HTP Hydra Smart RT-199, Service Manual

Page 1: ...o not try to light any appliance 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 performed by a qualified installer service agency or the gas supplier If the information in these in...

Page 2: ...ification 36 Control Panel Mode 36 Domestic hot water temperature control 38 Domestic hot water high temperature control 38 Water flow rate 39 Fan speed 39 Lock mode 40 Operating temperature Heat Exchanger 40 DHW Outlet Water Temperature 41 Exhaust Gas Temperature 41 DHW Inlet Water Temperature 42 Supply Power Time X 10 hours 42 View Burner Operating Time unit 1 Hour 43 View Burner Operating Time ...

Page 3: ... instructions Main Controller 77 Ignition Transformer 78 Flame Detection Sensor 79 Gas leak detector 79 Air Pressure Switch 80 Gas valve 81 Condensate trap 82 Flow control sensor 83 Cold water inlet filter assembly 84 Cold water inlet filter 85 Mixing valve 85 Air gas mixer AGM 86 BLDC Fan assembly 87 Chapter 6 Maintenance Cleaning Air Intake Filter 88 Cleaning Cold Water Inlet Water 88 Flushing W...

Page 4: ...tion 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 W17 3 H27 6 D14 8 Weight 88 lbs Sub Heat Exchanger Water Capacity DHW Under 2 Gallon Control Panel Main Controller P 920C GTH 9500C Water Pressure Min 15 Max 150 PSI Connection Sizes Cold...

Page 5: ...Mixing Valve 10 Air Pressure Switch 11 N A 12 Manual Power Switch 13 Water Adjustment Valve 14 Main Controller 15 Secondary Heat Exchanger Assembly 16 Gas Inlet Pipe 1 17 Flame sight glass 18 Burner Case NO Name of Component 19 Exhaust Duct 20 Gas Valve 21 Gas Inlet Pipe 2 22 BLDC Fan 23 Air Intake Pipe Adapter 24 Gas Inlet Adapter 25 Freeze Protector 26 DHW Outlet Adapter 27 Condensate Trap 28 Co...

Page 6: ... 1 5s 2s If normal ignition Time chart Flow chart If Flame Extinguishes If abnormal ignition Alarm after the 10 trial IGNITION IGNITION IGNITION GAS VALVE GAS VALVE GAS VALVE FLAME DETECTION FLAME DETECTION FLAME DETECTION Chapter 1 Product Characteristics Chapter 1 Product Characteristics ...

Page 7: ... Flow Chart Operation Flow Chart Check setting values Setting Temp Errors Initializing equipment Timer Stepping Motor Gas Valve and Others Clear Watchdog Check communication Check A DC Check Error Check Water Flow ignore below 0 39 GPM Igniter Gas Valve OFF RPM for Pre purge Time Setting SetRPM for Pre purge Setting for Fan stop MCU Testing Igniter ON Water Flow 0 39 GPM and Doesn t have Error Fro...

Page 8: ...13 14 LP 532 REV 8 13 2014 LP 532 REV 8 13 2014 CN11 CN9 CN10 CN12 CN8 CN6 CN1 CN3 CN14 CN4 CN5 CN7 Wiring diagram Chapter 1 Product Characteristics Chapter 1 Product Characteristics Jumper Wire ...

Page 9: ...lame Detect Sensor SELV 5VDC 8 2 OP S Operation water temperature sensor SELV 5VDC 9 3 DH S DHW temperature sensor SELV 5VDC 10 4 I S Inlet water temperature sensor SELV 5VDC 11 5 BG S Exhaust temperature sensor SELV 5VDC 12 6 ST S Unused 13 7 SP S Unused 14 CN12 SMW250 07 1 AGM AGM Stepper motor coil Y phase SELV 24VDC 2 AGM Stepper motor coil Y phase SELV 24VDC 3 AGM Stepper motor coil X phase S...

Page 10: ... 2 5mW Min While not boiling 4 Fixed Number of Heating 8 15 Sec Max 63 2 reaching time while boiling 5 Range of Workable Temperature 4 230 F Chapter 2 Components description Chapter 2 Components description CN7 Description Part HX Temperature Sensor 7850P 081 Exhaust Temp Sensor 7850P070 Water Outlet Sensor 7850P 019 Water Inlet Sensor 7850P 015 Check Point Main PCB CN7 Function The controller com...

