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lp-672 Rev. 000 Rel. 002 Date 10.3.18

Figure 67 - Heat Exchanger Replacement Parts

NUMBER

DESCRIPTION

PART NUMBER NUMBER

DESCRIPTION

PART NUMBER

Exhaust Temperature Sensor Clip

7855P-349

27-4

Ceramic Fiber Burner - 150 Model

7855P-635

Exhaust Temperature (Eh) Sensor

7855P-092

Ceramic Fiber Burner - 199 Model

7855P-420

Exhaust Pipe Assembly - 150 Model

7855P-630

27-5

Ignition Rod

7855P-607

Exhaust Pipe Assembly - 199 Model

7850P-273

27-6

Igniter Gasket

7855P-252

Exhaust Pipe Gasket - 150 Model

7855P-351

27-7

Burner Overheat Switch

7855P-066

Exhaust Pipe Gasket - 199 Model

7855P-418

27-8

Burner Body - 150 Model

7855P-646

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

7855P-636

Burner Body Assembly - 150 Model

7855P-632

Burner Refractory - 199 Model

7855P-612

Burner Body Assembly - 199 Model

7855P-619

Flame Sensor

7855P-031

27-1

Burner Body Top Gasket

7855P-426

HX Water (OH) Temperature Sensor

7855P-614

27-2

Burner Body - 150 Model

7855P-633

Flame Sensor Cover

7855P-031

Burner Body - 199 Model

7855P-606

Water Level Detection Sensor

7855P-029

27-3

Burner Gasket - 150 Model

7855P-634

Recirculation Water (Rt) Sensor

7855P-615

Burner Gasket - 199 Model

7855P-419

Sight Glass Assembly

7855P-401

Table 36 - Heat Exchanger Replacement Parts

Содержание Crossover 150

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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