HTP RT-180, RT-199 Installation & Maintenance Instructions Manual

Page 1

Hydra Smart

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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.

WHAT TO DO IF YOU SMELL GAS

 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.

Residential

INSTALLATION

START-UP

MAINTENANCE

PARTS

Models*

RT-180 / RT-199

*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.

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.

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

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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.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property

damage.

NOTICE

SAFETY INSTRUCTIONS

NOTICE is used to address practices not related to personal injury.

SAFETY INSTRUCTIONS (or equivalent) signs indicate specific safety related instructions or procedures.

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This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

NOTE: Contains additional information important to a procedure.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the water heater. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or others having statutory authority. 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 appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the water heater, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

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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. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70. NOTE: The gas manifold and controls met safe lighting and other performance criteria when the water heater underwent tests specified

in ANSI Z21.10.3 – latest edition.

TABLE OF CONTENTS

PART 1 – ITEMS SHIPPED WITH THE WATER HEATER ......................................................................................................... 6

PART 2 – SAFETY REGULATIONS ........................................................................................................................................... 7

A. OPERATION AND INSTALLATION WARNINGS ....................................................................................................................... 7

C. IMPROPER COMBUSTION ....................................................................................................................................................... 8

D. GAS ............................................................................................................................................................................................ 8

E. WHEN SERVICING THE WATER HEATER .............................................................................................................................. 8

F. WATER QUALITY....................................................................................................................................................................... 8

G. FREEZE PROTECTION ............................................................................................................................................................. 9

PART 3 – TECHNICAL SPECIFICATIONS ................................................................ ................................................................. 9

PART 4 – PREPARE WATER HEATER LOCATION ................................................................................................................ 11

A. BEFORE LOCATING THE WATER HEATER .......................................................................................................................... 12

B. LEVELING ................................................................................................................................................................................ 13

C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................ 13

D. RESIDENTIAL GARAGE INSTALLATION ............................................................................................................................... 13

E. EXHAUST VENT AND INTAKE PIPE....................................................................................................................................... 13

F. PREVENT COMBUSTION AIR CONTAMINATION .................................................................................................................. 14

G. REMOVING A WATER HEATER FROM A COMMON VENT SYSTEM .................................................................................. 14

H. UNCRATING THE WATER HEATER ....................................................................................................................................... 15

I. WALL-MOUNTING THE WATER HEATER ............................................................................................................................... 15

PART 5 – VENTING ................................................................................................................................................................... 16

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES ................................................................................................................ 16

B. APPROVED VENT MATERIALS .............................................................................................................................................. 18

C. ALLOWED SCHEDULE 40 VENT LENGTHS (PVC, CPVC, PP) ............................................................................................. 19

D. TIGHTENING WATER HEATER COLLAR TO EXHAUST VENT AND INTAKE PIPE ............................................................. 19

E. VENT TERMINATION .............................................................................................................................................................. 20

1. Horizontal Vent Terminations ................................................................................................................................................... 20

2. Vertical Vent Termination ......................................................................................................................................................... 21

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3. Direct Vent, Optional Horizontal and Vertical Concentric Vent ............................................................................................. 21

4. Screen Installation ..................................................................................................................................................................... 22

PART 6 – INSTALL THE CONDENSATE DRAIN ..................................................................................................................... 22

PART 7 – GAS PIPING .............................................................................................................................................................. 22

A. GAS PIPE SIZING TABLES ..................................................................................................................................................... 23

1. Gas Pipe Sizing .......................................................................................................................................................................... 23

2. Natural Gas Pipe Sizing ............................................................................................................................................................ 23

3. LP (Liquid Propane) Gas Pipe Sizing ....................................................................................................................................... 23

B. GAS CONNECTION REQUIREMENTS ................................................................................................................................... 23

C. ADJUSTING GAS PRESSURE AT THE WATER HEATER ..................................................................................................... 25

PART 8 – WATER PIPING ........................................................................................................................................................ 25

A. GENERAL PLUMBING CONNECTION GUIDELINES ............................................................................................................. 25

B. INSTALL A BACKFLOW PREVENTER .................................................................................................................................... 25

C. PIPING THE WATER HEATER ................................................................................................................................................ 26

D. PIPING DIAGRAM.................................................................................................................................................................... 26

E. PRESSURE RELIEF VALVE .................................................................................................................................................... 27

PART 9 – CONNECT ELECTRICAL POWER / INITIAL STARTUP ......................................................................................... 27

A. WIRING INFORMATION .......................................................................................................................................................... 28

B. DIP SWITCHES ........................................................................................................................................................................ 28

PART 10 – OPERATING SYSTEM INSTRUCTIONS ................................................................................................................ 34

A. CONTROL PANEL ................................................................................................................................................................... 34

B. LCD DISPLAY DESCRIPTIONS .............................................................................................................................................. 34

C. START-UP SEQUENCE .......................................................................................................................................................... 34

D. CHANGING THE DHW SET-POINT ........................................................................................................................................ 35

E. CHANGING THE TEMPERATURE INDICATOR ..................................................................................................................... 35

G. STATUS DISPLAY MODE ....................................................................................................................................................... 35

H. INSTALLER MODE .................................................................................................................................................................. 36

F. ERROR MODE ......................................................................................................................................................................... 37

G. ERROR TREE ANALYSIS ....................................................................................................................................................... 40

1. FLAME DETECTION ................................................................................................................................................................... 40

2. GAS DETECTION ....................................................................................................................................................................... 41

3. AIR PRESSURE SWITCH ........................................................................................................................................................... 41

4. Inlet / DHW / Operating Temperature SENSORS ..................................................................................................................... 41

PART 11 – FINAL INSTALLATION CHECKLIST ..................................................................................................................... 42

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

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ITEM

DESCRIPTION

QUANTITY

Residential Tankless Water

Heater

RT-199 / RT-180

Quick Reference Guide, User,

and Installation Manuals

1 Each

Condensate Hose

Anchors and Wall Mounting

Bracket

Spare Parts Kit

(Gaskets and O-Rings)

Vent Screens (3”)

2 Screens

OPTIONAL PARTS (Not Included)

150 PSI Pressure Relief Valve

Tankless Isolation Valves

Vent Screens (2” Mesh)

2 Screens

PART 1 – ITEMS SHIPPED WITH THE WATER HEATER

Table 1 – Items Included with the Water Heater

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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.

This water heater must be installed by a licensed plumber, licensed gas fitter, and/or professional 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.

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.

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 professional 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 professional 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.

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.

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.

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.

The water heater temperature is factory set to 125oF (51.7oC). 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.

NOTICE

If the water heater is exposed to the following, do not operate until all corrective steps have been made by a qualified service technician:

1. FIRE

2. DAMAGE

3. WATER

DO NOT alter or modify the water heater or water heater controls. This can be dangerous and WILL VOID the warranty.

PART 2 – SAFETY REGULATIONS

A. OPERATION AND INSTALLATION WARNINGS

To avoid serious injury or death, read, understand, and follow all the precautions listed here.

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NOTICE

This water heater is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

This water heater provides a overheat shutdown limit. In the event the water heater water exceeds the set point of the control limit, the cutoff will trip and the water heater will shut down. 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.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury, or death.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Be sure to disconnect electrical power before opening water heater cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the water heater. Wiring errors can cause improper or dangerous operation. Failure to do so could result in an electrical shock, improper water heater operation, property damage, serious personal injury, or death.

Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. Failure to keep the exhaust vent and intake pipe clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

Contaminant

Maximum Allowable Level

Total Hardness

200 mg/l (12 grains/gallon)

Aluminum

0.05 to 0.2 mg/l

Chloride

250 mg/l

Copper

1 mg/l

Iron

0.3 mg/l

Manganese

0.05 mg/l

6.5-8.5

Sulfate

205 mg/l

Total Dissolved Solids (TDS)

500 mg/l

Zinc

205 mg/l

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the water heater rating label.

C. IMPROPER COMBUSTION

D. GAS

Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the appliance.

E. WHEN SERVICING THE WATER HEATER

 To avoid electric shock, disconnect electrical supply before performing maintenance.  To avoid severe burns, allow water heater to cool.  Do not use petroleum-based cleaning or sealing compounds in a water heater system. Gaskets and seals in the system may

be damaged, possibly resulting in substantial property damage.

 Do not use “homemade cures” or “patent medicines”. Substantial property damage, damage to water heater, and/or serious

personal injury may result.

 Always verify proper operation after servicing the water heater.

F. WATER QUALITY

Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in Table 2. If your water contains contaminants higher than outlined by EPA, then water treatment is recommended and additional maintenance may be required. If you suspect that your water is contaminated in any way, discontinue use of the water heater and contact an authorized technician or licensed professional.

Table 2 – Water Quality Specifications

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Consider water heater piping and installation when determining water heater location.

