual Power Switch 1 This water heater must be properly grounded Ensure the electrical receptacle is properly grounded Do not remove the grounding prong from the water heater plug 2 Do not attach...

Страница 39: ...aster control will use the water temperature from the sensor to control operation of the Cascade System If0 10Visused the0 10Vshouldbewiredtothelowvoltageterminal strip marked for the 0 10V If the 0 1...

Страница 40: ...LP 644 Rev 8 10 17 40 Figure 38 Electrical Wiring Diagram...

Страница 41: ...LP 644 Rev 8 10 17 41 Figure 39 Ladder Diagram...

Страница 42: ...1 RS 485 RS 485 Cascade Connection SELV 5V DC 2 RS 485 3 4 RS 485 5 RS 485 CN4 LWD1140 06 1 FAN NOT USED 2 GND 3 VDD SELV 14V DC 4 Fan power start coil SELV 8 26V AC 5 Fan power end coil 6 Fan speed f...

Страница 43: ...sonal injury or death Make sure the gas line pressures are within normal limits Pressures outside normal limits can result in poor performance and hazardous operating conditions Failure to do so could...

Страница 44: ...e gas line check the manufacturer s minimum and maximum flow capacity ratings An improperly sized EFV will not allow for a full flow of gas to the water heater and will cause the water heater to malfu...

Страница 45: ...Button Less than 5 Seconds Turns Control Power Panel ON OFF Hold this Button More than 5 Seconds When Control Panel Power is ON Status Display Mode When Control Panel Power is OFF Installer Mode Pres...

Страница 46: ...ng or showering D Changing the Time Press and hold the button for five seconds when the display panel is powered ON to change the time The settings can be adjusted as follows Year Month Date Hour Minu...

Страница 47: ...our units 2 rh Burner 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...

Страница 48: ...um Storage Tank Temperature Range rE 95 140oF or Co 95 160oF 11 dd 7F Storage Tank Differential Set Point Storage Tank Differential Set Point Range 5 30o F 12 Pr 1 MIN System and Heater Pump Post Run...

Страница 49: ...ct vented with an exhaust vent and intake air pipe vented to the outdoors DO NOT power vent Common Vented units Doing so will result in property damage severe personal injury or death For each floor c...

Страница 50: ...e set point temperature of the water heater The control interprets the 0 10 volt signal as follows when the signal is between 0 and 1 5 volts the water heater will be in standby mode not firing When t...

Страница 51: ...gs are more than 2 5DC before ignition less than 2 5DC after ignition 4 Check igniter transformer for proper connection 5 Clean the spark igniter with steel wool to remove oxides Ensure proper separat...

Страница 52: ...sensor If an aquastat ensure AquA is selected in Installer Mode 39 If a sensor ensure connections are secure 2 Check DHW sensor resistance If resistance is zero or does not match that in Table 38 rep...

Страница 53: ...onsecutive Times This Error Code will go away when the condition is remedied If Error happens again 1 Ensure all valves are open to the water heater and there are no leaks 2 Ensure all air has been pu...

Страница 54: ...LP 644 Rev 8 10 17 54 B Error Tree Analysis 1 Flame Detection Figure 52 Flame Detection Error Analysis Tree 2 Air Pressure Switch Detection Figure 53 Air Pressure Switch Analysis Tree...

Страница 55: ...ve The water temperature is not hot enough or turns cold during use 1 Is an error code flashing on the display panel 2 Is the outlet water temperature set too low 1 Open the faucet to allow more water...

Страница 56: ...1 Start Up A Check Control Water Chemistry Chemical imbalance of the water supply may affect efficiency and cause severe damage to the appliance and associated equipment Water quality must be professi...

Страница 57: ...condensate neutralizer if required by local authorities can be made up of lime crystals marble or phosphate chips that will neutralize the condensate This may be done by the installer or you may purc...

Страница 58: ...r 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 t...

Страница 59: ...ssure 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...

Страница 60: ...t Vent and Intake Piping Visually inspect the exhaust vent for any signs of blockage leakage or deterioration of the piping Inspect the exhaust vent bracing Ensure bracing is undamaged and in good con...

Страница 61: ...IOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending o...

Страница 62: ...aker 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 chambe...

Страница 63: ...Tapping 7855P 386 B 12 M4 X 15 PW M S 7855P 395 B 4 M4 X 8 TH M S 7855P 387 B 13 M4 X 20 TH Self Tapping 7855P 396 B 5 M4 X 10 FH M S 7855P 388 B 14 M5 X 14 Flange Bolts M S 7855P 397 B 6 M4 X 10 TH...

Страница 64: ...ake Gaskets 7850P 210 14 Control Board 7855P 408 5 3 Exhaust Duct 7855P 333 15 Display Panel 7850P 006 5 4 Combustion Analyzer Port Plug O Ring 7855P 334 16 Manual Power Switch 7855P 014 5 5 Combustio...

Страница 65: ...Sensor Cover 7855P 357 32 Heat Exchanger Assembly 7860P 011 37 Outlet Pipe 7860P 012 32 1 Burner Body Assembly 7855P 417 37 1 Outlet Pipe Gasket 7855P 074 32 2 Burner Overheat Switch 7855P 066 38 Inle...

Страница 66: ...as Valve 7855P 034 50 Fan and Mixer Assembly 7855P 427 55 4 Gas Valve Inlet Adapter 7850P 077 50 1 Fan 7855P 025 55 5 Gas Valve Bracket 7855P 436 50 2 Fan O Ring 7855P 371 56 1 2 Gas Pipe Gasket 7855P...

Страница 67: ...ater heater in accordance with the maintenance procedure listed in the manufacturer s provided instructions Preventive maintenance can help avoid any unnecessary breakdown of the water heater and keep...

Страница 68: ...ned to HTP for warranty analysis will become the property of HTP and will not be returned even if credit is denied If all warranty conditions are satisfied HTP will provide replacement parts to the re...

Страница 69: ...LP 644 Rev 8 10 17 69 Notes...

Страница 70: ...f 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 Ple...

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