Page 11: ...tor Description Part Burner Overheat Switch 7850P 009 Check Point Main PCB CN9 CN11 Function Bunner Overbheat Switch prevents damages to the burner plate caused by temperature exceeding 302 F Failure Event Detects overheating temperature is switch has an obnormal condition Effects Water Heater shuts down if burner plate temperature exceeds the setting temperature Error Code Er 20 Er 43 Diagonostic...

Page 12: ...ion white connector Description Part Gas Leak Detection Sensor 7850P 093 Check Point Main PCB N A Function This senosr shutsdown the unit if gas leak is detected Failure Event Gas leak detection sensor is not operating properly Effects Risk of explosion and personal injury Error Code Er 40 Diagonostic Follow instruction on the first page of the manual Check for leakage around the gas valve and gas...

Page 13: ... sensor green connector Flow2 sensor blue connector DC 14V white connector Description Part APS Air Pressure Switch 7850P 047 Check Point Main PCB CN 11 Function This component monitors the flue for blockage Failure Event Combustion noise is generated Imperfect and lifting flame occurs The unit will not ignite Effects Pressure due to exhaust blockage will affect the water heater operation Error Co...

Page 14: ... flow rate is not detected and water leakage occurs around the flow control valve Effects Ignition sequence does not start Operation of product is stopped once water leakage is detected Error Code Er 65 Diagonostic Restart the unit Check the connection around the flow control valve Color Wire Number IWM Inlet Water Modulation GND yellow connector IWM Stepper motor position green connector VDD whit...

Page 15: ... Generates sparks energy to ignite the fuel Failure Event Sparks energy is not generated Effects The unit does not ignite Error Code Er11 Diagonostic Check wiring for proper connection Check voltage range Color Wire Number Ignition Transformer red connector Ignition Transformer red connector Input voltage Output current Output voltage 120V 60Hz 15 2kW 6 2mA 1 Electrical Characteristics Maximum wor...

Page 16: ...xide exceeding the reference Error Code Er 67 Diagonostic Restart the water heater Check wiring for proper connection Check the fan intake Color Wire Number Air Gas Mixer black connector AGM Y Phase Air Gas Mixer brown connector AGM Y Phase Air Gas Mixer red connector AGM X Phase Air Gas Mixer orange connector AGM X Phase Air Gas Mixer yellow connector GND Air Gas Mixer green connector AGM Positio...

Page 17: ...ion Supplies ir and fuel to the burner Failure Event Abnormal noise occurs at the fan Abnormal fan speed RPM Poor connection Effects Abnormal combustion Abnormal noise occurs The unit does not operated Error Code Er 41 Diagonostic Check vent blockage Check BLDC fan wiring for proper connection Check voltage range using a multimeter Color Wire Number BLDC FAN GND blue ⓒ connector 30vDC Fan start co...

Page 18: ...c Check the hose for blockage or bending Color Wire Number N A Description Part Heat Exchanger STS 7850P 032 Check Point Main PCB N A Function The component heats the water by absorbing high temperature heat generated by the burner Failure Event Water or exhaust gas leakage through the crack Abnormal heat exchange Effects Operation of product is stopped Exhaust gas leakage Abnormal noise occurs Er...

Page 19: ...call reset when the frequency is whithin 3Hz of frequency standards Over heating protection The water heater has two overtemperature switch Over temperature switch is attached to the burner and the outlet side against the failure of the temperature sensor dual protection device Overheat error occurs when the temperature switch is open and close until the fan is operated Gas leakage detecting The c...

Page 20: ...hange 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 Tim...

Page 21: ...PM by pressing dial button for 1 sec when b Fr shows up Press the dial button for 1 sec when d Lc shows up Press dial button for a sec again to go back to b Fr mode Press dial button for a sec again to go back to d Lc mode Press current status button with b Fr mode to go back to the initial status Press current status button with d Lc mode to go back to the initial status Fan RPM s current status ...

Page 22: ...or 1 sec when H Eh shows up Press dial button for a sec again to go back to the previous mode Press current status button with H Eh mode to go back to the initial status Current exhaust gas temperature status will be displayed ex 130 After A GA has been displayed by pressing current status button for 5 secs turn the dial until it shows h In Press dial button for 1 sec when h In shows up Press dial...