MODEL

RT-180

RT-199

Installation

Indoor, Wall Hung, Fully Condensing

Minimum / Maximum Input (Btu/Hr)

18,000 / 180,000

19,900 / 199,000

Hot Water Capacity

35oF Rise

10 Gal

11 Gal

45oF Rise

8 Gal

8.5 Gal

77oF Rise

4.6 Gal

5 Gal

Flue System

Sealed Combustion Direct Vent

Vent Run

2” (15 feet), 3” (100 feet), Schedule 40 PVC, CPVC, PP

Weight (lbs)

Orifice Size

.374” (9.5 mm)

Consult Factory

Gas Supply Pressure

3.5” to 14” WC

Manifold Pressure

Min (3”)

NG: -.01” / LP: -.11” WC

Max (3”)

NG: -.03” / LP: -.09” WC

Power Supply

Main Supply

120V 60 Hz

Maximum Power

Consumption

135W

General Operating Conditions

Temperature

 Ambient Temperature Range: 33 – 104oF (0.6 – 40oC)  Operating Relative Humidity: Up to 90% at 140oF (40oC)  Shipping and Storage Temperature Range: -4 – 176oF (-20 – 80oC)

Input Ratings

 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 Infrared

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 14.8”

Sub Heat Exchanger Water Capacity (DHW)

Under 2 Gallons

Main Controller / Control Panel

P-920C / GTH-9500C

Water Pressure

Min 15 – Max 150 PSI

Connection Sizes

Cold Water Inlet /

Hot Water Outlet

¾” NPT

Gas Inlet

¾” NPT

Materials

Cabinet

Cold Rolled Carbon Steel

Heat Exchanger

Primary Heat Exchanger: Stainless Steel

Secondary Heat Exchanger: Stainless Steel

Safety Devices

Flame Rod, Burner Overheat Cut Off Device 302oF (150oC), Gas Leak Detector,

Flue High Limit Switch 149oF (65oC), Water Temperature High Limit Switch 199oF

(93oC), Freeze Protection Ceramic Heater (Turns on at 42oF / 6oC, Turns off at

59oF / 15oC)

G. FREEZE PROTECTION

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

Table 3 – Technical Specifications

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DESCRIPTION

DIAMETER

Exhaust Outlet Pipe

3”

Air Intake

3”

Gas Inlet

¾”

DHW Outlet Adapter

¾”

DHW Inlet Adapter

¾”

Condensate Adapter

½”

DHW Inlet Filter

N/A

Figure 1 – RT-180 / RT-199 Specifications and Dimensions

Table 4 – RT-199 Adapter Specifications

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NUMBER

COMPONENT DESCRIPTION

NUMBER

COMPONENT DESCRIPTION

Exhaust Vent Adapter

Exhaust Duct

Air Inlet Pipe

Gas Valve

AGM (Air Gas Mixer)

Gas Inlet Pipe 2

Ignition Transformer

BLDC Fan

Igniter

Air Intake Pipe Adapter

Flame Detection Sensor

Gas Inlet Adapter

Primary Heat Exchanger Assembly

Freeze Protector

Hot Water Outlet

DHW Outlet Adapter

Mixing Valve

Condensate Trap

Air Pressure Switch

Cold Water Inlet Adapter

N/A

Cold Water Inlet Filter

Manual Power Switch

Control Panel

Water Adjustment Valve

Operating Temperature Sensor

Main Controller

High Limit Overheat Switch

Secondary Heat Exchanger Assembly

Ceramic Heater

Gas Inlet Pipe 1

DHW Sensor

Flame Sight Glass

Condensate Trap Hose

Burner Case

Burner Overheat Switch

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.

Figure 2 – RT-180 / RT-199 Components

Table 5 – RT-180 / RT-199 Component List

PART 4 – PREPARE WATER HEATER LOCATION

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Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the water heater installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.

Failure of water heater or components due to incorrect operating conditions IS NOT covered by product warranty.

The service life of the water heater’s exposed metallic surfaces, such as the cabinet, as well as internal surfaces, such as the heat exchanger, are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other water heater components. In these environments, water heaters must not be installed using direct vent systems which draw outdoor air for combustion. Such water heaters must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.

This water heater is certified for indoor installations only. Do not install the water heater outdoors. Failure to install this water heater indoors could result in substantial property damage, severe personal injury, or death.

Locate the water heater where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower floors of the building. 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.

Failure to keep water heater area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

Do not connect the water heater to any heating systems or components that have been previously used for non-potable applications.

Do not introduce toxic chemicals, such as antifreeze or water heater treatments, into the water heater or any piping meant for potable water purposes.

Ensure that all piping and components connected to the water heater are suitable for potable water applications.

A. BEFORE LOCATING THE WATER HEATER

1. Installation Area (Mechanical Room) Operating Conditions

 Ensure ambient temperatures are higher than 32oF/0oC and lower than 104oF/40oC.  Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual.  Avoid continuously high levels of humidity  Never close existing ventilation openings

2. Check for nearby connections to:

 System water piping  Venting connections  Gas supply piping  Electrical power  Condensate drain

3. Check area around water heater. Remove any combustible materials, gasoline, and other flammable liquids.

4. Gas control system components must be protected from dripping water during operation and service.

5. If the water heater is to replace an existing water heater, check for and correct any existing system problems, such as:

 System leaks  Location that could cause the system and water heater to freeze and leak.  Incorrectly-sized expansion tank

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Do not use this water heater for space heating applications.

Circulators suitable for DHW applications must be used.

Space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the water heater. The water heater cover must be securely fastened to prevent it from drawing air from the water heater room. This is particularly important if the water heater is in a room with other appliances. Failure to comply with the above could result in substantial property damage, severe personal injury, or death.

MINIMUM CLEARANCES

Installation Clearances from Non-Combustibles / Combustibles

Recommended Service and Proper Operation Clearances

Top

9 in. (228.6 mm)

Back

5/8 in. (15.9 mm)

Front

6 in. (152.4 mm)

24 in. (609.6 mm) or more (Front of Water heater)

(A combustible door or removable panel is acceptable front

clearance.)

Right Side

3 in. (76.2 mm)

Left Side

Bottom

12 in. (304.8 mm)

Vents must be properly supported. The water heater exhaust and intake connections are not designed to carry heavy weight. Vent

support brackets must be within 1’ of the water heater and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’ from the water heater.

In order for the condensate to properly flow out of the collection system, the water heater must be installed level.

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.

B. LEVELING

C. CLEARANCES FOR SERVICE ACCESS

See Table 6 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the water heater without removing it from the space.

Table 6 – Minimum Installation and Service Clearances NOTE: The exhaust vent piping for this direct vented appliance is approved for zero clearance to combustible construction. NOTE: If the water heater is installed in a narrow space or corner, ensure that there is sufficient space for service and maintenance

access. There should be easy access to the gas and water lines and internal components for future service. A combustible door or removable panel is acceptable front clearance.

D. RESIDENTIAL GARAGE INSTALLATION

If the water heater is located in a residential garage, per ANSI Z223.1:

 Mount the bottom of the water heater a minimum of 18” above the floor of the garage, to ensure the burner and ignition

devices are well off the floor.

 Locate or protect the water heater so it cannot be damaged by a moving vehicle.

E. EXHAUST VENT AND INTAKE PIPE

You must also install air intake piping from outdoors to the water heater flue adaptor. The resultant installation is categorized as direct vent (sealed combustion).

NOTE: To prevent combustion air contamination, see Table 7 in this section when considering exhaust vent and intake pipe termination.

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Ensure that the intake air will not contain any of the contaminants below. For example, do not pipe intake near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the water heater, resulting in possible substantial property damage, severe personal injury, or death.

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

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 and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

NOTE: DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to the limited warranty for complete terms and conditions).

Do not install the water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Figure 3 - CO Warning Label

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. Exhaust vent and intake piping lengths, routing, and termination method must comply with methods and limits given in the venting section.

F. PREVENT COMBUSTION AIR CONTAMINATION

Install intake piping for the water heater as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

Table 7

G. REMOVING A WATER HEATER FROM A COMMON VENT SYSTEM

When removing an existing water heater, the following steps must be followed.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.

3. If practical, close all building doors, windows and all doors between 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 appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

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UNCRATING WATER HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Cold weather handling – If water heater has been stored in a very cold location (below 0oF) before installation, handle with care until the plastic components come to room temperature.

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 heavy for one person to lift. It is highly recommended to install the water heater with two people. Use caution as to not drop the water heater, which could damage the water heater and cause property damage and/or severe personal injury. Verify that the water heater is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the water heater could result in substantial property damage, severe personal injury, or death.

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the water heater could result in substantial property damage, severe personal injury, or death.

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.

7. Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

H. UNCRATING THE WATER HEATER

Remove all sides of the shipping crate to allow the water heater to be lifted into its installation location.

I. WALL-MOUNTING THE WATER HEATER

The water heater may be installed on any suitable internal wall (suitable sound-proofing may be required when installing onto a stud partition wall).

POSITIONING THE WATER HEATER ON THE WALL

1. Attach the wall bracket on the location where you want to install the water heater. Ensure it is level and on stud (16” centers) before proceeding.

2. Mark the four drill holes with a pencil or marker. Remove the wall bracket.

3. Drill four (4) holes using a 5/32 drill bit at the marked hole locations.

4. Mount the wall bracket to the wall with the four (4) included anchor bolts. Ensure the mounted bracket is level. See Figure 4A.

5. Align the heater bracket grooves on the back of the water heater with the tongues on the wall bracket and hang the water heater on the bracket. See Figure 4B.

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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.

DO NOT use an electric damper, vent damper, or draft hood with this water heater.

DO NOT locate the exhaust vent or intake pipe terminations where exposed to prevailing winds.

Moisture will be produced by the exhaust vent. Take precautions when determining exhaust vent termination. Moisture may fall from the vent termination to the ground and turn to ice in freezing conditions. Moisture or ice can produce a hazardous condition.

Exhaust condensate is acidic, and could deteriorate the surface below the exhaust vent termination. Ensure this surface is in good repair (sealed, painted, etc.) to prevent deterioration.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

Figure 4 – Wall Mounting the Water Heater

PART 5 – VENTING

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES

1. Vent system must be installed in accordance with local codes, or, in absence of local codes, the National Fuel Gas Code, ANSI Z223.1 / NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

2. For installation in Canada, installer supplied plastic vent piping must comply with CAN/CGA B149.1 and be certified to the Standard for Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products. Clean and dry all applicable surfaces before applying cement.

3. This water heater is designed to be installed as a direct vent (sealed combustion) type. Combustion air must be supplied directly from the outdoors to the burner, and the flue (exhaust) gases should be vented directly to the outdoors through the wall or roof.

4. This water heater uses 2” or 3” diameter pipe for exhaust vent and intake pipe. It is important to ensure an airtight seal from the water heater collar to the vent terminations. It is EXTREMELY IMPORTANT that the maximum allowed combined venting lengths are not exceeded. See Table 9 for a list of Approved Vent Materials and Table 10 for Approved Vent Lengths.

5. Do not install venting system components on the exterior of the building except as specifically required by these instructions.

 Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.  Maintain the correct clearance and orientation between the exhaust vent and intake pipe terminals.  The exhaust vent and air intake terminals must be at the same height and their center lines must be spaced apart 1 foot

minimum.

 The bottom of the exhaust vent and intake pipe terminals must be at least 1 foot above the normal snow accumulation level. In

no case should these terminals be installed less than 1 foot above normal snow accumulation level.

 Do not install the exhaust vent terminals directly above windows or doors.  Intake pipe terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming

pools.

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All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.

 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.

 Remove all burrs and debris from joints and fittings.  When using PVC or CPVC pipe, all joints must be properly cleaned,

primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe. NOTE: DO NOT CEMENT POLYPROPYLENE PIPE.

 Ensure the vent is located where it will not be exposed to prevailing

winds.

 In all roof venting applications, exhaust discharge must point away

from the pitch of the roof.

 To prevent water leakage, install adequate roof flashing where the pipe

enters the roof.

 Do not locate vent over public walkways, driveways, or parking lots.

Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.

 Due to potential moisture build-up, sidewall venting may not be the

preferred venting option. To save time and cost, carefully consider venting installation and location.

 Horizontal lengths of exhaust vent must slope back towards the water

heater not less than ¼" per foot to allow condensate to drain from the vent pipe.

 The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or

plants.

 In vacant chimney applications, install and seal a rain cap over existing chimney openings.  All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where

condensate may form.

 Do not use the water heater to support any piping.

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DESCRIPTION

CANADA

Clearance above grade, veranda, porch, deck, or balcony

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

Clearance to outside corner

* G Clearance to inside corner

Clearance to each side of center line extended above meter

/ regulator assembly

3 feet with a height 15 feet

above meter / regulator

assembly

Clearance to service regulator vent outlet

3 feet

Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other appliance

1 foot

3 feet

Clearance to a mechanical air supply inlet

3 feet above if within 10 feet

horizontally

6 feet

Clearance above paved sidewalk or driveway located

7 feet

Clearance under veranda, porch, deck, or balcony

1 foot

NOTICE

Consult Table 9 or the most recent edition of ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 as well as all applicable local codes and regulations when selecting vent pipe materials.

Figure 5 – Vent Termination Detail

Table 8 – Vent Termination Clearances *NOTE: For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA-B 149.1, please use clearances in accordance with local

installation codes and the requirements of the gas supplier.

B. APPROVED VENT MATERIALS

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APPROVED EXHAUST VENT AND INTAKE PIPE MATERIAL

Item

Material

Standards for Installation in:

United States

Canada

Exhaust vent or Intake

pipe and fittings

CPVC schedule 40

ASTM-D2846

PP, CPVC, and PVC venting must be

ULC-S636 Certified. IPEX is an approved

manufacturer in Canada, supplying vent

material listed to ULC-S636.

PVC schedule 40

ANSI/ASTM D1785

Polypropylene

ULCS636

Stainless Steel AL29-4C

Certified for Category IV and direct vent appliance venting

Certified for Category IV and direct vent

appliance venting

Pipe cement/primer

PVC

ANSI/ASTM D2564

IPEX System 636 Cements & Primers

CPVC

ANSI/ASTM F493

 This water heater has a built-in control to limit the exhaust temperature to 149oF (65oC).  The exhaust and intake components installed with this water heater must be used for near water heater piping BEFORE

transitioning to the approved materials listed above. DO NOT REMOVE these installed components. Doing so WILL VOID warranty.

 PVC/CPVC pipe and fittings of the same diameter are considered interchangeable.  DO NOT use Foam Core Pipe (CPVC cellular core, Radel, etc.) in any portion of the exhaust piping from this water heater.  DO NOT connect PVC/CPVC to PP without an approved vent connector.  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.

 DO NOT insulate non-metallic exhaust vent pipe or fittings.  DO NOT obstruct the flow of combustion or ventilation air.  When using Pipe Cement/Primer, follow the instructions included with the Cement/Primer closely. Clean and dry all applicable

surfaces before applying.

Failure to follow these directions will result in substantial property damage, severe personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this boiler and related components near high heat sources.

Vent adaptors are not designed as load-bearing devices, and must not be used to support exhaust vent piping. All vent pipes must be properly connected, supported, and the exhaust must be pitched a minimum of ¼” per foot back to the heater to allow drainage of condensate. Failure to properly support vent piping and follow the information in this statement could result in product damage, severe personal injury, or death.

MODEL

2” COMBUSTION AIR / VENT PIPE

3” COMBUSTION AIR / VENT PIPE

MAX

MAX ALLOWED NUMBER OF ELBOWS

MAX

MAX ALLOWED NUMBER OF ELBOWS

RT-180 / RT-199

15’ (4.5M)

100’ (30M)

Table 9 – Approved Venting Materials

C. ALLOWED SCHEDULE 40 VENT LENGTHS (PVC, CPVC, PP)

Table 10 – Approved Vent Lengths NOTE: When using more than 1 elbow, reduce maximum allowable length:

 5 feet (1.5M) for each additional 3” 90o elbow  2.5 feet (.75M) for each additional 3” 45o elbow  8 feet (2.4M) for each additional 2” 90o elbow  4 feet (1.2M) for each additional 2” 45o elbow

D. TIGHTENING WATER HEATER COLLAR TO EXHAUST VENT AND INTAKE PIPE

This appliance uses 2” or 3” diameter pipe for exhaust vent and intake pipe. In order to use 2” pipe, it is required to reduce pipe size in a vertical length of pipe with a reducing coupling (not included). Follow the steps below to install 3” pipe into the appliance collar. See Figure 6 for additional details.

1. Clean and dry the appliance connection. DO NOT use primer or cement on the appliance connection.

2. Push the length of pipe into the connection until it touches the bottom of the fitting.

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3. Tighten the clamps using a screwdriver.

4. Ensure the pipe is secure before continuing installation.

5. 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 – Transitioning from 3” to 2” Vent Pipe

E. VENT TERMINATION

1. Horizontal Vent Terminations

Figure 8 – Direct Vent, Sidewall Vent Termination

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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)

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SAFETY INSTRUCTIONS

Do not connect any other appliance vents to the water heater exhaust vent or intake pipes.

FIRE AND/OR EXPLOSION HAZARD

To avoid serious injury or death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional.

Always match the water heater with the type of gas supplied to the unit (natural gas or LP gas). This water heater must be converted into propane operation unless specifically manufactured for use with propane. Follow Gas Conversion Manual instructions (separate document). Propane ready water heaters have the suffix “LP” after the model serial number.

Make sure the gas line pressures are within normal limits. Pressures outside normal limits can result in poor performance and hazardous operating conditions.

This water heater must be converted into propane operation unless it is specifically manufactured to operate on propane. Propaneready water heaters have the suffix “LP” after the model serial number. Failure to ensure the water heater is set to operate on the provided gas supply could result in property damage, personal injury, or death.

Figure 12 – Condensate Detail

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 – Screen Installation - NOTE: Vent termination elbow is meant to be installed open end facing the ground. Orientation in Figure 11 is meant to demonstrate proper Vent Screen installation ONLY.

PART 6 – INSTALL THE CONDENSATE DRAIN

1. Due to its efficient design, the water heater produces condensate (water) as a normal by-product. This condensate is acidic, with a pH level between 3 and 4. This condensate must be drained away from the water heater and disposed in accordance with all local regulations.

2. Use corrosion-resistant materials to drain condensate. Use the included flexible

plastic hose or ½” PVC and CPVC drain pipe complying with ASTM D1785, F441,

or D2665 may be used. Cement and primer must comply with ASTM D2564 or F493. For Canadian applications, use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

3. Local building codes may require an in-line neutralizer (1) to be installed (not included) to treat the condensate. Follow all the installation instructions included with the neutralizer. If a neutralizer is installed, periodic replacement of the limestone (or neutralizing agent) will be required. The rate of depletion of the limestone varies with usage of the water heater. During the first year of water heater operation, check the neutralizer every few months for depletion.

4. Route the drain line to a nearby floor drain (2), laundry tub (3), or condensate pump (4).

NOTE: If a nearby laundry tub is used as a disposal for waste water from the washing machine, draining the condensate into this tub allows the soapy water discharge to neutralize the acidic condensate.

5. An error will appear on the water heater display if condensate line is blocked. The water heater will not operate with a blocked condensate line. It is extremely important to have this condition repaired by a qualified service technician.

PART 7 – GAS PIPING

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Maximum Natural Gas Delivery Capacity – Length of Corrugated Stainless Steel Pipe in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

½”

¾”

192

137

112

1”

383

269

218

188

168

153

132

118

1 ¼”

639

456

374

325

292

267

232

208

171

148

1 ½”

1260

888

723

625

559

509

440

393

320

277

2”

2930

2080

1700

1470

1320

1200

1040

933

762

661

Maximum Natural Gas Delivery Capacity – Length of Black Iron Pipe (Sch. 40 Metallic) in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

½”

172

118

¾”

360

247

199

170

151

137

117

104

1”

678

466

374

320

284

257

220

195

157

134

1 ¼”

1390

957

768

657

583

528

452

400

322

275

1 ½”

2090

1430

1150

985

873

791

677

600

482

412

2”

4020

2760

2220

1900

1680

1520

1300

1160

928

794

Maximum Liquid Propane Delivery Capacity – Length of Corrugated Stainless Steel Pipe in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

½”

129

¾”

303

216

177

153

137

126

109

1”

605

425

344

297

265

241

208

186

143

129

1 ¼”

971

661

528

449

397

359

307

270

217

183

1 ½”

1990

1400

1140

988

884

805

696

621

506

438

2”

4640

3290

2680

2330

2080

1900

1650

1480

1210

1050

Maximum Liquid Propane Delivery Capacity – Length of Black Iron Pipe (Sch. 40 Metallic) in Feet

Pipe Size

Cubic Feet per Hour (0.60 Specific Gravity, 0.5 WC Pressure Drop)

100

150

200

½”

291

200

160

137

122

110

101

¾”

608

418

336

287

255

231

212

197

175

140

1”

1150

787

632

541

480

434

400

372

330

265

1 ¼”

2350

1620

1300

1110

985

892

821

763

677

543

1 ½”

3520

2420

1940

1660

1480

1340

1230

1140

1010

814

2”

6790

4660

3750

3210

2840

2570

2370

2200

1950

1570

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/ft3. Contact the local gas supplier for actual BTU/ft3 rating.