Page 23: ...al button for 1 sec when I rt shows up Press dial button for 1 sec when I rt shows up Press dial button for 1 sec when I rt shows up Press dial button for a sec when 2 rh shows up Current power input time will be shown ex 375hr Press current status button for 1 sec after confirmation to go back to the initial status Turn the dial until 2 rh shows up Press dial button for a sec when 3 rh shows up P...

Page 24: ...atus button for 5 secs during panel power off to enter installer setting mode Press dial button for 1 sec when 2 cE shows up Turn the dial to set on status when initial off shows up Default off mode Press dial button during on status to save the setting 2 cE is displayed and then press the dial button for one second Press current status button for a sec to go back to initial status after confirmat...

Page 25: ... up Turn the dial to the desired setting when initial 0 is displayed Range 30 30 Default 0 Turn the dial to on state Default off Press dial button to save the setting Press dial button to save the setting Press current status button for a sec to go back to initial status after confirmation Press current status button for a sec to go back to initial status after confirmation 5FH is displayed and th...

Page 26: ...l shows up Turn the dial until 9 Cn shows up Turn the dial to on status when initial off shows up Default off Press dial button to save the setting Press dial button to save the setting Turn the dial to set the cascade oper ation quantity Press dial button to save the setting Turn the dial to master product is 01 slave products from the 02 set 12 dl is displayed and then press the dial button for ...

Page 27: ...button for 5 secs turn the dial until it shows J AG Press dial button for 1 sec when J AG shows up Turn the dial to on status when initial off shows up Default off Press dial button to save the setting 11 dr is displayed and then press the dial button for one second Chapter 3 How to use control panel 2 Gas Detection 1 Flame detection Chapter 3 How to use control panel ...

Page 28: ...heat 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 ...

Page 29: ...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 Register Ram Rom I O Port AD Abnormal Important EPROM Data or Safe Data Abnormal This Error Code will go away when t...

Page 30: ...ter closing front cover ITEM Normal operating settings Before ignition More than DC 2 5V After ignition Less than DC 2 5V Please check flame sensor wire color of connector in the main controller Chapter 4 Troubleshootion Error code Meaning Cause DHW overheating issue Automatic reset If the temperature on the water temperature sensor tagged OP on Pppe and the water outlet sensor exceed 199 4F error...

Page 31: ...temperature is not high Check connector and if no problem measure resistance of the overheating switch located at heat exchanger outlet and replace overheating switch when the value is 0Ω Chapter 4 Troubleshootion Error code Meaning Cause Air Pressure Switch open Manual reset When exhaust vent or condensate blockages occur error code 29 will appear Failure event In case of vent or condensate block...

Page 32: ...malfunction so sensor needs to be replace Chapter 4 Troubleshootion Error code Meaning Cause Water Outlet Sensor error Automatic reset Error is displayed when DHW outlet temperature sensor wiring line is disconnected or faulty Failure event Water outlet sensor faulty or disconnected Check point Check if Water Outlet Temperature Sensor wiring and main controller connected at water outlet adapter is...

Page 33: ...ter temperature sensor s socket and measure the resistance value If value is 0Ω it s a sensor s malfunction so replace it Chapter 4 Troubleshootion Error code Meaning Cause Exhaust Temperature sensor error Automatic reset When exhaust temperature sensor wiring line is disconnected or faulty Failure event Exhaust temperature sensor faulty or disconnected Check point Check if exhaust temperature sen...

Page 34: ...ver is secured Flame detection sensor can dtect external light source and cause an error code Please check flame detection sensor s connecting line and ensure correct position as shown From more than DC 2 5V after ignition safety cut off will appear ⓐ When setting before ignition is less than DC 2 5V Replace infrared sensor ⓑ When setting after ignition is more than DC 2 5V Replace infrared sensor...

Page 35: ...etermined repair leak and reassemble Check conditions of O rings and gaskets and replace them if damaged If leaks are not present on the gas piping and valve start the unit and monitor for leaks around blower assembly and connection to determine source of leaks If all things are normal replace main controller Chapter 4 Troubleshootion Error code Meaning Cause Excess fan speed detected Manual reset...

Page 36: ...re event When burner overheating switch s temperature exceeds 392 F error code will appear Check point Check to see if the default DIP SWITCH settings have been changed from the factory settings assure that default settings are set to correct overheating condition When all the things are normal check gas nozzle Check assembly condition of burner and heat exchanger Check burner plate for distortion...