2. Natural Gas Pipe Sizing

The following tables list maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 14” or less and a pressure drop of

0.5 inches water column, based on a 0.60 specific gravity for natural gas.

Table 11 – Natural Gas Delivery Capacity – Corrugated Stainless Steel Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

Table 12 – Natural Gas Delivery Capacity – Black Iron Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

3. LP (Liquid Propane) Gas Pipe Sizing

The following is intended for use for piping between a Single or Second Stage (Low Pressure) Regulator and the water heater. The following tables list maximum capacity of pipe in cubic feet of gas per hour for an inlet pressure of 11 inches water column and specific pressure drop of 0.5 inches water column based on 1.5 specific gravity for liquid propane.

Table 13 – Liquid Propane Delivery Capacity – Corrugated Stainless Steel Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

Table 14 – Liquid Propane Delivery Capacity – Black Iron Pipe – Refer to ANSI Z223.1 – National Fuel Gas Code, Latest Edition

B. GAS CONNECTION REQUIREMENTS

1. The gas connection fitting on the water heater is ¾” female NPT. NOTE: The pipe size must not be less than ¾”. LP-505 REV. 4.29.14

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.

3. Measure the length of the gas supply line from the gas meter to the water heater. Water heater must be installed downstream of the

gas meter to ensure adequate gas supply. Use the tables in this manual or refer to the gas line manufacturer’s sizing information to determine the correct supply pipe size.

4. A manual gas shut-off valve should be installed in the gas supply line close to the water heater. See Figure 13 for detail.

5. To facilitate any future maintenance, it is also recommended that an approved gas union fitting be installed in the supply line between

the shut-off valve and the ¾” female NPT connection on the water heater.

Figure 13 – Gas Line With Shut-Off Valve Detail

6. Test the gas pressure to make sure it meets the minimum standards and does not exceed the maximum standards of the water

heater.

7. Leak test the gas line pipe before placing the water heater in operation. Only use approved leak detector liquid solutions to check for

leaks.

8. Do not operate the water heater until all connections have been completed and the heat exchanger is filled with water.

Figure 14 – Natural Gas Piping Installation – NOTE: Capacity to be not Less than Total Capacity of Connected Appliances

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LP GAS

NATURAL GAS

Minimum Pressure

3.5” WC

Minimum Pressure

3.5” WC

Maximum Pressure

14” WC

Maximum Pressure

14” WC

NOTICE

Do not fire (operate) the water heater until all connections have been completed and the heat exchanger is filled with water. Doing so will damage the water heater and void the warranty.

Figure 16 – Inlet Gas Pressure Port Detail

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.

1. The water heater and its individual shutoff valve must be disconnected from the

gas supply piping system during any pressure testing of the system at test pressures greater than ½ psi (3.5 kPa).

2. The water heater must be isolated from the gas supply piping system by closing its

individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).

The minimum and maximum inlet gas line pressures must meet the requirements shown in Table 15.

Table 15 – Gas Pressure Requirements

PART 8 – WATER PIPING

A. GENERAL PLUMBING CONNECTION GUIDELINES

 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.  Do not apply a torch within 12” of the bottom connections of the water heater. Doing so could damage the water heater. Such

damages ARE NOT covered by product warranty.

 The size of the hot water pipe should be ¾” diameter.  Isolation (shutoff valves) should be used to ease future servicing.  All piping should be insulated.

B. INSTALL A BACKFLOW PREVENTER

It may be recommended to use a back flow preventer – check local codes. If a back flow preventer or a no return valve is used, a thermal expansion tank must be installed on the cold water supply between the water heater and valve.

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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.

Use at least the MINIMUM 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.

C. PIPING THE WATER HEATER

Use both thread tape and pipe dope to connect to the ¾” domestic water inlet and outlet. Tankless isolation valves between the city water supply and tank inlet are recommended for ease of service.

D. PIPING DIAGRAM

Figure 17 – DHW Piping

Figure 18 – Piping with Recirculation

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To avoid water damage or scalding due to relief valve operation:

 Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a

manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

 Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.  Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain, making discharge clearly

visible.

 Discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375oF or greater.  Do not pipe discharge to any location where freezing could occur.  No shutoff valve may be installed between the relief valve and water heater or in the discharge line. Do not plug or place any

obstruction in the discharge line.

 Test the operation of the relief valve after filling and pressurizing the system by lifting the lever. Make sure the valve

discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.

 Test relief valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the water heater “off”

and call a plumber immediately.

 Take care whenever operating relief valve to avoid scalding injury or property damage.  For water heaters installed with only a pressure relief valve, the separate storage vessel must have a temperature and

pressure relief valve installed. This relief valve shall comply with Relief Valves for Hot Water Supply Systems, ANSI Z21.22 CSA4.4.

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

Install wiring and electrically ground water heater in accordance with the authority having jurisdiction or, in the absence of such an authority, follow the National Electrical Code, NFPA 70, and/or CSA C22.1 Electrical Code-Part 1 in Canada. Failure to follow all applicable local, state, and national regulations, mandates, and building supply codes for guidelines to install the electrical power supply could result in property damage, serious personal injury, or death.

ELECTRICAL SHOCK HAZARD – To ensure safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so could result in property damage, serious personal injury, or death.

Figure 19 – Relief Valve Details

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). The 150 psi Pressure Relief Valve must be installed on the DHW supply line to ensure a compliant installation and safe operation.

This water heater has a high-temperature shut-off switch built in as a standard safety

feature. Therefore, a “pressure only” relief valve is required. DO NOT operate this

water heater before the supplied pressure relief valve is installed with sufficient relieving capacity in accordance with the ASME rating plate on the water heater.

Pressure relief valves must be installed as close to the water heater as 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 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 discharges freely. If the valve fails to operate correctly, replace it with a new relief valve. Ensure that the maximum BTU/H rating on the pressure relief valve is equal to or greater than the maximum input BTU/H rating of the combination water heater.

PART 9 – CONNECT ELECTRICAL POWER / INITIAL STARTUP

LP-505 REV. 4.29.14

Page 28

NOTICE

If the water heater display does not come ON, first check the plug. Also check the electrical panel circuit breaker and reset it if necessary. If the circuit breaker trips again, do not reset. Disconnect the plug and have a qualified technician diagnose the problem.

DIP SWITCH

OFF

1 – 3

NOT USED

Gas Type

High Fire

Normal

High Fire

Low Fire

Normal

Low Fire

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 – Proper Grounding – Internal Manual Power Switch

3. The wiring diagrams contained in this manual are to be used for reference purposes only.

4. Refer to these diagrams and the wiring diagrams of any external controls used with the installation when wiring the water heater.

Read, understand, and follow all wiring instructions supplied with the controls.

5. Do not disconnect the power supply when the water heater is in normal operation.

NOTE: For additional electrical protection, the use of a whole house surge protector is recommended. Damage caused by power surges is not covered by the warranty.

B. DIP SWITCHES

There is one DIP switch. DIP switches 6 and 7 need to be set to OFF for the water heater to operate normally.

Figure 21 – Dip Switch Detail

DIP SWITCH GROUP

Table 16 – DIP Switch Group

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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)

DHW SET TEMPERATURE RANGE

95oF (35oC) - 140oF (60oC)

DHW OFF TEMPERATURE

DHW Target Temperature + DHW Differential Temperature

50oF (10oC)

DHW ON TEMPERATURE

Below DHW Target Temperature 41oF (5oC)

DHW WATER ON MINIMUM WATER FLOW

.5 gallons (2 liters) (12Hz)

DHW WATER OFF MINIMUM WATER FLOW

.4 gallons (1.5 liters) (8Hz)

SYSTEM CONTROL SETTINGS

Table 17 – System Control Settings

LP-505 REV. 4.29.14

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LP-505 REV. 4.29.14

Figure 22 – Electrical Wiring Diagram

Page 31

Figure 23 – Ladder Diagram

LP-505 REV. 4.29.14

Page 32

CONNECTOR

DESCRIPTION

HT SELV

NO. OF LOCATION

BOARD SILK

CN9

65001WS-12

UNUSED

Power Supply Line

HT (120V~)

CP1

UNUSED

Ignitor

L(HT)

Ceramic Heater (Freeze Protection)

Gas Valve

EARTH GROUND

8 N Power Supply Neutral

9-12 AC Power COM Line

CN1

SMW250-03

RS-485

RS485 +

SELV (5V)

GND

RS485 -

CN4

LWD1140-06

FAN

Unused

GND

SELV (30V)

VDD

SELV (14V)

Fan power (start coil)

SELV (30V)

Fan power (end coil)

Fan speed feedback signal

SELV (14V)

CN8

SMW250-04

MCU ISP

GND

SELV (5V)

ISP / Reset Port

ISP TOOL0 Data Port

VCC

CN11

HWL

Unused

LWL

Unused

Connect to the Display Control

(Thermostat)

SELV (14V)

APS

Air Pressure Switch

Unused

Burner Limit

High Limit

Table 18 – Water Heater Wiring 1

LP-505 REV. 4.29.14

Page 33

CONNECTOR

DESCRIPTION

HT SELV

NO. OF LOCATION

BOARD SILK

CN7

LWD1140-14

F.S

Flame Detect Sensor

SELV (5V)

OP.S

Operating Water Temperature Sensor

DH.S

DHW Temperature Sensor

I.S

Inlet Water Temperature Sensor

BG.S

Exhaust Temperature Sensor

ST.S

Unused

SP.S

Unused

CN12

SMW250-07

AGM

AGM Stepper Motor Coil / Y Phase

SELV (24V)

AGM Stepper Motor Coil / X Phase

GND

AGM Stepper Motor Position

SELV (14V) 7 VDD

SELV (24V)

CN10

SMW250-08

DHM

DHM Stepper Motor Coil / Y Phase

SELV (14V)

DHM Stepper Motor Coil / X Phase

GND

DHM Stepper Motor Position

Unused

VDD

CN14

SMW250-09

IWM

GND

IWM Stepper Motor Position

VDD

IWM Stepper Motor Coil X Phase

IWM Stepper Motor Coil Y Phase

VDD

IWM Stepper Motor Coil / X Phase

IWM Power IWM Stepper Motor Coil / Y

Phase

Unused

CN3

SMW250-06

WPS

Unused

FLUX1

VCC

SELV (5V)

Water Flow Sensor

GND

CN5

SMW250-10

RPM

Fan RPM Check

GND

Table 19 – Water Heater Wiring 2

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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)  The display has timed out for approximately 2 minutes

C. 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.

After start-up, the display appears as follows.

Figure 26 – Initial Display Screen

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Hotter water increases the risk of scald injury. Scalding may occur within 5 seconds at a setting of 140oF (60oC). Water temperature over 125oF can instantly cause severe burns, or death, from scalds. Children, disabled, and elderly are at the highest risk of being scalded. See instruction manual before setting temperature at appliance. Feel water before bathing or showering!

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. CHANGING THE DHW SET-POINT

The display shows the icon when the DHW set-point can be changed.

Figure 27 – DHW Set-Point Screens

Press the button when the display panel is powered ON to change the DHW Set-Point. The DHW icon and current set-point will display and flash. This indicates that the DHW Set-Point can be changed. Factory DHW Set-Point is 125oF (51oC). Initial DHW SetPoint range is 95 – 120oF (35 – 49oC).

Turn the dial counterclockwise to lower and clockwise to raise the DHW set-point. After changing the temperature, press the button to save the set-point.

To change the DHW Set-Point above 120oF (49oC), press and hold the button for five seconds when the display panel is powered ON. The current DHW set-point will display. The DHW icon will flash. And the scald warning letter “H” (high temperature) will display. High temperature DHW Set-Point range is 121 – 140oF (49.4 – 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 set-point.

E. CHANGING THE TEMPERATURE INDICATOR

To change the temperature indicator from Fahrenheit to Celsius, press and hold the Thermometer button for more than five seconds. This will toggle the temperature unit from the unit indicated on the display.

G. STATUS DISPLAY MODE

Status Display Mode will activate when button B is pressed and held for five seconds at Standby Mode.

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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

C: Lc

Lock Mode

Lock Mode is In Use (ON) or Unused (OFF)

Allows user to lock out any temperature change.

d: oP

OP Temperature

Current Operating Temperature

E: dH

DHW Temperature

Current DHW Temperature

F: Eh

Exhaust Temperature

Current Exhaust Temperature

h: In

Inlet Temperature

Current Inlet Temperature

L:rt

Running Time

Display Running Time

L:rt

1: PH

Power Supply Time

Power Supply Time: 100 hour increments

2: rh

Burner Operating Time

Burner Operating Time: 1 hour increments

3: rH

Burner Operating Time

Burner Operating Time: 1,000 hour increments

4: It

Ignition Attempts Number

Ignition Attempts Number: 10 times unit displayed

5: IH

Ignition Attempts Number

Ignition Attempts Number: 10,000 times unit displayed

J: AG

N/A

Figure 28 – Status Mode Screens

Table 20 – Status Mode Display Screen Descriptions – NOTE: Shaded Parameters Not Used on This Software Version

Turn the dial counterclockwise and clockwise to scroll through the displayed parameters. To view parameter details, press the button at the appropriate screen. Press the or buttons to leave the parameter.

Press the button again to return to Operation Mode.

To turn on Lock Mode, press the button at the C:Lc parameter. Turn the dial counterclockwise and clockwise to scroll On or Off. Press the button to save the selection and return to the parameters.

Press the button again to return to Operation Mode. NOTE: The Control System will not allow the changes if Lock Mode is activated. Lock Mode will have to be turned off before making

further changes.

H. INSTALLER MODE

Installer Mode will activate when button B is pressed and held for five seconds while the water heater is powered Off.

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Index

Default

Parameter

Description

1: EH

E0:00

History

Most Recent History Error Codes (H0 – H9)

2: cE

OFF

Clear Error History

Clears Error History

3: In

OFF

System Reset

Restores System to Default Settings

(Burner operation time, Ignition cycles, and Supply

power time will not be reset)

Range: ON or OFF

4: Fu

Flow Unit

Displays Flow Rate in Liters/Minute or Gallons/Minute

Range: GA or Li

5: FH

N/A

6: FL

N/A

7: dr

Reset Burner Operation Time

8: dI

Reset Number of Ignition

9: HA

N/A

10: Cn

N/A

11: CI

N/A

12: Eh

N/A

Figure 29 – Installer Mode Screens

Table 21 – Installer Mode Descriptions – NOTE: Shaded Parameters Not Used on This Software Version

Toggle through displayed items by turning the dial . To change an item, press the Dial button .

Displayed items can be changed by turning the dial counterclockwise to lower, and clockwise to raise, the displayed value. To save settings, press the Dial button again.

To leave Installer Mode, press button B again. The water heater will return to power off mode.

F. ERROR MODE

When the water heater encounters an error, the display will flash “Er” followed by a numerical code. The water heater shall enter a soft lockout condition if the error is such that it can return to normal operation once the condition relieves itself (overheat conditions, NTC open or shorts, etc.). The water heater shall enter a hard lockout if the condition indicates something more serious (flame, ignition, condensate line, etc.) To clear a hard lockout Error Code, press the Power button.

The following screen will display when the water heater encounters an error.

Figure 30 – Error Mode Screen

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Error Code

Error Code Description

Possible Remedies

Er:10

Flame has Extinguished 8

(Eight) Times

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.

2. Check gas valve wire. Ensure connection is secure.

3. Check flame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

4. Check vent terminations. Ensure there are no blockages.

5. Assure that the flame is stable when lit.

6. If the problem persists, replace the main control.

Er:11

Ignition has Failed 10

(Ten) Times

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.

2. Check gas valve wire. Ensure connection is secure.

3. Check flame detection sensor. Ensure connections are secure. Normal operating settings 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 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 Error Code will go away when the DHW temperature decreases. If Error happens again:

1. Check if dip switch High Fire setting is ON. Switches 6 and 7 should be OFF for normal operation.

2. Check if DHW pipe is blocked. Ensure there is enough water flowing to the water heater.

3. Check DHW sensor at DHW outlet. If resistance is zero, replace the sensor.

4. Check Operating Temperature sensor at the heat exchanger. If resistance is zero, replace the sensor.

5. If the problem persists, replace the main control.

Er:20

High Limit Overheat

Switch – Closed is

Normal, 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 zero, replace the switch.

3. If the problem persists, replace the main control.

Er:29

APS/Condensate –

Closed is Normal, Open is

Fault (Condensate Drain

Trap)

Press the Power button to clear the Error Code.

1. Check APS/Condensate and main controller connections. Ensure all are secure.

2. Check APS/Condensate resistance. If resistance is zero, replace the switch.

3. Check APS/Condensate hose. Ensure it is connected and in good condition.

4. Check condensate line and termination for blockages.

5. Check exhaust vent for blockages.

6. If the problem persists, replace the main control.

Er:31

Inlet Water Sensor Open

or Short

This Error Code will go away when inlet water temperature decreases. If Error happens again:

1. Check inlet water temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

Er:32

DHW Sensor Open or

Short

This Error Code will go away when outlet water temperature decreases. If Error happens again:

1. Check DHW outlet temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

Er:33

Operating Temperature

Sensor Open or Short

This Error Code will go away when outlet water temperature decreases. If Error happens again:

1. Check operating temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. If the problem persists, replace the main control.

Er:35

Exhaust Sensor Open or

Short

This Error Code will go away when exhaust temperature decreases. If Error happens again:

1. Check exhaust temperature sensor. Ensure connections are secure.

2. Check sensor resistance. If resistance is zero, replace the sensor.

3. Check exhaust vent for blockage.

4. If the problem persists, replace the main control.

Er:38

Error Appears When

Control Stores Data, but

Data is not Saved

Press the Power button to clear the Error Code. Replace the main control.

Er:39

Flame Detected after

Exiting a Flame On

Condition

This Error Code will go away when the false flame condition is remedied. If Error happens again:

1. Check the water heater cover. Ensure it is secure. Flame detection sensor can detect an external light source.

2. Check flame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

3. If the problem persists, replace the main control.

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Error Code

Error Code Description

Possible Remedies

Er:40

Gas Leakage is Detected

in 10 Minutes, or three

times within One Hour

(Greater than 5 Seconds

Each Time)

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. Press the Power button to clear the Error Code. If Error happens again:

1. Check the water heater cover. Ensure it is secure.

2. Check gas connections for leakage with a soapy solution. Fix any leaks.

3. Check condition of the burner assembly.

4. If the problem persists, replace the main control.

Er:41

Fan Speed too High with

Flame On

Press the Power button to clear the Error Code. If Error happens again:

1. Check the vent connections for blockages.

2. Check the burner assembly.

3. Check fan operation. If fan appears to be operating normally but RPMs are too low or too high, replace the fan.

4. If the problem persists, replace the main control.

Er:42

Jumped Wire

Disconnected

Press the Power button to clear the Error Code. If Error happens again:

1. Ensure the jumped wire is properly connected.

2. If the problem persists, replace the main control.

Er:43

Burner Overheat Switch

Open

Press the Power button to clear the Error Code. If Error happens again:

1. Check burner overheat switch connections. Ensure connections are secure.

2. Check switch resistance. If resistance is zero, replace the switch.

3. If the problem persists, replace the main control.

Er:61

Fan Speed Feedback

Signal Abnormal

This Error Code will go away when the condition is remedied. If Error happens again:

1. Check the connections to the fan. Ensure all are secure.

2. If the fan does not rotate during the ignition sequence, check for 120V power at the fan connection. If 120V power is present at the control, replace the fan. If the blower does not have 120V power, check power at the control. If 120V power is not present at the control, replace the control.