Page 37: ...otion Error code Meaning Cause Mixing valve error Manual reset Unable to operate normally due to manual reset error When flow rate decreases temperature gap gets bigger Failure event Mixing valve operation error Check point If all things are normal replace main controller Mixing Valve recognizes zero point after turning off and on the power Check indication of error after basically turning off and...

Page 38: ...ping the operation Chapter 4 Troubleshootion Error code Meaning Cause Flame detector error Automatic reset When flame is detected before ignition error code 72 appears Failure event Flame detected before ignition Check point From more than DC 2 5V after ignition safety cut off will appear When setting before ignition is less than DC 2 5V Replace infrared sensor When setting after ignition is more ...

Page 39: ...detects vent temperature higher than 149 F Er 94 is displayed Failure event Exhaust temperature overheating issue Check point Please check the blockage of flue intake and exhaust pipes Check to see if the default DIP SWITCH settings have been changed from the factory settings assure that default settings are set to correct overheating condition When all check points are normal related to the inter...

Page 40: ...mer 1 Close the gas shut off valve 2 Turn the power off 3 Disconnect the electrical connection to the main controller 4 Remove the cable connected to the igniter 5 Remove two screws to separate ignition trans former from the water heater cabinet 6 Separate ignition transformer from the bracket by unlocking the palstic pieces on the back side of the bracket 7 Replace ignition transformer with new c...

Page 41: ...5 Replace flame detection sensor with new component 6 Assembly is in the reverse order as the part was repaired 7 Open the gas shut off valve 8 Turn the power on 9 Turn the unit on and ensure proper operation NOTE Ensure the flame detection sensor is properly secured Chapter 5 Replacement instructions Main components Replacement Instructions 5 Air pressure swtich APS 1 Close the gas shut off valve...

Page 42: ... result in death or serious personal injury Chapter 5 Replacement instructions Main components Replacement Instructions 7 Condensate Trap 1 Close the gas shut off valve 2 Turn the power off 3 Removed condensate trap drain cap and ensure it is drained properly 4 Loosen two screws to open the front cover 5 Remove hose inlet hocse from the HX condensate pan connected to condensate trap 6 Remove hose ...

Page 43: ...l water valves and drain water from unit 4 Loosen two screws to open the front cover 5 Loosen two screws and remove temperature sensor connected with DHW inlet filter 6 Remove two clips from flow control valve 7 Separate flow control valve from DHW pipe and DHW inlet filter 8 Loosen two top screws and four bottom screws connected with DHW supply filter and adapter 9 Replace cold water inter filter...

Page 44: ... water valves 13 Turn the unit on and ensure proper operation Chapter 5 Replacement instructions Main components Replacement Instructions 12 Air Gas Mixer AGM 1 Close the gas shut off valve 2 Turn the power off 3 Separate intake pipe attached to AGM 4 Remove AGM connector 5 Remove fan connector 6 Loosen gas pipe nut connected with AGM 7 Loosen burner plate bracket s by loosen two screws as shown 8...

Page 45: ...anel to turn off the water heater and turn off the gas valve 2 Disconnect power supply to water heater 3 Remove front cover of water heater 4 Pull the filter out of air intake adapter 5 Remove the filter from the plastic assembly and clean it with a small brush and clean running water 6 Dry the filter completely and then reinsert the filter into the plastic assembly 7 Replace the front cover and r...

Page 46: ... open shut off valve V1 Allow water to flow through the water heater for 5 minutes Close shut off valve V2 8 Disconnect all hoses 9 Remove the cold water inlet filter from 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 hot water faucet Run the water heater continuously for five m...

Page 47: ...ONDENSATE GUTTER 7850P 073 41 WATER PIPING CLIP 7850P 055 32 FAN ASSEMBLY 7850P 006 42 DHW INLET PIPE 7850P 048 32 1 FAN 7850P 002 43 CERAMIC HEATER 7850P 076 32 2 O RING 7850P 003 44 GAS VALVE PIPE 7850P 039 32 3 AGM ACTUATOR 7850P 004 45 GAS VALVE PIPE 7850P 040 33 SILENCER ELBOW 7850P 036 46 GAS VALVE ADAPTER STRAIGHT 7850P 077 34 SILENCER BODY 7850P 035 47 GAS VALVE ASSY W PLUG 7850P 078 35 BU...

Page 48: ...93 94 LP 532 REV 8 13 2014 LP 532 REV 8 13 2014 Memo Memo ...