3. If the problem persists, replace the main control.

Er:65

Supply Water Valve Error

Press the Power button to clear the Error Code. If Error happens again:

1. Turn power OFF and ON at the main power switch internal to the water heater.

2. Check wiring connections to supply water valve. Ensure all are secure.

3. Replace supply water valve.

4. If the problem persists, replace the main control.

Er:66

Mixing Valve Error

Press the Power button to clear the Error Code. If Error happens again:

1. Turn power OFF and ON at the main power switch internal to the water heater.

2. Check wiring connections to mixing valve. Ensure all are secure.

3. Replace mixing valve.

4. If the problem persists, replace the main control.

Er:67

AGM Error

Press the Power button to clear the Error Code. If Error happens again:

1. Turn power OFF and ON at the main power switch internal to the water heater.

2. Ensure fan inlet hole is completely open after turning the power OFF and ON.

3. Check wiring connections to the AGM. Ensure all are secure.

4. Check AGM operation.

5. Replace AGM components.

6. If the problem persists, replace the main control.

Er:70

Port, AD Abnormal,

Important EPROM Data or

Safe Data Abnormal

This Error Code will go away when the condition is remedied. If Error happens again:

1. Turn power OFF and ON at the main power switch internal to the water heater.

2. If the problem persists, replace the main control.

Er:72

Flame Signal Detected

before Ignition

This Error Code will go away when the condition is remedied. If Error happens again:

1. Check the water heater cover. Ensure it is secure. Flame detection sensor can detect an external light source.

2. Check flame detection sensor. Ensure connections are secure. Normal operating settings are more than 2.5DC before ignition, less than 2.5DC after ignition.

3. If the problem persists, replace the main control.

Er:73

DIP Switch is abnormal

This Error Code will go away when the condition is remedied. If Error happens again:

1. Check dip switches. Ensure switches match the ratings plate requirements of the water heater. See dip switch details, this manual, for default settings.

2. If the problem persists, replace the main control.

Er:76

Poor Communication

This Error Code will go away when the condition is remedied. If Error happens again:

1. Check connections from main control to display panel.

2. If the problem persists, replace the display and/or the main control.

LP-505 REV. 4.29.14

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Error Code

Error Code Description

Possible Remedies

Er:94

Exhaust NTC detects Vent

Temperature is Greater

than 149oF (65oC)

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.

2. Check exhaust temperature sensor. Ensure connections are secure.

3. Check sensor resistance. If resistance is zero, replace the sensor.

4. Check exhaust vent for blockage.

5. If the problem persists, replace the control.

6. If the problem persists, replace the heat exchanger.

This water heater is equipped with a blocked vent shutoff system. If Error Codes Er:29, Er:41, or Er:94 occur, turn off the gas valve at the manual shutoff. Check the vent terminations for obstructions. If no obstructions are found, reset the water heater by pressing the power button. If the error continues to occur, call a qualified service technician or the gas supplier to check the water heater. Failure to follow these instructions could result in property damage, personal injury, or death.

Table 22 –Diagnostics and Suggested Corrective Actions

G. ERROR TREE ANALYSIS

1. FLAME DETECTION

Figure 31 – Flame Detection Error Analysis Tree

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Page 41

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

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Page 42

YES

BEFORE INSTALLING

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 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?

INSTALL WATER PIPING

Does water heater loop piping meet the minimum sizing requirements listed? NOTE: Smaller piping will cause performance problems.

Has water chemistry been checked?

Does water chemistry meet requirements?

If water chemistry does not meet requirements, have treatment measures been put in place?

Has the system been cleaned and flushed?

INSTALL EXHAUST VENT AND INTAKE PIPING

Has the water heater been vented with the approved materials listed in this manual (3” PVC, CPVC, Polypropylene, etc.) or to meet local codes?

Is air supply sufficient for proper water heater operation?

Is total vent piping length within the maximum vent length restriction listed in this manual?

Have venting lengths been minimized?

Are terminations properly spaced from windows, doors, and other intake vents?

Have all vent terminations been installed at least one foot above exterior grade and one foot above normal snow accumulation level?

Is vent piping properly supported?

Has vent piping been checked for leaks?

Has the exhaust vent line been pitched back to the water heater at a rate of ¼” per foot?

Have the exhaust vent and intake pipes been properly installed into the connectors provided on the water heater?

INSTALL CONDENSATE PIPING / TUBING AND COMPONENTS

Have all condensate line components included with the water heater been installed?

Is the condensate line piped with the approved materials listed in this manual?

Has the condensate line been routed to a laundry tub or other drain?

INSTALL GAS PIPING

Is the gas supply line a minimum of ¾” in diameter?

Is the gas supply line length and diameter adequate to deliver the required BTUs?

Has gas supply 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?

PRESSURE RELIEF VALVES

Have you installed approved pressure relief valves on the hot water outlet near the water heater?

Is the pressure relief valve in the DHW line at least ¾” in diameter?

WIRE THE WATER HEATER

Connect the power and control wiring per water heater wiring diagram, this manual.

Have all DIP switches been set on the main water heater board?

Is electrical connection polarity within water heater requirements?

Do power specifications meet water heater requirements? 120V AC?

START-UP, ADJUST, AND TEST

Has the water heater been started?

If necessary, has the water heater gas valve been adjusted?

Has the installation been customized per installation location requirements?

Have all customized system parameters been tested?

Has proper water heater operation been confirmed?

BURNER FLAME

Has the burner flame been checked?

Is the burner flame a proper blue color?

If the flame does not appear normal, it may need to be cleaned by a qualified service technician. See Figure 35 for flame sight glass window location.

FINAL INSTALLATION APPROVALS

SIGNED BY TECHNICIAN

DATE

PART 11 – FINAL INSTALLATION CHECKLIST

Table 23 – Final Installation Checklist

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TROUBLESHOOTING CHART

PROBLEM

POSSIBLE CAUSES

POSSIBLE REMEDIES

No electrical power to the water heater

1. Is the plug on the power supply cord unplugged from the electrical outlet?

2. Is electrical panel’s 10 Amp circuit breaker tripped?

3. Is the fuse on the circuit board good?

4. Is there a power outage to the home?

1. Reset the plug.

2. Reset the circuit breaker.

3. If the display panel is blank, unplug the unit or contact an authorized service technician.

4. Contact the power company.

No water available when a faucet is opened

1. Is the water supply valve shut off at the meter (do cold water faucets work)?

2. Is the water supply valve near the unit open?

3. Is the water pipe frozen?

4. Is an error code flashing on the display panel (leak detected)?

1. Open the closed supply valve.

2. Open the water supply valve.

3. Turn OFF the unit, close all water valves and the gas valve. Contact an authorized service technician.

4. Refer to error code information and contact an authorized service technician.

Hot water is not available when the faucet is opened.

1. Does the water heater have power (plugged in)?

2. Is the water heater turned ON?

3. Is an error code flashing on the display panel?

4. Is the gas supply valve open or shut off at the meter (do other gas devices work)?

1. Restore electrical power to the unit.

2. 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 0.6 gallons (2.3L) per minute through the water heater?

2. Is an error code flashing on the display panel?

3. Is the outlet water temperature set too low?

1. Open the faucet to allow more water flow.

2. Refer to the Diagnostic and Error Codes section in this manual.

3. Adjust the outlet water temperature (refer to the procedure in this manual).

It takes a long time before hot water flows from the faucet.

Is the faucet some distance from the water heater?

a. Allow time for the cold water already in the pipes to flow from the faucet. b. Have recirculation valves and/or plumbing return line(s) installed and program the unit for recirculation mode.

The water is not hot enough.

Is the water temperature set too low?

Adjust the temperature setting.

The water at the faucet is too hot.

Is the water temperature set too high?

Adjust the temperature setting.

A fan can be heard even when the unit is not operating.

1. The fan continues to operate after the burner shuts off to clear the exhaust vent of combustion gases.

2. The fan may run to help prevent freezing.

1. This is normal operation – no action is required.

2. Protect the water heater from freezing temperatures or shut off and drain the unit.

Figure 35 – Flame Sight Glass

PART 12 – TROUBLESHOOTING

LP-505 REV. 4.29.14

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PROBLEM POSSIBLE CAUSES

POSSIBLE REMEDIES

White “smoke” can

be seen coming out of the exterior exhaust gas vent.

Depending on the outside temperature, water vapor can be produced as the exhaust is vented.

This is normal operation – no action is required.

Display

Condition

Diagnostic

Possible Corrective Actions

Nothing appears

on the display

control panel but

the fan runs at full

speed

Control is not

receiving power

Check wiring for short circuit or incorrect

wiring

Correct wiring per wiring diagram including

connection of transformer to the control

Check transformer connection to the

control per wiring diagram. Check for

14V output of panel wire

Push the Power button on the control panel

Nothing appears

on the display

control panel and

no other water

heater

components are

operating

Control is not

receiving 120V power

Ensure service switch and/or circuit

breaker to water heater is turned ON

Turn on service switch or circuit breaker to

power water 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 the

installation manual

Inspect the fuse. Replace as necessary

Replace the fuse with the proper part found

in the replacement part section of this

manual. If fuse blows again, recheck the

wiring per diagram

Nothing appears

on the display

control panel, but

the water heater is

operating

Occurs when

communications is

lost from the control

to the display

Check for loose connections and proper

pin alignment / engagement on the

control’s plug

Check for continuity on the wire harness from the display to the control. See repair parts section for proper replacement part.

Cycle power off and on using water

heater power switch and check for

operation

Replace with new display module. See

repair parts section for proper replacement

part.

The water heater must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the maintenance and care of the water heater as outlined in this manual must be performed by the user/owner to assure maximum efficiency and reliability. Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could damage the water heater or system components, resulting in substantial property damage, severe personal injury, or death.

To prevent the potential of substantial property damage, severe personal injury, or death, eliminate all the materials listed in Error! eference source not found. from the area surrounding the water heater and the vicinity of the combustion air intake. If contaminates are found:

 Remove products immediately from area.  If contaminates have been there for an extended period, call a qualified service technician to inspect the water heater for

possible damage from acid corrosion. If products cannot be removed, immediately call a qualified service technician to re-pipe the combustion air intake piping away from the contaminated areas.

Table 24 – Troubleshooting Chart DIAGNOSTICS AND SUGGESTED CORRECTIVE ACTIONS

The water heater control is able to record information about the water heater’s condition at the time of the ten previous faults or errors. This information is available to view in the Installer Mode under the History screen.

The following screens may be displayed when reviewing the water heater history. The table below also includes diagnostic information and possible corrective actions.

Table 25 –Diagnostics and Suggested Corrective Actions

PART 13 – MAINTENANCE PROCEDURES

Check the Surrounding Area

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Failure to inspect the venting system and have it repaired by a qualified service technician can result in vent system failure, causing severe personal injury or death.

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. Read the list of potential contaminates and areas likely to have these contaminates in Error! eference source not found., Part 2. If any of these contaminates are in the room where the water heater is located, or combustion air is taken from one of the areas listed, the contaminates must be removed immediately or the intake pipe must be relocated to another area.

Ensure the Water Heater Cabinet is Closed

Ensure the water heater cabinet is closed. Tighten the two upper and lower screws to secure it. The cabinet must be closed while the water heater is running.

Check the Power Source

Make sure the power cord is properly connected. The main power line is connected to the manual switch box inside the water heater.

Check the Status of the Control Panel

Observe the Control Panel to ensure the water heater is powered on, and to check for any error codes. Clear any debris from the panel.

Check Exhaust Vent 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 service technician to inspect the water heater and the vent system.

Check Exhaust 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 condition. Notify a qualified service technician immediately if any problems are found.

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 sealed. Inspect the intake pipe bracing. Ensure bracing is undamaged and in good condition. Notify a qualified service technician if any problems are found.

Check Pressure Relief Valve

 Visually inspect the primary pressure relief valve and discharge pipe for signs of weeping or leakage.  If the pressure relief valve often weeps, the expansion tank may not be operating properly. Immediately contact a qualified

service technician to inspect the water heater and system.

Check the Condensate Drain System

 While the water heater is running, check the discharge end of the condensate drain tubing. Ensure no flue gas is leaking from

the condensate drain tubing by holding your fingers near the opening.

 If you notice flue gas leaking from the opening, this indicates a dry condensate drain trap. If problem persists, contact a

qualified service technician to inspect the water heater and condensate line and refill the condensate trap.

 If applicable, check the condensate neutralizer and ensure it is full of condensate neutralizing marble chips.

Cleaning the Air Intake Filter

The air intake filter should be cleaned once a month. If not, the water heater could encounter combustion problems. To clean the air intake filter:

1. Press the Power button on the control panel to turn off the water heater.

2. Disconnect the power supply from the water heater.

3. If water heater has been operating, wait for it to cool before continuing.

4. Remove the front cover of the water heater cabinet.

5. Pull the filter out of the air intake adapter.

6. Remove the filter from the plastic assembly and clean it with a toothbrush and clean running water. See Figure 36.

LP-505 REV. 4.29.14

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Have leaks fixed at once by a qualified service technician. Failure to comply could result in substantial property damage, severe personal injury, or death.

To avoid water damage or scalding due to relief valve operation, a discharge line must be connected to the valve outlet and directed to a safe place of disposal. This discharge line must be installed by a qualified service technician or heating/plumbing installer in accordance with the water heater installation manual. The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharge.

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

 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 service technician.

 Visually inspect for leaks around the internal water heater water connections and around the heat exchanger. Visually inspect

the external system piping, circulators, and system components and fittings. Immediately call a qualified service technician to repair any leaks

Operate Pressure Relief Valve

 Before proceeding, verify that the relief valve outlet has been piped to a safe place of discharge, avoiding any possibility of

scalding from hot water.

 Shut power off to the water heater. To avoid scalding, wait for water heater to cool before operating the relief valve.

 List the relief valve lever. If water flows freely, release the lever and allow the valve to seat. Watch the end of the relief valve

discharge pipe to ensure that the valve does not weep after the line has had time to drain. If the valve weeps, lift the lever again to attempt to clean the valve seat. If the valve does not properly seat and continues to weep, contact a qualified service technician to inspect the valve and system.

 If water does not flow from the valve when you completely lift the lever, the valve or discharge line may be blocked.

Immediately shut the water heater down per instructions on page 2 and call a qualified service technician to inspect the valve and system.

LP-505 REV. 4.29.14

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 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. Place a bucket under the appliance to collect the residual water inside the water heater.

2. Press the Power button on the control panel to turn off the electrical power to the water heater. Then turn off the gas valve.

3. Valve off the water heater from the system. If the water heater cannot be isolated from the system, turn off the main water valve. Open the hot water faucets in the system to aid in draining the system.

5. Remove the cold water inlet filter. Then clean it with a toothbrush and clean running water. See Figure 37.

Figure 37 – Draining the Water Heater

6. Reinstall the cold water inlet filter.

7. Restore water service to the water heater by opening the isolation valves, or turning on the main water valve.

8. Turn on the gas valve. Turn on electrical power to the water heater and press the Power button to turn the water heater 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 warranty.

1. Disconnect electrical power to the water heater.

2. Close the shutoff valves on both hot water outlet and cold water inlet lines (V1 and V2). See Figure38.

3. Connect one hose (D1, Figure 38) to the valve (V3) and place the free end in a bucket. Connect one of the hoses (D3) to the circulation pump outlet and the cold water inlet line to valve V4. Connect the other hose (D2) to the circulation pump inlet and place the free end in the bucket.

Figure 38 – Flushing the Water Heater

4. Pour tankless water heater cleaning solution into the bucket. Ensure the cleaning solution is approved for potable water systems. Place the drain hose (D1) and hose D2 to the pump inlet in the cleaning solution.

LP-505 REV. 4.29.14

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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. This will remove any possible harmful scale deposits.

7. Rinse the cleaning solution from the combination water heater as follows: a. Remove the free end of drain hose D1 from the bucket. b. Close service valve V4 and open shutoff valve V2. c. Do not open shutoff valve V1. d. Allow water to flow through the water heater for 5 minutes. e. Close shutoff valve V2.

8. Disconnect all hoses.

9. Remove the cold water inlet filter from the water heater and clean out any residues.

10. Reinsert the filter and ensure the filter cap is securely tightened.

11. Connect electrical power to the water heater.

12. Open a hot water faucet. Run the water heater continuously for five minutes to ensure all cleaning solution is purged from the

system. Check for leaks and ensure the water heater is operating properly.

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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

3-1

FRONT COVER

7850P-062

CONTROL

7850P-058

3-2

DISPLAY PANEL BRACKET

7850P-024

CONTROL BRACKET

7850P-066

3-3

DISPLAY PANEL

7850P-023

ROCKER SWITCH

7850P-059

IGNITION TRANSFORMER

7850P-045

FLOW CONTROL VALVE

7850P-053

GAS INLET NIPPLE

7850P-043

WATER INLET VALVE ASSY

7850P-018

OVERHEAT SENSOR

7850P-050

18-1

WATER INLET VALVE BODY

7850P-067

DHW SUPPLY PIPE ASSY

7850P-020

18-2

WATER INLET SENSOR

7850P-015

7-1

DHW SUPPLY PIPE

7850P-063

18-3

WATER INLET FILTER

7850P-017

7-2

WATER OUTLET SENSOR

7850P-019

18-4

WATER INLET FILTER CAP

7850P-016

N/A

CASE BRACKET (LEFT)

7850P-068 9 SIPHON ASSY

7850P-014

CASE BRACKET (RIGHT)

7850P-069

SIPHON AIR PRESSURE HOSE

7850P-064

INTAKE AIR ASSY

7850P-022

REPLACEMENT PARTS

Figure 39 – Cabinet Replacement Parts

Table 26 – Cabinet Replacement Parts

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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

31-3

EXHAUST GASKET 1

7850P-071

WATER TEMPERATURE

SENSOR

7850P-081

31-4

EXHAUST PIPE ASSY (DOWN)

7850P-034

WATER TEMPERATURE

OVERHEAT SENSOR

7850P-051

31-5

EXHAUST GASKET 2

7850P-072

DHW OUTLET PIPE

7850P-049

31-6

CONDENSATE GUTTER

7850P-073

WATER PIPING CLIP

7850P-055

FAN ASSEMBLY

7850P-006

DHW INLET PIPE

7850P-048

32-1

FAN

7850P-002

CERAMIC HEATER

7850P-076

32-2

O-RING

7850P-003

GAS VALVE PIPE

7850P-039

32-3

AGM (ACTUATOR)

7850P-004

GAS VALVE PIPE

7850P-040

SILENCER ELBOW

7850P-036

GAS VALVE ADAPTER

(STRAIGHT)

7850P-077

SILENCER BODY

7850P-035

GAS VALVE ASSY W/ PLUG

7850P-078

BURNER ASSY

7850P-011

47-1

GAS VALVE

7850P-012

35-1

BURNER HEAD

7850P-007

47-2

GAS VALVE PLUG

7850P-013

35-2

IGNITION ROD BRACKET

7850P-010

GAS VALVE ADAPTER

(90 DEGREE)

7850P-079

35-3

IGNITION ROD

7850P-008

GAS VALVE BRACKET

7850P-080

35-4

BLOWER HEAD BRACKET

7850P-074

BOTTOM HEAT EXCHANGER

BRACKETS

7850P-028

35-5

OVERHEAT SENSOR (BURNER)

7850P-009

TOP HEAT EXCHANGER

BRACKETS

7850P-082

Figure 40 – Heat Exchanger Replacement Parts

Table 27 – Heat Exchanger Replacement Parts

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Residential Use Warranty

Commercial Use Warranty

10 years – Heat Exchanger, 5 years – Parts

5 years – Heat Exchanger, 1 Year – Parts

USE DEFINTIONS - Residential Use means potable water heating in a single family residence. Commercial Use refers to all other

applications, including any space heating applications.

Advanced Heating and Hot Water Systems

P.O. Box 429 ∙ 120 Braley Road ∙ East Freetown, MA 02717 ∙ 508-763-8071∙ Fax: 508-763-3769

Limited Warranty for RT-180 / RT-199 Water Heaters

HTP warrants each instantaneous water heater and its parts to be free from defects in materials and workmanship according to the following terms, conditions, and time periods. The replacement water heater will be warranted for the unexpired portion of the applicable warranty period of the original water heater. The number of replacement water heaters is limited to one (1) per original water heater purchased. Replacement parts will be warranted for 90 days. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original owner of this water heater, and is non-transferable.

COVERAGE

A. Should a defect or malfunction result in a leakage of water within the above-stated warranty periods due to defective material or workmanship, malfunction, or failure to comply with the above warranty, HTP will replace the defective or malfunctioning water heater or part(s) with a replacement of the nearest comparable model available at the time of replacement. 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. These remedies are the purchaser’s exclusive remedies for breach of warranty. C. If government regulations, industry certification, or similar standards require the replacement water heater or part(s) to have features not found in the defective water heater or part(s), the owner will be charged the difference in price represented by those required features. If the owner pays the price difference for those required features and/or to upgrade the size and/or other features available on a new replacement water heater or part(s), the owner will also receive a complete new limited warranty for that replacement water heater or part(s). D. If at the time of a request for service the owner cannot provide a copy of the original sales receipt or the warranty registration, the warranty period for the water heater shall then be deemed to have commenced thirty (30) days after the date of manufacture of the water heater and NOT the date of installation of the water heater. E. This warranty extends only to water heaters utilized in heating applications that have been properly installed by qualified professionals based upon the manufacturer’s installation instructions.

OWNER RESPONSIBILITIES

To avoid the exclusion list in this warranty, the owner or installer must:

1. Maintain the water heater in accordance with the maintenance procedure listed in the manufacturer’s provided instructions.

Preventive maintenance can help avoid any unnecessary breakdown of your water heater and keep it running at optimum efficiency.

2. Maintain all related system components in good operating condition.

3. If the cold water supply line has a backflow preventer, then an expansion tank should be installed to allow for water expansion.

4. Use the water heater at water pressures not exceeding the working pressure shown on the rating plate.

WARRANTY EXCLUSIONS

This limited warranty will not cover:

1. Any water heater purchased from an unauthorized dealer or online retailer.

2. Any water heater not installed by a qualified heating installer/service technician, or installations that do not conform to ANSI, CSA,

and/or ETL standards, as well as any applicable national or local building codes.

3. Service trips to teach you how to install, use, maintain, or to bring the water heater installation into compliance with local building

codes and regulations.

4. Failure to locate the water heater in an area where leakage of the tank or water line connections and the combination temperature

and relief valve will not result in damage to the area adjacent to the water heater or lower floors of the structure.

5. Any failed components of the heat system not manufactured by HTP as part of the water heater.

6. Water heaters repaired or altered without the prior written approval of HTP.

7. Damages, malfunctions, or failures resulting from failure to install the water heater in accordance with applicable building

codes/ordinances or good plumbing and electrical trade practices.

8. Damages, malfunctions, or failures resulting from improper installation, failure to operate the water heater at pressures not exceeding

the working pressure shown on the rating plate, or failure to operate and maintain the water heater in accordance with the manufacturer’s provided instructions.

9. Failure to operate the water heater in an open system with a properly sized and installed thermal expansion tank.

10. Failure or performance problems caused by improper sizing of the water heater, expansion device, piping, or the gas supply line,

the venting connection, combustion air openings, electric service voltage, wiring or fusing.

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EPA DEFINITION OF POTABLE WATER

Contaminant

Level

Aluminum

0.05 to 0.2 mg/l

Chloride

250 mg/l

Color

15 color units

Copper

1.0 mg/l

Corrosivity

Non-corrosive

Fluoride

2.0 mg/l

Foaming Agents

0.5 mg/l

Iron

0.3 mg/l

Manganese

0.05 mg/l

Odor

3 threshold odor number

6.5 – 8.5

Silver

0.1 mg/l

Sulfate

250 mg/l

Total Dissolved Solids (TDS)

500 mg/l

Zinc

5 mg/l

11. Damages, malfunctions, or failures caused by improper conversion from natural gas to LP gas or LP gas to natural gas.

12. Damages, malfunctions, or failures caused by operating the water heater with modified, altered, or unapproved parts.

13. Damages, malfunctions, or failures caused by abuse, accident, fire, flood, freeze, lightning, acts of God and the like.

14. Tank failures (leaks) caused by operating the water heater in a corrosive or contaminated atmosphere.

15. Damages, malfunctions, or failures caused by operating the water heater with an empty or partially empty tank (“dry firing”), or

failures caused by operating the water heater when it is not supplied with potable water, free to circulate at all times.

16. Failure of the heater due to the accumulation of solid materials and lime

deposits.

17. Any damage or failure resulting from improper water chemistry, or

heating anything other than potable water. DEFINITION OF POTABLE WATER - Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in the table. HTP, Inc. will warrant the heat exchanger coil for hardness up to 12 Grains per gallon.

18. Components of the water heater that are not defective, but must be

replaced during the warranty period as a result of reasonable wear and tear.

19. Damages, malfunctions, or failures caused by subjecting the water

heater to pressures or firing rates greater than those shown on the rating label.

20. Damages, malfunctions, or failures resulting from the use of any

attachment(s) not supplied by HTP.

21. Water heaters moved from the original installation location.

22. Water heaters that have had their rating labels removed.

PROCEDURES FOR WARRANTY SERVICE REQUESTS

Any claim for warranty assistance must be made promptly. Determine if the water heater is “in-warranty” (that is, within the applicable warranty period) by reviewing a copy of the original sales receipt or warranty registration. The owner must present a copy of the original sales receipt or warranty registration for a warranty service request. If the water heater is “in-warranty”, contact the distributor from whom the water heater was purchased (or the installer) for assistance. Be prepared to provide the retailer or installer with a copy of the original receipt, complete model and serial numbers, and the date of installation of the water heater, in addition to explanation of the water heater problem. Warranty coverage is subject to validation of “in-warranty” coverage by HTP claims department personnel. All alleged defective or

malfunctioning parts must be returned to HTP via the local distribution channels where original purchase was made. NOTE: Any

parts 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 all warranty conditions are satisfied, HTP will provide replacement parts to the retailer.

For questions about the coverage of this warranty, please contact HTP at the address or phone number stated below:

HTP P.O. Box 429 120 Braley Road East Freetown, MA. 02717 Attention: Warranty Service Department

1(800) 323-9651

SERVICE, LABOR AND SHIPPING COSTS

This limited warranty does not extend to any shipping charges, delivery expenses, or administrative fees incurred by the owner in repairing or replacing the water heater or part(s). This warranty does not extend to labor costs beyond the coverage specified in this warranty document. All such expenses are the owner’s responsibility.

LIMITATIONS OF YOUR HTP WARRANTY AND REMEDIES

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM HTP’S NEGLIGENCE, ACTUAL OR IMPUTED. THE REMEDIES OF THE PURCHASER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL DAMAGES, SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, PROPERTY DAMAGE, LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF HTP TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE. NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES, REMEDIES OR THIS LIMITATION WILL BE BINDING UPON HTP. UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF HTP. THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL PURCHASER ONLY.

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. These are the only written warranties applicable to the commercial water heater manufactured and sold by HTP. HTP neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said commercial water heaters. HTP reserves the right to change specifications or discontinue models without notice.

LP-505 REV. 4.29.14

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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. Such product failures ARE NOT covered under warranty.

INSPECTION ACTIVITIES

DATE LAST COMPLETED

PIPING

1st YEAR

2nd YEAR

3rd YEAR

4th YEAR*

Near water heater piping

Check water heater and system piping for any sign of leakage. Leaking pipes could cause property damage. Make sure all piping is properly supported. Flush tankless heat exchanger annually (more in hard water conditions). See User’s Information manual for instructions.

Vent

Check condition of all vent pipes and joints. Ensure all vent piping is properly supported. Check for obstructions exhaust and intake termination points.

Gas

Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.

SYSTEM

Visual

Do a full visual inspection of all system components.

Functional

Test all functions of the system (Heat, Safeties)

Temperatures

Verify safe settings on water heater or Anti-Scald Valve

Temperatures

Verify programmed temperature settings

ELECTRICAL

Connections

Check wire connections. Make sure they are tight.

Smoke and CO detector

Verify devices are installed and working properly. Change batteries if necessary.

Circuit 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 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 with clean water.

Neutralizer

Check condensate neutralizer. Replace if necessary.

Condensate hose

Disconnect condensate hose. Clean out dirt and re-install. (NOTE: Verify the flow of condensate, making sure that the hose is properly connected during final inspection.)

GAS

Pressure

Measure incoming gas pressure (3.5” to 14” W.C.)

Pressure Drop

Measure drop in pressure on light off (no more than 1”

W.C.)

Check gas pipe for leaks

Check piping for leaks. Verify that all are properly supported.

COMBUSTION

CO/CO2 Levels

Check CO and CO2 levels in Exhaust. Record at high and low fire.

SAFETIES

ECO (Energy Cut Out)

Check continuity on Flue and Water ECO. Replace if corroded.

MAINTENANCE REPORT

The water heater requires minimal periodic maintenance under normal conditions. However, in unusually dirty or dusty conditions, periodic vacuuming of the cover to maintain visibility of the display and indicators is recommended.

Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the water heater. Installer must also inform the owner that the lack of proper care and maintenance of the water heater may result in a hazardous condition.

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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 4th year as required.

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MAINTENANCE NOTES

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Customer’s Name:

Installation Address: Date of Installation:

Installer’s Code/Name: Product Serial Number(s):

Combustion Setting at Time of Installation:

Comments: Installer’s Phone Number:

Signed by Installer:

Signed by Customer:

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.

IMPORTANT NOTES:

Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative.

Distributor/Dealer: Please insert contact details.

LP-505 REV. 4.29.14

HTP RT-180, RT-199 Installation & Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual