IBC 199,000 Btu/hr High Efficiency Condensing Tankless Water Heater

Product Information: High Efficiency Condensing Tankless Water Heater

The High Efficiency Condensing Tankless Water Heater is a powerful and efficient heating system that provides hot water on demand. It has a maximum input of 199,000 BTU/hr and can be fueled by either natural gas or propane. The water heater is designed for indoor installation only and is wall-hung for space-saving convenience. It features electronic ignition and forced draft direct venting for safe and reliable operation.

The water heater is equipped with safety devices such as a flame proving module, flue gas temperature sensor, and protective fuse. It also has freeze protection to prevent damage in cold weather conditions. The unit comes with a certified design and meets all necessary safety standards.

Key Specifications

• Input: 199,000 BTU (Natural Gas or Propane)
• U.E.F DHW Flow Rate: 28.5-199 GPM (LPM)
• Water Pressure: 40-150 psig
• Dimensions: 17.7 x 29.8 x 10.9 inches (450 x 757 x 277 mm)
• Weight: 68 lbs (31 kg)
• Venting Type: Forced Draft Direct Vent
• Power Supply: 120Vac, 60Hz

Product Usage Instructions:

Installation:

1. Ensure that installation is performed by competent, qualified, licensed, and trained heating technicians.
2. Follow all instructions and applicable national and local codes for a safe and proper installation.
3. Choose an appropriate location for indoor installation, ensuring proper venting and clearance from combustible materials.
4. Connect the water heater to the cold water inlet, hot water outlet, and gas inlet using the provided 3/4 Male NPT connections.
5. Ensure proper electrical supply with 120Vac and 60Hz.

Operating:

1. Ensure that the gas supply (Natural Gas or Propane) is connected and the gas pressure is within the specified range.
2. Turn on the main water supply to the unit.
3. Set the desired temperature using the controls on the water heater.
4. The water heater will automatically ignite and heat the water to the desired temperature.

Safety Considerations:

• Never operate the water heater without proper ventilation.
• Avoid contact with hot surfaces to prevent burns.
• Keep children and pets away from the water heater to prevent accidents.
• In case of any issues or malfunctions, contact a qualified technician for servicing.

Following these instructions will ensure the safe and efficient operation of your High Efficiency Condensing Tankless Water Heater. Refer to the user manual for additional details and maintenance guidelines.

INSTALLATION AND OPERATING INSTRUCTIONS

HIGH EFFICIENCY CONDENSING TANKLESS WATER HEATER 199,000 Btu/hr Model
(Natural Gas or Propane)
WARNING: 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 or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: · Do not try to light any appliance. · Do not touch any electrical switch; 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.

TANKLESS WATER HEATER 199

WARNING
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.

SAFETY CONSIDERATIONS
Installation, start-up and servicing of the unit must be done with due care and attention, and must only be performed by competent, qualified, licensed and trained heating technicians. Failure to read and comply with all instructions and applicable National and local codes may result in hazardous conditions that could result in property damage and injury to
occupants which in extreme cases might result in death.

HAZARDS & PRECAUTIONS

DANGER
Points out an imminently hazardous situation which must be avoided in order to prevent serious injury or death.

WARNING
Points out a potentially hazardous situation which must be avoided to prevent serious injury or death.

CAUTION
Points out a potentially hazardous situation which must be avoided to prevent possible moderate injury and/ or property damage
BEST PRACTICES
Points out recommendations for better installation.

NOTE
Points out installation, maintenance and operation details that will result in enhanced efficiency, longevity and proper operation of your unit.

Supplied with the unit – The unit is shipped with an accessory parts kit consisting of the following items:
· 1 x Wall Mounting Kit- Part # P-081344 · 1 x Condensate trap assembly · 1 x Documentation set · 1 x Propane Conversion Kit: Part # P-081014

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SPECIFICATIONS

SPECIFICATION Input (Natural Gas or Propane*) – MBH U.E.F DHW Flow Rate – GPM (LPM)

35°F (19°C) Temp Rise 45°F (25°C) Temp Rise

199,000 BTU 28.5-199 0.9 10.1 (38) 7.9 (30)

Dimensions – in/mm Weight (empty) – lbs/Kg Installation Type Venting Type
Water Pressure – psig Min Gas Pressure (Nat. Gas or Propane*) – inch w.c.

67°F (36°C) Temp Rise

5.4 (20)

17.7 x 29.8 x 10.9 (450 x 757 x 277)

68 / 31

Indoor only wall-hung

Forced Draft Direct Vent

Electronic Ignition

40 – 150

4

Max Gas Pressure (Nat. Gas or Propane*) – inch w.c.

14

Minimum Flow Rate to activate DHW heating GPM (LPM)

0.5 (1.9)

Connection Sizes

Cold Water Inlet

3/4″ Male NPT

Hot Water Outlet

3/4″ Male NPT

Gas Inlet

3/4″ Male NPT

Pressure Vessel water content ­ USG/Liters Ambient Temperature ­ Low (°F/°C)

0.19 / 0.72 32 / 0

Ambient Temperature ­ High (°F/°C)

122 / 50

Max relative humidity (non-condensing)

90%

Min water Temperature ­ Domestic Hot Water (°F/°C)

105 / 40

Max water Temperature ­ Domestic Hot Water (°F/°C)

149 / 65

Power Supply

Main Supply

120Vac, 60Hz

Watts @ full fire

100 watts

Materials

Casing

Painted steel and plastic

Heat Exchangers

Copper tubes in AL block

Venting

Intake & Exhaust

2″ or 3″ PVC, CPVC, Polypropylene

Canada venting must meet ULC S636

Venting Clearances

0″ to combustibles

Safety Devices

Flame Proving module, Flue Gas Temperature Sensor, Protective fuse

Certified design

ANSI Z21.10.3 · CSA 4.3

Freeze Protection

Yes

• Units ship configured for Natural Gas (NG) with a Propane (LP) conversion kit included. Converting an LP unit back to NG requires the certified NG conversion kit that can be ordered separately.

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DANGER

HOT

BURN

° Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.
° Children, disabled, and elderly are at highest risk of being scalded. ° See instruction manual before setting temperature at water heater. ° Feel water before bathing or showering. ° Temperature limiting valves are available, see manual.

TIME/TEMPERATURE RELATIONSHIP IN SCALDS

WATER TEMPERATURE TIME TO PRODUCE A SERIOUS BURN

120°F (49°C)

More than 5 minutes

125°F (52°C)

1 ½ to 2 minutes

130°F (54°C)

About 30 seconds

135°F (57°C)

About 10 seconds

140°F (60°C)

Less than 5 seconds

145°F (63°C)

Less than 3 seconds

150°F (66°C)

About 1 ½ seconds

155°F (68°C)

About 1 second

Table courtesy of Shriners Burn Institute

WATER HEATER INSTALLATION GUIDELINES
WARNING
° This unit must be installed in accordance with local codes, if any; if not follow the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CAN/CSA B149.1, as applicable.
° Failure to correctly install and operate this appliance can result in severe personal injury
or death.
° The unit shall have a pressure relief valve installed within 6″ [152mm] of the DHW HOT
outlet connection. Refer to the unit’s User Manual before operating the relief valve.
° The unit requires a pressure relief valve identified with the ASME V or HV symbol and
set to relieve at or below 150psi of domestic water pressure and a minimum relieving capacity of 199,000 Btu/hr with 3/4″ NPT threads. For safe operation of the unit, the relief valve must not be removed from its designated point of installation or plugged.
° Read and follow warnings and instructions.

CAUTION
° Hotter water increases the risk of scald injury. Before changing the temperature setting, see
instruction manual.
ADJUSTABLE TEMPERATURE SETTING

° Touch the panel above the white dot , then touch the Faucet . Adjust the water temperature

with the Plus + and Minus ­ then touch the Return button

to save the changes.

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TANKLESS WATER HEATER 199

DANGER
Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead shut off the gas supply at a location external to the appliance.
WARNING
Do not use this unit if any part has been under water. Immediately call a qualified service technician to inspect the unit and to replace any part of the control system and any gas control that has been under water.
CAUTION
Care must be taken to properly size the unit for its intended use. Prolonged full-fire run time, oversizing or under-sizing, and incorrect flow rates through the unit can lead to increased maintenance costs, equipment stress and premature failure.

PRE-INSTALLATION CHECK
Carefully consider clearances and access, vent travel and termination, gas supply, condensate removal and combustion air supply.
Consider the following:
· Install the water heater in areas where the combustion air source is free of
contamination. Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a unit. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning fluids, de- greasers and paint-removers all contain vapors that can form corrosive acid compounds when burned in a gas flame. Avoid airborne chlorides such as those released with the use of laundry detergents.
· Locate the unit where water leakage will not result in damage to the area (for
example, do not install above carpeting). If you cannot find a suitable location, install a drain pan with an adequate drain under the appliance.
· At a new construction site, or during renovations, protect the unit from drywall
dust or other construction related contaminants.
Ensure combustion air is drawn from a CLEAN source (e.g. outdoors).
Isolate the unit from interior dust sources.
· When the unit is in operation, assess the impact of the steam plume normally
experienced at the exhaust terminal of a condensing water heater. Generally, intake and exhaust pipes should terminate at a rooftop or wall location free of obstructions. Water heater condensate is corrosive. Protective measures must be taken to prevent corrosion damage to metal roofs or other metal building components in contact with the condensate. Keep exhaust plumes well away from all building air intakes including those of neighboring properties by following all requirements of the jurisdiction having authority and this installation manual.
· Place the exhaust outlet so it reaches 12″ minimum above the down-turned
intake to avoid flue gas contamination of the combustion air.
· For sidewall venting options: Both the inlet and exhaust terminations must
be located on the same side of the building. You can elevate both pipes in “periscope style” after passing them through the wall to gain required clearance above grade and snow level.
· Examine the condensate outlet to ensure proper disposal of condensate
will occur during operation. A condensate neutralizer must be installed if the condensate will flow into a drain subject to corrosion.
· Ensure that the pressure relief valve is installed with no valves or other
means of isolation between its inlet and the unit. Pipe the relief valve with unobstructed piping (minimum 3/4″ diameter) to a safe discharge location.
· In locations where power supply quality varies or is unstable, consider
installing surge protection and power conditioners (up to and including battery back-up uninterrupted power supply devices).
· Ensure the domestic hot water demands are considered before purchasing
the Tankless Water Heater. You may need to add a storage tank.

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NOTE
Commercial use is allowed only if the unit is regularly maintained, and the heat exchanger is cleaned at least once a year, or more often if the unit is experiencing heavy use. Note: If the appliance is serving only one residential home in a multi-family building, then the appliance shall be considered used for residential use.

1.0 INSTALLATION
1.1 GENERAL
This High Efficiency Condensing tankless water heater is designed to be used for domestic (residential) purposes. Domestic use is considered to be an average annual gas usage of less than 4000 m3 (140,000 ft3) for natural gas or 5680 L (1500 US gallons) for propane. The products are fully condensing units with variable input ranges (see specification chart – page 3). The units are approved as “Category IV” vented appliances using Direct Vent (sealed combustion). Figures 1a and 1b show outer case dimensions and piping. Use this diagram to find a suitable location for the unit. See also Section 1.3 Location.

3.1in [79mm]

17.7in [450mm]

10.9in [278mm]

29.8in [757mm] 4.3in [109mm] FRONT Figure 1a: Dimensions / Connections for Tankless Water Heater
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TANKLESS WATER HEATER 199

BRACKET
4.5in [114mm]

16in [406mm]

4.7in

4.7in

[120mm] [120mm]

B (ALTERNATEB)
F D

B (ALTERNATE)

TOP

A

CL E

C

3.7in [95mm]

2.6in 2in [65mm] [50mm]

6.7in [170mm]

BOTTOM

Figure 1b: Dimensions / Connections for Tankless Water Heater

DESCRIPTION

A Exhaust Outlet

B Combustion Air inlet

C

Cold Domestic Water Connection & inlet filter

D

Hot Domestic Water Connection

E Gas Inlet

F Condensate Outlet

Table 1: Connections

TANKLESS WATER HEATER 2″ Schedule 40 PVC 2″ Schedule 40 PVC 3/4″ Male NPT
3/4″ Male NPT 3/4″ Male NPT 3/4″ Hose

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WARNING
– Keep the unit area free and clear of combustible materials, gasoline, and other flammable vapors and liquids.
– Combustion air must not be drawn from areas containing corrosive air from swimming pools or spas, including air directly next to outdoor pools and spas.
– The unit must not be exposed to water leaks from piping or components located overhead. This includes condensation dropping from un-insulated cold water lines overhead.
– Ensure the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and when servicing (pump replacement, condensate trap servicing, control replacement, etc.)
-California Proposition 65
This product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.

1.2 CODE REQUIREMENTS
The Tankless Water Heater is certified under CSA 4.3 / ANSI Z21.10.3.
The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, (latest edition) in the US or Natural Gas and Propane Installation Code, CSA B149.1 (latest edition) in Canada. The installation must also conform to the Canadian Electrical Code Part 1 in Canada or the National Electrical Code ANSI/NFPA 70 (latest edition) in the US.
1.3 LOCATION
The unit is designed and approved for indoor installation. Its venting options provide flexibility of location; for example, placement in an alcove, basement, utility room or closet. The unit is approved for installation in a closet (see Table 2 for clearances to combustibles).
Conditions for safe installations
Ensure that the surrounding conditions are between 32°F [0°C] and 122°F [50°C] and less than 90% relative humidity.
Install the unit in areas where the combustion air source is free of contamination.
Exposure to corrosive chemical fumes such as chlorinated and/or fluorinated hydrocarbons can reduce the life of a water heater. Cleaners, bleaches, air fresheners, refrigerants, aerosol propellants, dry-cleaning fluids, de- greasers and paint-removers contain vapors that can form corrosive acid compounds when burned in a gas flame. Also avoid airborne chlorides such as those released with the use of laundry detergents.
This unit must not be installed in an area where water leakage will result in damage to the areas adjacent or below the unit. When such areas cannot be avoided, a suitable drain pan with adequate drain must be installed under the unit.
Water heater fastening
Approximate weight for the empty water heater is 68 lbs / 31 kg. For support fasteners, use at least two of the four supplied ¼” x 1¾” long lag screws. Installers must supply 1/4″ bolts if metal mounting systems are used. Attach the wall mounting bracket to a structurally sound wall that is capable of supporting the combined weight of the unit and piping components which can exceed 150 lbs. (68kg).
Water heater clearance
Other factors affecting potential mounting sites:
· Ensure minimum clearance requirements for combustible materials (see
Table 2) are satisfied.
· For ease of access, we recommend a minimum 24″ clearance at the front and
24″ above. Check local codes for additional access and service clearance requirements.
· At a new construction site, or during renovations, protect the unit from
drywall dust or other construction related contaminants. Combustion air must be drawn from a CLEAN source (e.g. outdoors) and the unit must be isolated from interior dust sources.

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TANKLESS WATER HEATER 199

WARNING
– Exposed water piping and associated components (relief valves, circulators, etc.) must not be in contact with combustible materials. Check local codes for required clearances and/or provide adequate insulation.
– DO NOT MOUNT THIS UNIT TO A HOLLOW SHEET ROCK WALL USING ANCHORS. The wall mounting bracket must be bolted to wall studs or a solid wall structure to support the combined weight of the unit which can exceed 150 lbs. (68kg) once installed.
– Take precautions to avoid injury during the installation of this unit.

SURFACE
Front Rear Left Side

DISTANCE FROM COMBUSTIBLE SURFACES 2″ 0″
1.5″

Right Side

4″

Top

2″

Bottom

8″

Table 2: Clearance from the unit cabinet

RECOMMENDED DISTANCE FOR INSTALLATION AND SERVICE
24″
0″
6″ (labels may be difficult to read with reduced clearance)
6″ (labels may be difficult to read with reduced clearance)
24″
24″

You must provide a minimum distance below the water heater of 8″ to allow clearance for the supplied condensation trap assembly. More clearance will typically be required to accommodate associated water and gas piping.

MOUNT BRACKET TO WALL, HOOUKNUINT IT OVER TOP.

FOR BRACKET USE TWO ¼” X 1¾” LAG SCREWS WITH FLAT WASHERS INTO STUDS. FOR METAL MOUNTING SYSTEM USE ¼” BOLTS WITH FLAT WASHERS.

Figure 2: Wall mounting of unit
1.3.1 Mobile Home Installations
TheTankless Water Heater is approved for installation in a manufactured home (mobile home). Units installed in a mobile or manufactured home must also conform to the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280 and/or CAN/CSA Z240 MH Series, Mobile Homes.

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CAUTION
The front panel has a rubber seal around the inner edge sometimes making it very stiff to slide off so please ensure the unit is secured to the wall correctly before attempting this procedure!

1.3.2 Removing/installing the front panel
· The front panel of the unit must be removed to perform various maintenance
activities.
· Loosen both screws (1) under the unit by using a 5 mm allen key. (They are
captive and therefore will not drop out of the lower housing).
· Slide the front panel (2) upward and then remove it by pulling it towards you.

2 1

WARNING
This is a room sealed cover and therefor extremely important that it is fitted correctly, failure to do so can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Figure 3: Loosen screws

Figure 4: Frontpanel upward

To replace the front panel, proceed as follows:
· Position the front panel (3) against the unit and slide it downwards until it is
correctly connected to the lower fascia panel.
· Hand tighten screws under the unit using a 5 mm allen key (do not over
tighten)

3

Figure 5: Positioning the frontpanel

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DANGER
Failure to properly vent the unit to the outdoors as outlined in this Venting section will result in death or serious personal injury. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, NEVER operate the unit unless it is properly vented and has adequate air supply for proper operation as outlined in this Venting section. This unit must have air supply connected and terminated to the outdoors.
WARNING
– Venting, condensate drainage, and combustion air systems for all units must comply with applicable codes and the instructions of their respective Installation manuals.
– Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.
– Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Failure to comply will result in severe personal injury or death.
DANGER
Do not common vent this tankless water heater with any other existing or new appliance, except as outlined in this units Common Vent Installation Instructions.

1.4 EXHAUST VENTING AND AIR INTAKE
When you plan the installation, ensure that you consider appropriate venting materials, travel and termination decisions. Consider the following when selecting a vent termination location:
· Select a location where the units exhaust will not damage nearby plants,
shrubs, air conditioning equipment or be objectionable to the homeowner.
· Exhaust gases will form a visible plume during cold weather. Avoid areas
where the plume could obstruct window views.
· Prevailing winds could cause water/ice buildup on nearby objects including
building surfaces.
· Avoid locations where people or pets could come in contact with exhaust
gases.
· Avoid locations such as inside building corners, near adjacent buildings or
surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas where wind could affect the unit’s performance or cause exhaust gas recirculation.
· Select a location where the termination is not likely to be damaged by foreign
objects such as stones or balls, or is subject to buildup of debris such as leaves.
FLUE GAS EXHAUST TO OUTDOORS
Tankless Water Heater
Figure 6: Basic exhaust vent assembly
Install venting in accordance with the requirements of the jurisdiction having authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any other local building codes are to be followed. In the USA the National Fuel Gas Code, ANSI 223.1, latest edition, prevails. Where there is a discrepancy between the installation instructions below, and the code requirements, you must apply the more stringent of the two requirements. Provisions for combustion and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 (latest edition) in the US or Clause 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1 (latest edition) in Canada or applicable provisions of the local building codes.

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NOTE
For the State of Massachusetts, use only plastic piping, fittings and vent terminations as specified in this manual which are approved by the Massachusetts Board of State Examiners of Plumbers and Gas for venting of appliances (see hyperlink below):
https://licensing.reg.state. ma.us/pubLic/pl_products/ pb_pre_form.asp

In the Commonwealth of Massachusetts
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through-the-wall vented gas appliances as follows:
(a) For all side-wall, horizontally vented, gas-fueled equipment installed in every dwelling, building, or structure used in whole or part for residential purposes, including those owned or operated by the Commonwealth and where the sidewall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied.
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall, horizontally vented, gas-fueled equipment, the installing plumber or gas fitter shall observe that a hard-wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery-operated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building, or structure served by the side-wall, horizontally vented, gas- fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall, horizontally vented, gas-fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery backup may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements, provided, however, that during said thirty (30) day period, a battery-operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034-listed and IAS-certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented, gasfueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
4. INSPECTION. The state or local gas inspector of the side-wall, horizontally vented, gas-fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08 (2)(a)(1 through 4).
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08 (2)(a) (1 through 4):
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board, and
2. Product-approved side-wall, horizontally vented, gas-fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS ­ GAS EQUIPMENT VENTING

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SYSTEM PROVIDED. When the manufacturer of product-approved side-wall, horizontally vented, gas-fueled equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS ­ GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of product-approved sidewall, horizontally vented, gas- fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting systems” instructions shall be included with the appliance or equipment installation instructions, and
2. The “special venting systems” shall be product-approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all product-approved side- wall, horizontally vented, gas-fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

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CAUTION – The minimum wall thickness for venting is 1″ and the maximum wall thickness for venting is 14″. – Do not connect this tankless water heater to a chimney flue serving a separate appliance designed to burn solid fuel. – The air intake fitting can be moved to the left or to the right of the exhaust fitting.
NOTE The flue gas temperature sensor reports the current flue gas exhaust temperature to the unit’s controller. If necessary, the controller will reduce the input of the tankless water heater to meet the flue gas exhaust temperature requirements of PVC material. The controller locks out the unit if this temperature is exceeded, and displays F003.

Removal of Existing Unit from Common Venting
When an existing appliance is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
At the time of removal of an existing appliance, the following steps must be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
· Seal any unused openings in the common venting system. · Visually inspect the venting system for proper size and horizontal pitch, and
determine that there is no blockage or restriction, leakage, corrosion and other deficiencies that could cause an unsafe condition.
· Insofar as is practical, close all building doors and windows and all doors
between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
· Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust the thermostat, so that the appliance operates continuously.
· 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, cigar, or pipe.
· After it has been determined that each appliance remaining connected to
the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gasburning appliance to their previous conditions of use.
· Any improper operation of the common venting system must be corrected
so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, (latest edition) in the US or the Natural Gas and Propane Installation Code, CSA B149.1 (latest edition) in Canada. When resizing any portion of the common venting system, the common venting system must be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, (latest edition) in the US or the Natural Gas and Propane Installation Code, CSA B149.1 (latest edition) in Canada.

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TANKLESS WATER HEATER 199

WARNING
– Do not mix venting materials from different venting manufacturers.
These venting materials are designed to be installed as part of a complete system.
Failure to comply may result in severe personal injury or death.
– Fully insert the approved venting material into the unit’s exhaust outlet and tighten clamp to ensure the venting connection is locked in place.
NOTE
For the State of Massachusetts, use only plastic piping, fittings and vent terminations as specified in this manual which are approved by the Massachusetts Board of State Examiners of Plumbers and Gas for venting of appliances (see hyperlink below):
https://licensing.reg.state. ma.us/pubLic/pl_products/ pb_pre_form.asp

1.4.1 Applications
All Tankless Water Heaters must be installed as a Direct Vent venting system. The combustion air must be piped in from the outdoors and connected directly to the unit’s combustion air connection. See section 1.4.7 for air intake piping requirements.
1.4.2 Exhaust Vent Material
Use of ABS, cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in venting systems is prohibited.
Exhaust Vent Material ­ CANADA
Use only PVC, CPVC, Polypropylene (PPS), or stainless steel vent components. Venting components must be approved for use with a Category IV appliance, listed under ULC S636 and must comply with CSA B149.1 (latest edition).
· PVC (ULC-S636) · CPVC (ULC-S636) · Polypropylene (ULC-S636)
· Stainless steel (ULC-S636)
Exhaust Vent Material ­ USA
Use only PVC, CPVC, Polypropylene (PPS), or stainless steel vent components. Venting components must be approved by the authority having jurisdiction and as follows:
· PVC (Schedule 40 ASTM D1785) · CPVC (Schedule 40 ASTM F441) · Polypropylene (UL1738 / ULC-S636) · Stainless Steel (Type BH), DuraVent FasNSeal, HeatFab Saf-T Vent, Z-Flex
Z-Vent This unit is equipped with a top mounted 2″ vent connection. Wet the vent connection gasket and pipe with clean water prior to assembly. Insert 2″ PVC or CPVC directly into the units vent connection and secure the pipe by tightening the clamp.
Polypropylene venting will require an adapter from the venting manufacturer to transition from the 2″ vent connection to the venting system. Centrotherm InnoFlue polypropylene venting requires adapter part number ISAAL0202. Wet the vent connection gasket and adapter with clean water prior to assembly. Insert the polypropylene adapter into the units vent connection and secure by tightening the clamp.
*Manufacturers of stainless steel Type BH venting systems must submit their approved transition fitting to us for evaluation and written approval.

Figure 7: Inlet and outlet vent connections. Note the flue exhaust test port.
1-10

1.4.3 Vent Travel
The maximum exhaust venting length is dependent upon the vent pipe size (2″ or 3″) and the venting material (PVC, CPVC, PPs). See Table 3 for maximum exhaust venting lengths and the required venting length reduction for each fitting in the venting system. Example: When using 6 x 90º CPVC elbows, the maximum lineal measure of pipe allowed using 3″ pipe is 72 feet (120′ ­ (6 x 8′ = 48′) = 72′).
INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING Combustion air must not be drawn from areas containing corrosive air from swimming pools or spas, including air directly next to outdoor pools and spas.
NOTE The bird screen is optional for exhaust piping in cold weather climates.
BEST PRACTICES To reduce the possibility of expansion noise, allow a 1/4″ gap around the exhaust and air intake piping.

For 3″ Flexible PPs, up to 35 actual lineal feet are allowed in a nominally vertical orientation (>45°). The equivalent length of 3″ Flexible PPs is calculated using a multiple of 1.4:1, e.g. 35′ x 1.4 = 49′ equivalent. The balance of the venting allowance is still available for use with rigid PPs piping material.
2″ Flexible PPs is not allowed.

EXHAUST PIPE SIZE/FITTINGS MAXIMUM EQUIVALENT LENGTH

Schedule 40 PVC, CPVC or PPs ­ Allowances are for each side separately.

2″

65’*

3″

120′

2″ or 3″ 90° Long Sweep Vent Elbow

Allow 5 equivalent feet

2″ or 3″ 90° Short Sweep Vent Elbow

Allow 8 equivalent feet

2″ or 3″ 45° Vent Elbow

Allow 3 equivalent feet

PPS

PPs 87-90° Elbow

Allow 8 equivalent feet

Flex PPS

2″ PPs Flex

Not Allowed

3″ PPs Flex

35′ Actual (Equivalent = Actual x 1.4)

Table 3: Maximum Exhaust Venting Length

• The input rate will derate as vent length increases. See table below for approximate derate at 2″ maximum vent length.

MAXIMUM FIRING RATE 199,000

APPROXIMATE DERATE 10 – 16%

Follow all installation instructions supplied by the pipe and fitting manufacturer. Prior to assembly, ensure all venting components are clean of burrs/debris which could clog the fan, burner, and heat exchanger.
General Venting/Piping Requirements
If the vent length requires increasing the vent pipe size to 3″, the transition from the 2″ vent connector to 3″ venting must occur within the first 18″ of the top of the unit and must be done in a vertical section to avoid pooling of condensate. Slope exhaust venting back towards the unit with a pitch of at least 1/4″ per foot. Follow venting manufacturer pitch requirements, so condensate runs back towards the trap. Support air intake and vent piping per local code and vent manufacturers requirements. In the absence of support requirements, support the air intake and vent piping at every vertical and horizontal transition as well as every 5′ of run.
Begin the vent system installation at the unit and work towards the outdoor termination. We recommend using a bird screen of 1/4″ stainless steel or plastic mesh (e.g., IPEX System 636 drain grate for CPVC systems) to guard against foreign objects.

Figure 8 INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

CAUTION
Vent termination clearances in this section are code minimum, or recommended minimum requirements, and may be inadequate for your installation. You must examine building envelope details, and take measures to avoid admission of moisture into building structures. Serious structural damage may occur if adequate precautions and clearances are not allowed for.
These precautions are to be observed for neighboring structures as well as for the structure the unit(s) are installed in.

Secure joints using appropriate solvent cement to bond the respective pipe material (Canada: PVC/CPVC cement approved under ULC-S636, in accordance with its manufacturer instructions; USA: PVC (ASTM D2564), or CPVC (ASTM F493). Use transition cement anywhere that PVC and CPVC are joined. Follow the cement manufacturer’s instructions closely when joining various components. For PPs, connections must be secured using approved retainer clips supplied by the respective PPs manufacturer.
Ensure that all vent connections are liquid and pressure tight. Prior to firing the unit, and before any of the venting run is concealed by the building construction, you must test the exhaust joints, using a soap/water solution. You must fill the condensate trap before testing.
1.4.4 Venting Passage Through Ceiling and Floor
· Confirm material meets local codes including fire stopping requirements.
Some local jurisdictions require that a minimum initial length of pipe be exposed or accessible for inspection.
· Pipe clearances best practice allows a minimum 1/4″ gap around the pipe to
prevent binding and expansion noise. Follow local codes.
· All piping must be liquid and pressure tight.
1.4.5 Rooftop Vent Termination
Direct Vent – Two Pipe
Rooftop vents must terminate as follows:
· The exhaust pipe can terminate in an open vertical orientation without concern
about rain infiltration; rain will drain away through the condensate trap.
· The intake air pipe is not typically drained, so it must be terminated with a down-
turned elbow (see Figure 10). The intake pipe does not need to penetrate the roof at the same elevation as the exhaust (as shown); lower down the roof is OK.
· The air intake pipe may terminate on the side wall of the building as long as
the air intake terminal is turned down and the side wall of the building is not exposed to large wind loads i.e.: prevailing winds. (see Figure 9)

Figure 9: Rooftop vent terminal configurations
WARNING
Condensate can cause corrosion of metal roofing components and other roofing materials. Check with the builder or roofing contractor to ensure that materials are resistant to acidic condensate. pH levels can be as low as 3.0
1-12

NOTE: THE BIRD SCREEN IS OPTIONAL IN COLD WEATHER CLIMATES
[18″ (457 mm) Canada] MIN.
Figure 10: Rooftop vent terminal configurations INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
· Optional bird screen may be placed in a termination fitting. Leave unglued,
and hold in place with a short nipple to allow easy access for cleaning.
· For roof top venting of multiple unit sets, group all intake terminals together
for a common penetration through a custom cap. Alternatively, place in the closest proximity achievable using commonly available pipe flashing. Similarly, group the exhaust pipes and place the 2 separate groups of pipes at least 3′ apart (the closest intake and exhaust pipes must be 36″ – or more apart). Use the same 12″ (minimum) vertical separation for 2 pipe option.
· DO NOT exhaust vent into a common venting system, except as outlined
in this units Common Vent Installation Instructions. DIRECT VENT CONCENTRIC ROOF TOP TERMINATION Roof Top Concentric Termination kits are approved for use with this unit. For vertical roof top concentric terminations, you must follow the installation instructions supplied by the manufacturer. Care must be taken to install the termination kit a minimum horizontal distance of 10′ (305cm) away from any portion of the building and a minimum of 12″ (305 mm) [18″ (457 mm) Canada] above the roof line plus the anticipated snow line (see Figures 11 and 12).
Figure 11: Vertical Concentric Termination – Two Kits

Figure 12: Vertical Concentric Termination – Single Kit INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

WARNING
– You must maintain at least the minimum separation of exhaust vent termination from unit’s intake air as illustrated in figures 9, 10 and 13 and 15. Failure to do so can result in a dangerous situation where exhaust gases are pulled in with combustion air. Damage to the unit can result from a failure to maintain these separations. Improper installation will void the warranty.

1.4.6 Sidewall Vent Termination
Direct Vent – Two Pipe
Sidewall direct vent applications must be vented as follows:
· Both the inlet and exhaust terminations must be located on the same plane
(side) of the building.
· The exhaust outlet is to be placed so as to reach 12″ minimum above the
down-turned intake – to avoid intake re-ingestion of exhaust gases.
· The elevation of both pipes can be raised in “periscope style” after passing
through the wall, then configured as in Figure 13, to gain required clearance.
· Use a 45° elbow on the exhaust termination to launch the plume up and off
the sidewall, for protection of wall.
· Optional bird screen may be placed in a termination fitting. Leave unglued,
and hold in place with a short nipple to allow easy access for cleaning.

– You must not cover nonmetallic vent pipe and fittings with thermal insulation.

– In areas of high snowfall,
users must be advised to check side wall vent and air intake terminations on
a regular basis to ensure blockage does not occur.

SNOW + 12″ [305mm] MIN.

SNOW + 12″ [305mm] MIN.

SNOW + 12″ [305mm] MIN.

WARNING
The vent for this appliance must not terminate:
1. Over public walkways in the US. In Canada 7′ above public walkways.
2. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage.
3. Wherever condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or to other equipment.

Figure 13: Sidewall vent termination – piping configuration

1-14

Figure 14: Prohibited installation INSTALLATION AND OPERATION INSTRUCTIONS

[305mm]

TANKLESS WATER HEATER 199

[915mm] [305mm] [152mm] [152mm]

Figure 15: Sidewall vent termination – multiple vent piping configuration

12″ [305mm] MIN.

For sidewall venting of multiple units, group all intake terminals together with 6″ (minimum) lateral spacing, and similarly group the exhaust pipes. Place the 2 groups on the same plane of the building (e.g., north facing wall). Place the 2 groups of pipes at least 3′ apart (the closest intake and exhaust pipes must be 36″ – or more ­ apart). Use same 12″ (minimum) vertical separation (see A in Figure 15). Alternatively, as long as the units are identical models – intake and exhaust terminals can maintain a minimum of 12″ of separation horizontally from any exhaust or inlet termination of an adjacent unit (see B in Figure 15).

DIRECT VENT SIDE WALL TERMINATION KITS
The sidewall Termination kits approved for use with the tankless water heater are subject to restrictions. NOTE: Some jurisdictions may not allow this type of side wall termination due to close proximity to the neighboring properties. See Figures 16, 17 and 18 on page 1-15, 1-16
You must follow the installation instructions, clearances and wall thickness requirements of the approved vent termination manufacturer.
Approved Side Wall Termination Kits are listed below:
· 2″ PVC low profile termination kit – Part #P-741 · 3″ PVC low profile termination kit – Part #P-742

Vent on Left or Right Side

Figure 16 PVC low profile termination acceptable orientations INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199
Concentric Side Wall Termination Kits Concentric Sidewall Termination kits approved for use with the tankless water heater are subject to restrictions. NOTE: Some jurisdictions may not allow this type of sidewall termination due to close proximity to the neighboring properties. You must follow the installation instructions, clearances, and wall thickness requirements of the approved vent termination manufacturer. Approved Concentric Sidewall Termination kits are:
· 3″ PVC (UL 1738) ­ Ipex #397006 · 3″ PVC (ULC-S636) ­ Ipex #196006 · 3″ CPVC (ULC-S636) ­ Ipex #197009 · 2″ Centrotherm Innoflue PPs – #ICWT242 (Termination)

ICTCR24 (2 Pipe Adapter)

· 3″ Centrotherm Innoflue PPs – #ICWT352 (Termination)

ICCT3503 (2 Pipe Adapter) Installation of multiple Concentric Side Wall

Termination kits must be:
· On the same horizontal line (not stacked) · With a minimum horizontal separation of 12″ center to center
12″ + Allowance for Snow Level
Figure 17: Horizontal Polypropylene Concentric Termination – Two Kits

1-16

Figure 18: Horizontal Polypropylene Concentric Termination – Single Kit INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING
– In addition to preventing ingestion of chemical contaminants, care must be taken to ensure air intake terminals are not installed in locations where contamination might occur due to ingestion of particulate foreign material (dust, dirt and debris).
– Intake air openings must be configured such that rain or other forms of moisture cannot enter the air intake piping system. Otherwise serious damage to the unit may result.
NOTE
Care must be taken when installing air intake piping to ensure that a “trap” is not formed in the piping so as to allow a build-up of water, and blockage of intake air. Such blockage will result in a unit’s safety shutdown.

Vent terminal clearance minimums are as follows:

CANADIAN INSTALLATIONS1, 3

US INSTALLATIONS2, 3

A= Clearance above grade,

12 in (30 cm)

veranda, porch, deck, or balcony

B= Clearance to window or door 36 in (91 cm) for appliances

that may be opened

over 100,000 Btuh (30kW)

12 in (30 cm) 12 in (30 cm)

C= Clearance to permanently closed window

• (Recommend minimum 1 * (Recommend minimum 1

ft (30 cm))

ft (30 cm))

D= Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft (61 cm) from the center line of the terminal.
E= Clearance to unventilated soffit F= Clearance to outside corner
G= Clearance to inside corner

• (Recommend minimum 2 * (Recommend minimum 2

ft (61 cm))

ft (61 cm))

*(Recommend minimum 1 ft (30 cm))

• (Recommend minimum 4 ft (122 cm))

• (Recommend minimum 4 ft (122 cm))

• (Recommend minimum 1 ft (30 cm))

• (Recommend minimum 4 ft (122 cm))

• (Recommend minimum 4 ft (122 cm))

H= Clearance to each side of center line extended above
meter/regulator assembly

3 ft (91 cm) within a height * of 15 ft (4.6m)

I= Clearance to service regulator 3 ft (91 cm)

vent outlet

J= Clearance to nonmechanical air supply inlet to building or the
combustion air inlet to any other
appliance

36 in (91 cm) for appliances over 100,000 Btuh (30 kW)

12 in (30cm)

K= Clearance to a mechanical air supply inlet
L= Clearance above paved sidewalk or paved driveway located on public property

6 ft (1.83 m) 7 ft (2.13 m)

M= Clearance under veranda, porch deck, or balcony

12 in (30 cm)

3 ft (91 cm) above if within 10 ft (3 m) horizontally
Vents cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard.

Clearance to adjacent wall

6 ft (1.83 m)

6 ft (1.83 m)

1 In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code
2 In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code
3 If locally adopted installation codes specify clearances different than those illustrated, then the most stringent shall apply.
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

• Clearance in accordance with local installation codes and the requirements of the gas supplier. The minimum distance from adjacent public walkways, adjacent buildings, openable windows, and building openings shall not be less than those values specified in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CSA B149.1

INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

Figure 19: Vent Terminal Clearance

Vent terminal Air supply inlets Area where terminal is not permitted

NOTE
Combustion air connection may be moved from one side to the other:
– Remove the retaining clip screws then lift tab at back of plug and rotate 1/8th of a turn counter-clockwise to remove from top of cabinet.
– Remove the retaining clip by removing both screws then lift tab at back of combustion air connection and rotate 1/8th of a turn counterclockwise to remove from top of cabinet.
– Reinstall plug and combustion air connection in the desired locations then rotate 1/8th of a turn clockwise until tab latches into the top of the cabinet.
– Reinstall the retaining clip over the combustion air connection tab and secure with two screws. Reinstall two screws in the top of the cabinet near the plug.
1-18

1.4.7 “Direct Vent” Combustion Air Intake Piping
The unit must always be installed as a Direct Vent venting system with the combustion air piped directly from the outdoors to the unit’s combustion air connection. Provisions for combustion and ventilation air are in accordance with the section “Air for Combustion and Ventilation”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (latest edition) in the US or Clause 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1 (latest edition) in Canada, or applicable provisions of the local building codes.

FLUE GAS COMBUSTION
EXHAUST TO AIR FROM
OUTDOORS OUTDOORS
ALTERNATIVE COMBUSTION AIR
CONNECTION

COMBUSTION FLUE GAS
AIR FROM EXHAUST TO
OUTDOORS OUTDOORS
ALTERNATIVE COMBUSTION AIR
CONNECTION

Tankless Water Heater

“DIRECT VENT” INSTALLATION CHECK AIR INTAKE OUTSIDE TO MAKE SURE IT IS CLEAR OF OBSTRUCTIONS

Figure 20: Direct vent combustion air intake INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

Intake Pipe Sizing
For 3″ Flexible PPs, you can use up to 35 actual linear feet in a nominally vertical orientation (>45°). The equivalent length of 3″ Flexible PPs must be calculated using a multiple of 1.4:1, e.g. 35′ x 1.4 = 49′ equivalent. The balance of the venting allowance is still available for use with rigid PPs piping material. 2″ Flexible PPs is not allowed.

INTAKE PIPE SIZE/FITTINGS MAXIMUM EQUIVALENT LENGTH

Schedule 40 PVC, ABS, CPVC or PPs ­ Allowances are for each side separately.

2″

65’*

3″

120′

2″ or 3″ 90° Long Sweep Vent Elbow

Allow 5 equivalent feet

2″ or 3″ 90° Short Sweep Vent Elbow

Allow 8 equivalent feet

2″ or 3″ 45° Vent Elbow

Allow 3 equivalent feet

PPS

PPs 87-90° Elbow

Allow 8 equivalent feet

Flex PPS

3″ PPs Flex Table 4: Maximum intake piping length.

35′ Actual (Equivalent = Actual x 1.4)

• The input rate will derate as intake length increases. See table below for approximate derate at 2″ maximum intake length.

MAXIMUM FIRING RATE 199,000

APPROXIMATE DERATE 10 – 16%

For inlet air, you can use Schedule 40 PVC, CPVC, ABS or PPs piping of any type. Use the same diameter as vent piping.

Insert combustion air piping directly into the 2″ female plastic fitting on the top of the unit, and run it horizontally or vertically to the outdoors. We recommend using a bird screen of 1/4″ stainless steel or plastic mesh (eg. IPEX System 636 drain grate for CPVC systems) to guard against foreign objects.
Care must be taken to ensure adequate separation is maintained between the air intake inlet and the vent termination. Refer to the vent termination configuration drawings in the “Vent Termination” section above.

Support air intake and vent piping per local code and vent manufacturers requirements. In the absence of support requirements, support the air intake and vent piping at every vertical and horizontal transition as well as every 5′ of run.
1.4.8 “Indoor Air” Combustion Air Intake

The use of indoor air for combustion is prohibited. Combustion air must be piped in from the outdoors and connected directly to the unit’s combustion air connection

1.4.9 Closet Installations

For installations in a confined space (such as a closet), ventilation openings may be needed through a door or wall to prevent build-up of excessive heat from
inside the space.

The unit must not be exposed to surrounding conditions above 122°F (50°C) or below 32°F (0°C).

INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

WARNING
Fill the trap with water before initial startup of the unit to prevent exhaust fumes from entering the room. Never operate the water heater unless the trap is filled with water.
Failure to comply will result in severe personal injury or death.
NOTE
It is the responsibility of the installing and/or service Contractor to advise and instruct the end user on how to perform the Trap cleaning procedure, and to advise that the trap be checked at least every two months and cleaned as required.

1.5 CONDENSATE REMOVAL
The specified vent configuration promotes the safe drainage of moisture from the unit and exhaust venting without flowing liquids back through the heat exchanger. Reliable system operation requires (1) proper design and installation of exhaust venting to allow condensate to run back to the drain/trap; (2) acid neutralization as appropriate. To achieve these: 1. Allow for a minimum 1/4″ per foot slope back to the vent connection, with
appropriate hangers to maintain that gradient (check with the venting manufacturer as their slope requirement may be stricter). 2. Ensure the supplied trap is correctly installed and filled with water. 3. When required, add (and maintain in good condition) a pH neutralization tank.
1.5.1 Condensate Trap
The condensate trap must be installed on the bottom of the condensate trap at the base of the unit.
1.5.2 Installing the Condensate Trap
1. Fill the condensate trap cup with water. 2. Install the condensate trap cup on the condensate trap base and twist toward
the right. 3. Attach the drain hose to the condensate trap outlet located to the left of the
condensate trap cup.

1-20

Figure 21: Condensate trap installation INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

DANGER
The water in the condensate neutralizer can cause severe burns to the skin. Use extreme caution when servicing the condensate neutralizer. Wear protective gloves and eyewear.

1.5.3 Further Installation Details
· Pipe the condensate drain to within 1″ of a drain, or connect it to a condensate
pump.
· Slope the drainage line down to the drain at a pitch of 1/4″ per foot, so that the
condensate runs towards the drain.
· Check the condensate trap every 2 months, and clean and refill as necessary.

CAUTION
When a condensate neutralization package is installed, the pH of the condensate discharge must be measured on a regular schedule to ensure the neutralizing agent is active and effective.
WARNING
If condensates are to be discharged into building drain piping materials that are subject to corrosion, a neutralization package must be used.
Figure 22: Condensate trap drainage

T Tankless Water Heater

Tankless Water Heater

Figure 23: Condensate neutralization tank INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

DANGER
When this system requires water for space heating at elevated temperatures (above 125°F [52°C]), a mixing or tempering valve MUST BE installed in the hot water supply line to the house in order to reduce the scald hazard potential.

1.6 WATER AND SPACE HEATING APPLICATION
The following guidelines must be followed when using the water heater for both potable water heating and space heating.
Any piping or components used in the installation of this water heater in a combination potable water and space heating application must be suitable for use with drinking water.
If this water heater is installed in an application intended to supply domestic hot water needs and hot water for space heating purposes, DO NOT connect the water heater to an existing heating unit or components of a heating system that have previously been used with a nondrinking water system.
Toxic chemicals such as those used for boiler treatment may be present and will contaminate the drinking water supply causing possible health risks. Never introduce toxic chemicals, such as glycol and those used for boiler treatment into the system.
This water heater is NOT approved as the dedicated space heating unit.
This water heater must be used for combination applications with an air handler only and not for indoor heating applications.

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INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

NOTE
Connection to space-heating circuit through potable water system as shown may be prohibited by local code.

Tankless Water Heater

4

1 Non-ferrous pump (sized for combined head loss of water heater and air handler)
2 Check valve (may be built into pump) 3 Potable water expansion tank 4 Mixing valve
Figure 24: DHW and Air Handler Piping

INSTALLATION AND OPERATING INSTRUCTIONS

1-23

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TANKLESS WATER HEATER 199
1.7 DOMESTIC HOT WATER SYSTEM
DANGER

HOT
BURN
° Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.
° Children, disabled, and elderly are at highest risk of being scalded. ° See instruction manual before setting temperature at water heater. ° Feel water before bathing or showering. ° Temperature limiting valves are available, see manual.

WATER HEATER INSTALLATION GUIDELINES
WARNING
° This unit must be installed in accordance with local codes, if any; if not follow the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CAN/CSA B149.1, as applicable.
° Failure to correctly install and operate this appliance can result in severe personal injury
or death.
° The unit shall have a pressure relief valve installed within 6″ [152mm] of the DHW HOT
outlet connection. Refer to the unit’s User Manual before operating the relief valve.
° The unit requires a pressure relief valve identified with the ASME V or HV symbol and
set to relieve at or below 150psi of domestic water pressure and a minimum relieving capacity of 199,000 Btu/hr with 3/4″ NPT threads. For safe operation of the unit, the relief valve must not be removed from its designated point of installation or plugged.
° Read and follow warnings and instructions.

CAUTION
° Hotter water increases the risk of scald injury. Before changing the temperature setting, see
instruction manual.
ADJUSTABLE TEMPERATURE SETTING

° Touch the panel above the white dot , then touch the Faucet . Adjust the water temperature

with the Plus + and Minus ­ then touch the Return button

to save the changes.

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING
HOT WATER CAN SCALD!
Water Temperatures over 125°F / 52°C can cause severe burns instantly or death from scalds.
Children, disabled, and elderly are at highest risk of being scalded. · Never leave them unattended
in or near the shower, bathtub or sink. · Never allow small children to use a not water faucet or draw their own bath.
TO AVOID INJURY: · Feel and adjust water
temperature before bathing or showering. · Water drained from the system drain valve may be extremely hot. · Make sure all connections are tight. · Direct water flow away from any person.
NOTE
The limited warranty provided with the water heater does not cover defects, malfunctions or failures resulting from water conditions that are not in accordance with the specifications in the table 5.

1.7.1 Domestic Hot Water System
This Tankless Water Heater has a copper piping circuit for efficiently generating Domestic Hot Water. When a faucet is opened to draw hot water, water flow is detected with a flow sensor and the unit fires up to begin generating domestic hot water.
The heat exchanger has copper water passageways encased in the aluminum heat transfer block. The aluminum heat exchanger acts as a heat buffer, eliminating the “cold water sandwich effect” when turning on and off the water repeatedly.
While the Tankless Water Heater unit is less susceptible to lime scale build- up than other units on the market, always consider water quality in the installation. We strongly recommend treating hard water and adjusting the pH to 6.5 and 8.5. As a reference Table 5 represents some of the drinking water guidelines published by the US EPA. Consult a water treatment adviser in your area to assess your local needs. Proper water treatment will aid in the longevity of the unit and ensure maximum efficiencies.
When installing and maintaining the water heater, you must consider water quality. Water conditions outside of the levels specified below may damage the water heater.

DESCRIPTION

MAX

Water Pressure

150 PSI

Programmable Water Temperature

149°F (65°C)

Minimum DHW Flow Rate to Initiate Operation N/A

pH

8.5

Total Dissolved Solids (TDS)

500 mg/L

Total Hardness

250 mg/L 14.6 gr/ gal

Aluminum

0.2 mg/L

Chlorides

250 mg/L

Copper

1 mg/L

Iron

0.3 mg/L

Manganese

0.05 mg/L

Zinc

5 mg/L

Table 5: Recommended Water Quality Guidelines

MIN 40 PSI 105°F (40°C) 0.5 GPM 6.5
0.05 mg/L

INSTALLATION AND OPERATING INSTRUCTIONS

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TANKLESS WATER HEATER 199

NOTE
See Domestic Hot Water Warnings on page 1-25.
Tankless Water Heater

DHW

DCW

Figure 25: Overview of piping connections

WARNING
– Bacteria growth can develop in domestic hot water tanks and indirect water heaters if the minimum water temperature is not set high enough to prevent its growth.
– Failure to support the boiler fitting with a second wrench while tightening field piping may lead to boiler damage.

1.7.2 Domestic Hot Water Piping
The domestic water piping connections are located at the bottom of the unit, see Figure 1b. The connections are 3/4″ male NPT threads. The cold water inlet is on the right side and the hot water outlet is on the left side.
Use two wrenches when tightening field piping onto the boiler. Use one wrench to hold the boiler fitting still while tightening with another wrench.
An installer supplied pressure relief valve meeting the following requirements must be installed:
Maximum pressure rating of 150 PSI. Minimum capacity of 200,000 Btu/hr. On the domestic hot water outlet prior to any isolation valve. Installation of a tankless water heater service valve kit with pressure relief valve is recommended for ease of servicing the DHW coil in the future.
The Tankless Water Heater can be connected to the pressurized 1/2″ or larger domestic cold water supply piping and the domestic hot water piping in the home. The minimum domestic water pressure required is 40PSI and recommended to be 50PSI or higher. Generating domestic hot water with a water pressure lower than 40PSI reduces the amount of hot water generated and increases the risk of scaling in the heat exchanger.
The domestic water piping must be installed with isolation valves and flushing taps installed on both the cold and hot domestic connections.
Thermal expansion of the water in the domestic hot water (DHW) system can occur without DHW usage such as in DHW Comfort Mode. As the small volume of DHW in the heat exchanger is heated, it expands in volume and creates an increase in the pressure within the water system. Check with your local water utility company to determine if a check valve has been installed in the cold water line. If a check valve has not been installed, the expanding water volume flows back into the main, dissipating pressure. If a check valve has been installed, the expanding water volume will increase the pressure within the homes water system. A DHW expansion tank is typically not required due to the low volume of DHW in the heat exchanger. If the pressure increase causes operation of the pressure relief valve, a DHW expansion tank must be installed.
The cold water inlet includes a filter to prevent contaminants from fouling the flow sensor and heat exchanger. See maintenance section 4.1.12 for cleaning procedure.

1-26

Graph 1: Water Heater Pressure Drop INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

CAUTION
A field supplied thermostatic mixing valve may be installed on the domestic hot water piping connections at the unit or at the outlet of a domestic hot water storage tank.

DOMESTIC HOT WATER DELIVERY

@ 67°F / 37.2°C temperature rise

199,000 Btu/hr

5.4 GPM

1.7.3 Tankless Domestic Hot Water with a Storage Tank
The Tankless Water Heater has the ability to connect a domestic hot water storage tank to the unit to provide larger volumes of domestic hot water during peak demands.
The storage tank is piped to the unit’s domestic hot and cold water piping connections (see B in Figure 26). You must install a bronze or stainless steel pump to circulate water from the storage tank through the unit’s domestic hot water coil.
The storage tank aquastat will enable the pump causing the unit to fire when the temperature drops below the aquastat setpoint. The units DHW setpoint must be set higher than the storage tank aquastat setpoint. Once the storage tank temperature has reached its setpoint, the aquastat will disable the pump.

Tankless WCaotmerbiHBeoailteer r

Tankless WCaotmerbHi Beoailteerr

Aquastat

Figure 26: Tankless DHW Piping Options ­ concept drawing. This drawing is only a simple schematic guide.

INSTALLATION AND OPERATING INSTRUCTIONS

1-27

TANKLESS WATER HEATER 199

See the Tankless Water Heater
Controller Manual for required parameter changes.

1-28

Figure 27: Typical DHW Recirculation piping ­ concept drawing. This drawing is only a simple schematic guide
INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING
Failure to support the boiler fitting with a second wrench while tightening field piping may lead to boiler damage.
WARNING
This tankless water heater can burn either natural gas or propane. Refer to section 3.3 for further instruction. If converting a unit from one fuel to another, you must order a conversion kit prior to the conversion. Install the conversion kit according to the detailed instructions supplied with the kit. Failure to perform the required fuel conversion correctly can result in serious injury or death.
NOTE
It is essential to check gas supply pressure to each unit with a manometer or other high-quality precision measuring device. Pressure should be monitored before firing the unit, when the regulator is in a “lock-up” condition and during operation, throughout the unit’s full modulation range.
Pay special attention to retrofit situations where existing regulators may have an oversized orifice and/or worn seats, causing pressure “creep” and high lock up pressures.

1.8 GAS PIPING

The unit must have an inlet gas pressure of at least 4.0″ w.c. for natural gas and propane. For either fuel, the inlet pressure shall be no greater than 14.0″ w.c. Confirm this pressure range is available with your local gas supplier.
The inlet gas connection of the unit’s gas valve is ¾” NPT (male).
Use two wrenches when tightening field piping onto the boiler. Use one wrench to hold the boiler fitting still while tightening with another wrench.
Adequate gas supply piping must be provided with no smaller than 1/2″ Iron Pipe Size and a 1″ w.c. pressure drop, in accordance with the following chart:

MODEL 199,000 Btu/hr (Natural Gas) 199,000 Btu/hr (Propane) Table 6: Maximum Pipe Length (ft)

1/2″ IPS 10′ 30′

3/4″ IPS 40′ 125′

1″ IPS 150′ 400′

Gas piping must have a sediment trap ahead of the unit’s gas valve (see Figure 29). A manual shutoff valve must be located outside the unit, in accordance with local codes/standards. All threaded joints in gas piping must be made with an approved piping compound resistant to the action of natural gas/propane. Use proper hangers to support gas supply piping as per applicable codes.
Before placing the boiler into operation, the boiler and all gas connections must be checked for leaks.
· Close the gas shutoff valve during any pressure testing equal to or less than ½
psi (3.5 kPa).
· Disconnect the boiler and gas shutoff valve from the gas supply during any
pressure testing greater than ½ psi (3.5 kPa).
The gas valve is provided with pressure taps to measure gas pressure upstream (supply pressure) and downstream (manifold pressure) of the gas valve (see Figure 28). Note that manifold pressure varies slightly in accordance with firing rates with the modulating series units, but will always be close to 0″ w.c.

WARNING
Do not check for gas leaks with an open flame, use the bubble test. Failure to use the bubble test or check for gas leaks can cause substantial property damage, serious injury, or death.

Figure 28: Gas Valve

Figure 29: Gas Piping

CHECK LOCAL CODE FOR SIZE REQUIREMENTS

INSTALLATION AND OPERATING INSTRUCTIONS

1-29

TANKLESS WATER HEATER 199

WARNING
Do not apply power to any connection point on the controllers terminal strips. A hazardous situation could occur resulting in possible serious injury or death.
NOTE
The unit (like any modern appliance that contains electronic equipment), must have a “clean” power supply, and can be disabled by power surges and spikes, lightning strikes and other forms of severe electrical “noise”. Power conditioning equipment (surge protectors, APC or UPS devices) may be required in areas where power quality is suspect.

1.9 ELECTRICAL CONNECTIONS
Electrical wiring to the unit (including grounding) must conform to local electrical codes and/or National Electrical Code, ANSI/NFPA No. 70 ­ latest edition in the US or The Canadian Electrical Code, C22.1 – Part 1 in Canada.
1.9.1 120VAC Line Voltage Hook-up
(Refer to Section 6.2.Wiring Diagram on page 6-4). Connect the unit to the grid power, using the supplied appliance plug in a separate non GFCI fused circuit and on/off switch within sight of the unit.
1.9.2 Accessing Controller Terminal Strip
Pull out on the two control module retaining tabs then flip down the control to access the terminal strip.

1-30

Figure 30: Pullling out the tray
1.9.3 Power Quality and Electrical Protection
In areas of unreliable power, appropriate surge protectors and/or power conditioning equipment should be installed to protect the unit.
INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
2.0 UNIT SYSTEM OPERATION
2.1 GENERAL
The Tankless Water Heater can be used as a tankless water heater, with or without a storage tank. The unit is equipped with an electronic unit controller that ignites the burner and continuously monitors the flame throughout each call for heat. The controller also displays the current operating conditions of the unit and any error messages should a problem occur. The unit’s controller also provides frost protection. When the unit’s heat exchanger temperature becomes too low the burner switches on to keep the heat exchanger warm. Ensure that the condensate trap is protected from freezing. The unit must be installed indoors in a heated space.
DANGER
HOT
BURN
° Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.
° Children, disabled, and elderly are at highest risk of being scalded. ° See instruction manual before setting temperature at water heater. ° Feel water before bathing or showering. ° Temperature limiting valves are available, see manual.

UNIT SYSTEM OPERATION

2-1

TANKLESS WATER HEATER 199
2.2 CONTROL

A

B

CD E

F GH

ICON

FUNCTION

A Numerical Display

Main Display

B Plus & Minus

Temperature Adjustment

C Flame

Burner ON Indicator

D Dot

Power ON Indicator

E Faucet

DHW Indicator

F Wrench

Service / Reset

G Return Arrow

Enter / Save

H Numerical Display

Service Display

Table 7: Controller Indicators and Touch Pad

2.3 INSTALLER INTERFACE

2.3.1 Turning Appliance ON/OFF
To turn on the unit, touch the area above the dot for 2 seconds. Now only the dot is illuminated.
To turn off the unit, touch the area above the dot for 2 seconds. A dash appears on the right and the text “OFF” is displayed on the left.

2-2

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

NOTE
The domestic hot water thermostat is adjusted to its lowest temperature position when shipped from the factory. It’s recommended to set the domestic hot water thermostat to 120°F/49°C as an initial setting and further adjust as required. For energy efficient operation, this setting should be set as low as practical for the consumer’s needs.

2.3.2 Programming Mode
There are two parameters available in the User Setup Menu. The controller has five levels: User Menu, Installer Menu (code 15), a Master Installer Menu (code 20), RF Menu (code 30) and Cascade Menu (code 35). See included Controller Manual for details. Adjusting the Domestic Hot Water Temperature To access the main menu: 1. Touch the area above the dot. 2. Touch the Faucet button.

3. To change the DHW target temperature, touch the Plus or Minus buttons.

4. · ·

To save the changes, touch the Return button. To exit without saving the changes, touch the area above the dot.

“P” to the right of the screen indicates that the changes have been saved.

UNIT SYSTEM OPERATION

2-3

TANKLESS WATER HEATER 199
2.4 TANKLESS DOMESTIC HOT WATER MODES
2.4.1 Tankless Domestic Hot Water – Standard and ECO Comfort Modes
Standard Mode (OFF): The heat exchanger will not maintain its domestic hot water temperature between demands for hot water. Comfort Mode (ON): The heat exchanger is maintained at the DHW temperature. ECO Comfort Mode (ECO): This mode operates like the Comfort Mode but has the added advantage of learning when the domestic hot water is used. During the low use periods, the heat exchanger is allowed to cool. To switch between the 3 modes: 1. Touch the area above the dot. 2. Touch the Faucet button twice.

3. To change the DHW mode, touch the Plus or Minus buttons.

4. · ·

To save the changes, touch the Return button. To exit without saving the changes, touch the area above the dot.

“P” to the right of the screen indicates that the changes have been saved.

2-4

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

NOTES
The unit is equipped with a frost protection feature. This feature operates the unit’s burner to help protect the unit from freezing. If the
unit is in a hard lock-out condition the burner will not operate. The manufacturer is not responsible for damages to the unit, and/or related components, nor property
damages that may result from
freezing conditions.

2.5 SEQUENCE OF OPERATION
When the unit is powered up the controller enters a self-diagnostic mode, and displays the controller software version in the main display.
The sequence of operation is as follows:
1. The unit receives a call for domestic hot water heating from the internal flow sensor.
2. The unit performs a safety check and energizes the fan for a pre-purge (Service Display = 3).
3. Once the 5-second pre-purge is complete, the unit enters a 5-second trial for ignition (Service Display = 4). If the unit fails to ignite, the unit will complete another 5-second pre-purge then 5-second trial for ignition. This is repeated 4 times before a hard lock-out occurs. The Return button must be pressed to reset the controller and begin another trial for ignition.
4. Once the burner is lit and flame has been proven the unit operates as it is programmed (Display = + for domestic hot water).
5. If the unit exceeds its target temperature and there is still a call for hot water the burner will turn off. (Service Display = 1)
6. If the burner is on to maintain the heat exchanger temperature for DHW Comfort mode (Service Display = 7).
7. If the burner is on for frost protection (Service Display = 9).

MAIN DISPLAY
OFF
(blank) XXX XXX
XXX XXX XXX

SERVICE DISPLAY
–
(blank) 1 2
3 4 +

DESCRIPTION
The unit is OFF. Press the space above the dot for 2 seconds to turn on the unit. No Call for Hot Water – Standby Unit water temperature exceeds target, call still present Self-test ­ When power is applied to the unit the controller enters a self diagnostic mode for 5 seconds Fan Pre-purge and Post- purge Trial for Ignition and Flame Proving Heating ­ DHW

XXX XXX

7

Burner on for DHW Comfort mode

9

Freeze Protection mode

Table 8: Operating Display and Service Display Codes.

UNIT SYSTEM OPERATION

2-5

TANKLESS WATER HEATER 199
2.6 ACCESSING THE INFORMATION MENU
The Information menu provides real time operating information to assist with troubleshooting. To access the Information menu: 1. Touch the area above the Dot. 2. Touch and hold the Wrench button for two seconds, let go when the minus,
plus, and wrench are displayed.
3. Again, touch and hold the Wrench button for two seconds to enter the information menu. See table 9 for a list of codes and corresponding description. 4. To scroll through the list of codes, use the Minus or Plus button. 5. To exit the information menu and return to the Service menu, press the area
above the Dot.

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INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
See below for a description of the codes:

Table 9: Information Menu
Note that display parameters may differ depending on the configuration. Where there is no DHW sensor, the display reading can be ignored.

UNIT SYSTEM OPERATION

2-7

TANKLESS WATER HEATER 199

CAUTION
The maintenance counter must only be reset after performing the maintenance procedures in Section 4.0 Maintenance of this manual. Failure to perform maintenance can result in a hazardous condition.

2.7 RESETTING THE MAINTENANCE COUNTER
Inspection of the unit must be performed annually by a qualified service technician. This unit includes a maintenance counter which tracks the amount of fuel burned within a two year period to ensure maintenance is performed if usage exceeds typical residential usage. When above average usage occurs within a two year period, a notification code will be displayed.
To reset the maintenance counter and clear a maintenance notification code:

1. Touch the area above the dot.

2. Touch the wrench for two seconds until the return button appears.

3. Touch wrench and return buttons together.

2-8

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
The code numbers are displayed in the left numerical display. 4. Change C000 to C090 by touching the + button.

5. Touch wrench to enter the maintenance menu. The current maintenance counter value is displayed in the left numerical display.

UNIT SYSTEM OPERATION

2-9

TANKLESS WATER HEATER 199

The following notifications will be displayed as the time for maintenance approaches.

MAINTENANCE COUNTER 80 100 120

NOTIFICATION CODE n120 – Maintenance recommended n121 – Maintenance required, limited DHW output n122 – Maintenance required, no DHW output

The notification code will be displayed for 30 seconds and the wrench will flash. Press the wrench button to see the notification code again after 30 seconds.

6. Touch the wrench to reset the maintenance counter to 0.

7. Touch return to resume normal operation.

P will be briefly displayed on the right screen to indicate the change has been stored.

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INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
3.0 STARTUP & COMMISSIONING
3.1 LIGHTING & SHUTTING DOWN THE UNIT
(LP)

t STARTUP AND COMMISSIONING

t
t 3-1

TANKLESS WATER HEATER 199

DANGER
– Fill trap with water before unit is first fired to prevent exhaust fumes from entering room. Never operate the unit unless the trap is filled with water.
Failure to comply will result in severe personal injury or death.
– It is forbidden to make adjustments to the gas valve except with a properly calibrated gas combustion analyzer by persons who are trained and experienced in its use. Failure to use an analyzer can result in an immediate hazard.

3.2 PRIOR TO START-UP

3.2.1 Pre-Ignition Checks
1. Fill the condensation trap. Ensure the venting system is complete and sealtested. Confirm that any common venting system at the installation site is isolated and independent of the unit, that any holes left from removal of a previous unit have been sealed, and that any resizing of the old flue has been done.
2. Confirm that the pressure relief valve is installed and discharge line is directed downward to a safe point of discharge
3. Check to see that adequate gas pressure is present at the inlet gas supply test port. With the unit gas valve shut off, using a Torx 15 screwdriver, open the test port by turning 1 full turn counterclockwise. Connect a manometer and open the manual gas valve. Requirements are minimum 4″ w.c. and maximum 14″ w.c. Check that there are no gas leaks.
4. Perform a final check of electrical wiring and provide power to the unit to initialize operation.

3.2.2 Test Ignition Safety Shutoff
With the unit in operation, test the ignition system safety shutoff device by shutting off the manual gas valve immediately outside the unit case. Ensure that the unit has shut off and that the appropriate error information is displayed on the main display screen. To restart the unit, press the Reset button.
3.3 COMMISSIONING

The Tankless Water Heater is factory calibrated to operate with natural gas at
sea level. High Fire combustion is set by the orifice installed and is not field adjustable. A low calorific value natural gas orifice (See Table 10) is available for locations where the natural gas calorific value falls below the expected range of 950-1100 BTU/Ft3. Consult your local fuel provider for your fuel’s calorific value. Low fire is field adjustable via the low fire adjustment on the gas valve but must be done with caution. No mixture adjustment may be performed unless done by a qualified technician using a properly functioning and calibrated combustion analyzer.
This unit can burn either natural gas or propane if equipped with the correct specified orifice. Examine the rating plate of the unit to ensure it is configured for the fuel you are using. If the unit is to be converted from natural gas to propane or from propane to natural gas a fuel conversion kit must be installed. For the correct fuel conversion kit part number, see the table below:

MODEL

NATURAL GAS PROPANE TO TO PROPANE NATURAL GAS

199,000 Btu/hr

P-081014

P-081024

Table 10: Fuel conversion kits

LOW CALORIFIC NATURAL GAS
P-081414

The gas valve will automatically de-rate the maximum input by approximately 2%
per 1,000′ above sea level. The gas valve’s zero governor will ensure that the gas-air mixture is not affected at altitude.

3-2

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING Check the rating plate of the unit to ensure it is configured for the fuel you are using. If the fuel is incorrect for the appliance, a conversion kit must be installed as listed in Table 10 and the gas valve adjusted accordingly. Failure to perform the required fuel conversion can result in an immediate hazard.
DANGER Attempting to change high fire combustion by adjusting the low fire combustion adjustment could lead to unstable operation, failed ignitions, or dangerous operating conditions.
Figure 31 Gas Valve Adjustment

To verify the proper operation of the gas valve in the field, the following procedure can be carried out by a qualified technician (see diagrams on this page).

1. Turn off the unit’s manual gas valve. With a Torx 15 screwdriver, open the inlet gas supply pressure test port by turning its screw 1 full turn counterclockwise. Attach a manometer to the pressure test port. Turn on gas to the appliance. Static manometer reading should be ideally 7″ w.c., for natural gas and 11″ w.c. for propane. Minimum and maximum static pressure must be between 4″ and 14″ w.c. Monitor pressure throughout the commissioning procedure. Pressure may droop up to 1″ at high fire.

2. Allow the unit to ignite / run against a large load. To maintain high fire, press the flame icon, then press and hold the Wrench icon for two seconds. Then while holding the Wrench icon press the Plus button twice. “H” will
show in the service display as the unit enters high fire.

NOTE: Allow the unit to operate at high fire for 3 minutes to stabilize. (The unit operates in manual mode for 10 minutes then switches back to the normal operating mode. To extend manual mode operation, press the Wrench and Plus together twice while the unit is operating in manual mode to reset the timer for 10 more minutes.) Do not take ameasurements if the service display shows an “h”.

3. Clock the natural gas meter to confirm full maximum rating plate input. With

a combustion analyzer probe in the flue gas test port, check the measured results against Table 11 – High Fire. If the results are outside the permitted

range, check the inlet pressure, and confirm that the correct orifice and

venturi are installed. High Fire CO2 is set by the orifice installed and is not field adjustable. For areas of lower calorific value natural gas, install the

alternative orifice listed in Table 10. 4. Switch the unit to low fire by pressing the Wrench

– button and Minus

buttons at the same time. The unit will drop to low fire. “L” will show on the service display. Compare the readings with Table 11 – Low Fire. If adjustment

is necessary, remove the low fire adjustment cap to reveal a Torx head

screw. Make minimal adjustments, typically less than 1/8th of a turn at a time.

Turn the screw clockwise to increase CO2 and counter-clockwise to reduce CO2. If the target cannot be met, even after a full turn, contact the factory. When finished, replace the low fire cap, and leave the manual mode by

pressing + AND – simultaneously.

5. Switch off the unit by pressing the space above the dot for two seconds. Turn off the gas at the unit’s manual gas valve. Remove the flue gas analyzer from the test port and reinstall the test port cap. Remove the gas pressure manometer from the gas valve and fully close the test port. Turn on the gas at the manual gas valve. Ensure that there are no gas leaks and reinstall the front cover. Turn on the unit by pressing the space above the dot for two seconds.

Figure 32: Flue gas test port plug

STARTUP AND COMMISSIONING

3-3

TANKLESS WATER HEATER 199

DANGER
Operating any unit using a fuel other than the fuel listed on its rating plate is prohibited. If the information in this section related to conversion to alternative fuels is not followed exactly, a dangerous situation can result, leading to fire or explosion, which may cause property damage, personal injury, or loss of life.

PROPANE ORIFICE CHART

MODEL

ORIFICE SIZE

199,000 Btu/hr 535

NATURAL GAS ORIFICE CHART

MODEL

ORIFICE SIZE

199,000 Btu/hr 660

3.4 FUEL CONVERSION
The unit is factory fire-tested to operate with natural gas as shown on the rating plate. Firing a unit with a fuel other than what is listed on the rating plate is prohibited unless the following conversion procedure is completed by a qualified technician.
Fuel conversion requires hardware adjustments (orifice replacement) as well as measurement and possible tuning of the low fire mixture. Detailed instructions including parts and labeling are found in Fuel Conversion kits. Refer to Table 10 for the correct kit number.

NATURAL GAS

PROPANE

CO2 VALUE (%) AT HIGH FIRE WITH THE FRONT COVER OPEN¹

Max. CO2 value

10.3%

11.0%

Min. CO2 value

8.7%

9.8%

CO LIMIT (PPM) AT HIGH FIRE WITH THE FRONT COVER OPEN²

Max. CO limit

< 150ppm

<250ppm

CO2 VALUE (%) AT LOW FIRE WITH THE FRONT COVER OPEN

Max. CO2 value

= value at High

= value at High ­ 0.3%

Min. CO2 value

8.7%

9.5%

Table 11: Acceptable High and Low Fire Combustion Values

¹ High Fire CO2 is set by the orifice installed and is not field adjustable.
² If the CO reading exceeds the limit in this table, the unit must be shut down until the cause of excessive CO readings is corrected.

Figure 33: Orifice and O-ring
WARNING Ensure the part kit and orifice are correct for the appliance model and fuel type prior to performing the fuel conversion.

The following procedure must be carried out by a qualified technician.
1. Ensure that the gas supply is turned off at the manual gas valve. 2. Disconnect the electrical power.
3. Disconnect the nut at the gas valve outlet (top of the gas valve) and remove the orifice and O-ring.
4. Insert the correct orifice into the O-ring, and re-install into the nut at the gas valve outlet (top of the gas valve) and then tighten the nut.
5. Restore the gas supply by opening the manual gas valve.
6. Test for leaks by using an approved leak detection solution on all joints. 7. Carefully follow the “Prior to Start-Up” ­ Section 3.2 and “Commissioning” ­
Section 3.3 procedures on the preceeding page 3-2.

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INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199
WARNING Each unit is equipped with a back flow valve installed at the outlet of the fan. Inspect the back flow flapper annually.

Figure 34: Back Flow Valve

Figure 35: Blower and Gas Valve Assembly

NOTE
The Caution reguarding burner refractory on page 4-2 of this manual must be observed.
CAUTION
When removing the heat exchanger cover in step 6, be careful not to damage the burner and refractory material located on the opposite side of the heat exchanger cover. Use caution when handling refractory materials. See Caution on page 4-2.

3.4.1 Gaining access to combustion chamber, burner removal instructions
DISASSEMBLY
1. Turn off the main power switch to the unit. 2. Turn off the gas supply valve to the unit.
There is no need to drain the unit unless the unit will be exposed to freezing conditions while off. 3. Remove the front cover, and allow the unit to cool. 4. Unplug the electrical connector at the gas valve and fan. 5. Loosen the lower gas valve connection nut. NOTE: There is an O-ring in the lower gas connection. Cover the gas piping connections to prevent debris from entering the gas piping. 6. Remove all 6mm Allen bolts and lock washers from the heat exchanger cover and carefully remove the front cover complete with the fan and the gas valve attached. 7. Place the heat exchanger cover in a safe location.

STARTUP AND COMMISSIONING

3-5

Figure 36: Tighten hex bolts in cross pattern direction.

TANKLESS WATER HEATER 199
REASSEMBLY
1. Replace the heat exchanger gasket. Inspect, and when needed change other gaskets. If necessary, inspect and clean the gasket mating surface.
2. Place the heat exchanger cover onto the heat exchanger and loosely install the 6mm Allen bolts and lock washers removed in step 6. Tighten the 6mm Allen bolts in a cross pattern as shown in the Figure 36.
3. Connect the gas line to the gas valve ensuring the O-ring is in place. Tighten the gas valve nut. Ensure the upper gas valve connection is tight. Re- connect the gas valve electrical connection.
4. Re-connect the electrical connection to the fan. 5. Inspect the condensate trap for debris. Remove and clean if necessary. Fill
the condensate trap with water. 6. Turn on the gas supply valve to the unit and inspect for gas leaks. Use an
approved leak detection solution. Soap test all joints. 7. Ensure the unit is full of water and purged of air if the unit was drained during
disassembly. 8. Turn on the power to the unit and create a call for domestic hot water. 9. Inspect the gasket around the unit cover. 10. Check flue gases for proper combustion. See Section 3.3 Commissioning for
proper adjustments. 11. Re-install the unit’s cover and set the unit into normal operation.

3-6

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

WARNING – Fill the trap with water before the unit is first fired to prevent exhaust fumes from entering the room. Never operate the unit unless the trap is filled with water. Failure to comply will result in severe personal injury or death.
– Whenever the burner is removed for inspection or servicing, examine the sealing gaskets and replace if damaged.
CAUTION – The owner is responsible for general care of the unit. Improper maintenance of the unit may result in a hazardous condition.
– When servicing controls, label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation.
– When removing a burner, a new burner gasket is required.

4.0 MAINTENANCE
4.1 WATER HEATER MAINTENANCE
4.1.1 General Care · Keep combustible materials and flammable liquids and vapors away from the unit. · Keep vent terminals clear of obstructions (snow, dirt, etc.).
4.1.2 Inspection · Inspection of the unit must be performed annually by a qualified service
technician.
4.1.3 Venting · Check vent terminals for any obstructions (e.g. leaves, dust, other debris). · Check and clean or replace intake air filters or screens as required. · Check for holes or leaks in venting. Replace venting as needed. · Examine for any signs of moisture caused by sweating intake air pipes.
Insulate as required.
· Ensure proper resealing or reinstallation of venting at each servicing.
4.1.4 Condensate Trap · Examine the condensate trap every two months to see if cleaning is
necessary (refer to trap cleaning instructions, section 4.1.15 of this manual). Ensure that the trap has been re-filled completely before firing the unit.
· Check the pH level of the condensate discharge if using condensate
neutralization.
4.1.5 Burner · At the first annual service, remove the burner to inspect the extent of fouling
(refer to burner removal and reassembly instructions, section 3.4.1 of this manual). Blow clear using compressed air. Evaluate the magnitude of cleaning required, and establish a reasonable burner inspection schedule. Some installations may call for annual service, others showing clean burners will only need attention every 2 years. Consider adding air filtration if the burner requires cleaning every year. In alternate years, visually inspect burner through the sight glass. Ensure the flame is stable and without excessive fluttering. Normal flame pattern is evenly distributed over the burner surface.
· If the burner is operating improperly, remove and clean or replace. Use a
combustion analyzer to determine proper combustion. See Table 11 for correct values.

MAINTENANCE

3/16″ / 4.5MM Figure 37: Checking igniter gap using 251-001 Ignitor Gapping Tool
4-1

TANKLESS WATER HEATER 199

CAUTION
The heat exchanger has a small amount of combustion chamber insulation (refractory) that contains ceramic fibers.
When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite, classified as a possible human carcinogen.
Avoid disturbing or damaging the refractory. If damage occurs, contact the factory for directions.
Avoid breathing in fumes and contact with skin and eyes. Follow these precautions:
1. For conditions of frequent use or heavy exposure, you need a respirator. For respirators certified by NIOSH, refer to the “NIOSH Guide to the Selection and Use of Particulate Respirators Certified under 42 CFR 84”.
For current information, contact NIOSH on 1-800-3564676 or on the web at
www.cdc.gov/niosh.
2. Wear long sleeved, loose fitting clothing, gloves and eyes protection.
3. Assure adequate ventilation.
4. Wash with soap and water after contact.
5. Wash potentially contaminated clothes separately from other laundry, and rinse clothes thoroughly.
6. Discard used insulation in an air tight plastic bag.
NIOSH first aid guidelines:
· Eye contact – Irrigate and wash immediately.
· Breathing in fumes – Provide fresh air.

4.1.6 Heat Exchanger
During annual inspection (with the heat exchanger cover removed), examine the heat exchanger for signs of contamination and clean if necessary. In areas of poor gas quality or contaminated combustion air, there may be a build-up of black plaque (typically sulfur). Other fouling agents are airborne dust, debris and volatiles. Clean the heat exchanger surface with a stiff plastic bristle brush only. During maintenance, the heat exchanger gasket must be replaced. Inspect other gaskets, and change when needed. Refer to the heat exchanger cover removal instructions in Section 3.4.1 for access to the combustion chamber and heat exchanger. Observe the safety warning regarding the burner refractory on this page.
4.1.7 Gas Piping
Check for damage or leaks, and repair as needed.
4.1.8 Control Module · Check that unit operation is consistent with the steps in Section 2.5
Sequence of Operation.
· Check that water temperature target is satisfactory, and that it has not been
adversely adjusted.
4.1.9 Freeze Protection
The controller ignites the burner as needed to protect the unit from freezing.
4.1.10 Relief Valve – Maintenance and Testing
Relief valve manufacturers require that under normal operating conditions a “try lever test” must be performed quarterly. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, you must test more often. Also perform a “try lever test” at the end of any non-service period.
Test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris. Then release the lever and permit the valve to snap shut.
If the lever does not activate, or there is no evidence of discharge, discontinue use of equipment immediately, and contact a licensed contractor or qualified service personnel. If the relief valve does not completely seal, and fluid continues to leak from the discharge pipe, perform the test again to try and flush any debris that may be lodged in the valve. If repeated attempts fail to stop the leakage, contact a licensed contractor or qualified service personnel to replace the valve.
4.1.11 Domestic Hot Water System
Verify that domestic hot water generation is performing as expected and that water quality is within the guidelines shown in Table 12. Clean the internal DHW coil using nontoxic tankless water heater cleaning solution as required to maintain peak DHW operation and efficiency. Fouling of the DHW coil will

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CAUTION
Before testing the relief valve, make certain the discharge pipe is properly connected to the valve outlet, and arranged to contain and safely dispose of equipment discharge.

accelerate and require more frequent cleaning with increased water hardness. Installation of a water softener at sites with hard water is recommended to reduce
fouling and cleaning frequency. Failures caused by lime, mineral buildup, or scale due to a lack of maintenance will not be covered under warranty.

DESCRIPTION

MAX

Water Pressure

150 PSI

Programmable Water Temperature

149°F (65°C)

Minimum DHW Flow Rate to Initiate Operation N/A

pH

8.5

Total Dissolved Solids (TDS)

500 mg/L

Total Hardness

250 mg/L 14.6 grains/gal

Aluminum

0.2 mg/L

Chlorides

250 mg/L

Copper

1 mg/L

Iron

0.3 mg/L

Manganese

0.05 mg/L

Zinc

5 mg/L

Table 12: Domestic Water Quality Guidelines

MIN 40 PSI 105°F (40°C) 0.5 GPM 6.5
0.05 mg/L

4.1.12 DHW Coil cleaning instructions
Clean the DHW coil as follows:
1. These instructions assume that a set of service valves have previously been installed.
2. These instructions assume the use of a tankless water heater flush kit. 3. Turn off the unit by touching the area above the dot for 2 seconds. 4. Open a hot water faucet until the heat exchanger is sufficiently cool. 5. Close the gas valve and DHW hot and cold water isolation valves.
6. Attach two hoses to the DHW hot and cold water service valve hose connections.
7. Attach the cold water hose to the flush kit pump and place in a 5 gallon bucket.
8. Place the loose end of the hot water hose in the bottom of the 5 gallon bucket and open the DHW hot and cold water service valves.
9. Pour 2 gallons of nontoxic tankless water heater cleaning solution in the bucket.
10. Plug in the pump and allow the cleaning solution to circulate in accordance with the manufacturer’s instructions.
11. After cleaning the DHW coil, disconnect the wire harness from the flue gas temperature sensor on models equipped with an internal domestic hot water bypass valve. The lockout will cause the internal domestic hot water bypass valve to send cleaning solution through the bypass line.
12. Allow the cleaning solution to circulate in accordance with the manufacturer’s instructions.
13. After cleaning the bypass line, unplug the pump and close the DHW cold water service valve.
14. Remove the hot water hose from the 5 gallon bucket and route to a suitable drain.

MAINTENANCE

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TANKLESS WATER HEATER 199

15. Open the DHW cold water isolation valve and flush out the bypass line for about 5 minutes.
16. Reconnect the wire harness to the flue gas temperature sensor and reset the lockout by pressing the wrench for 2 seconds.
17. Flush out the DHW coil for about 5 minutes then close the DHW hot water service valve and open the DHW hot water isolation valve.
18. Disconnect the two hoses from the DHW hot and cold water service valve hose connections.
19. Open the gas valve and turn on the unit by touching the area above the dot for 2 seconds to resume normal operation.

4.1.13 DHW Filter cleaning instructions
Clean the DHW water filter during annual maintenance as follows: 1. Turn off the unit and disconnect power. 2. Turn off the DHW hot and cold isolation valves. 3. Place a bucket under the drain and drain the DHW water from the unit. 4. Unscrew the water filter from the unit’s cold water inlet. 5. Clean the water filter under running water. Use a soft brush if necessary. 6. Reinstall the water filter in the unit’s cold water inlet. 7. Open the DHW hot and cold isolation valves. 8. Reconnect the power and return the unit to operation.

DANGER
When servicing or replacing the fan, you must transfer the venturi from the old fan to the new fan.
Failure to relocate the venturi to the new fan may cause an immediately hazardous situation which must be avoided in order to prevent serious injury or death.

4.1.14 Fan removal instructions
1. Turn off the power and the gas supply to the unit. 2. Remove the front cover, and allow the unit to cool down.
3. Disconnect the electrical plug attached to the fan.
4. Loosen the union nut at the top of the gas valve. Carefully remove the orifice and O-ring, and keep in a safe place for re-installation later. Ensure you protect the gas valve outlet from dust and debris.
5. Remove the 2 hex nuts connecting the fan to the burner housing, and carefully remove the fan. You will find a gasket attached to the fan outlet as well as an internal check valve. Keep these items in a safe place for reinstallation.
6. If the removed fan is to be re-installed, ensure the fan and venturi are clean and dust free. If the fan is being replaced, move the venturi over to the new fan. Note that the fit is tight.

4.1.15 Fan installation instructions
1. Place the fan gasket on the outlet of the fan housing. The gasket has 2 locator pins to ensure the gasket does not move during installation.
2. Reinstall the check valve in the burner housing and attach the fan to the burner housing with the 2 hex nuts. Tighten the 2 hex nuts with a wrench.
3. Insert the orifice and O-ring between the gas valve outlet and the gas line to the fan. Tighten the gas valve union nut with a wrench. Ensure that the gas valve inlet (lower) nut is tight.
4. Connect the electrical plug to the fan. 5. Restore the gas supply to the unit, and test the gas valve inlet for gas leaks.

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TANKLESS WATER HEATER 199
6. Restore the power to the unit, and create a call for hot water. 7. Check for leaks at the gas valve outlet and the connection between the fan
and the burner housing. 8. Install the cover to the unit. 9. Return the unit to normal operation.

4.1.16 Cleaning the Condensate Trap
1. Turn off the power and the gas supply to the unit. 2. Remove the front cover, and allow the unit to cool down. 3. Remove the flexible hose (1) from the condensate trap and drain. 4. Detach the condensate trap cup (2) by rotating it to the left (counterclockwise) and then pulling it downwards.
5. Empty the condensate trap cup (3).
6. Detach the condensate trap base (4) by pressing the three securing clips in, while simultaneously pushing the condensate trap base downwards (4).
7. Remove the circlip and the plastic ball from the condensate trap base (5)

1

2

MAINTENANCE

3

4

2 1
1
1

8. Clean the following components with water:
the inside of condensate trap base plastic ball circlip condensate trap cup opening of the flue pipe

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TANKLESS WATER HEATER 199

5

6

2 ¼” (60 mm)

DANGER
Make sure that the condensate trap base is returned to its original position, firmly locked into the bottom with no gaps.
Incorrectly attaching the condensate trap base (or not attaching it at all) will result in products of combustion leaking into the room creating a dangerous situation.

9. Return the plastic ball to the condensate trap base and attach the circlip.
10. Check that the ball and circlip have been installed correctly (6). Make sure that the top of the circlip is about 2 1/4″ (60 mm) below the edge of the condensate trap base.
11. Replace the O-ring (part #150-367) at the bottom of the flue pipe.

12. Attach the condensate trap base to the bottom by pushing it high enough so

that the securing clips click over the lip (8).

13. Make sure the condensate trap cup is ¾ filled

with water (7) before installation, slide it into the

condensate trap base and rotate it to the right (clockwise) until it is correctly secured (9).

­CL ICK!­

7

8

9

10

14. Slide the flexible hose onto the condensate trap base and into the drain (10)

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CAUTION
The maintenance counter must only be reset after performing the maintenance procedures in Section 4.0 Maintenance of this manual. Failure to perform maintenance can result in a hazardous condition.

4.1.17 Reset the Maintenance Counter
The maintenance counter should be reset after all maintenance items in this section have been completed. Refer to Resetting the Maintenance Counter, section 2.7 of this manual.

NOTE
Damage to the Tankless Water Heater caused by freezing water is not covered by the warranty.

4.1.18 Winterization
The Tankless Water Heater must be winterized along with the rest of the domestic water system when the system will be shut down for an extended period of time and be subject to freezing conditions. 1. Turn off the power and the gas supply to the unit. 2. Drain the units domestic hot water coil along with the rest of the domestic
water system.
3. Remove the condensate trap cup and empty.
4. If present, empty condensate pump.

MAINTENANCE

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NOTE
This appliance is equipped with a blocked vent shut-off system that closes the gas supply when it detects an irregular venting condition.

5.0 TROUBLESHOOTING
The troubleshooting section is divided into four sections:
5.1 Preliminary Checks 5.2 Electronic Components 5.3 Faults and Notifications 5.4 Other Faults
Often, you can identify and solve a problem through simple checks of the basics: confirming the electrical power supply and gas flow. To help with preliminary checks, the unit’s control module offers a visual display of the status of the various control circuit components.
Should a problem remain unsolved after applying the preliminary checks, proceed to the detailed system review in this guide. The Troubleshooting chapter covers potential error conditions, grouped into the following categories:
5.3.1 Fault Codes 5.3.2 Notification Codes 5.4.1 No domestic hot water (DHW) 5.4.2 Domestic hot water does not reach the correct temperature 5.4.3 Burner ignites loudly 5.4.4 Burner resonates Below each section is a list of symptoms, diagnoses, and solutions. Some diagrams (see Section 6.0) are included for use with troubleshooting including:
· Electrical wiring diagrams · Water heater component layout diagrams

5.1 PRELIMINARY CHECKS
As a first step in troubleshooting, you should review the controller’s display screen. Diagnostic features evaluate system integrity, display error conditions, and indicate initial troubleshooting action.
In addition to checking the controller’s display, try these troubleshooting steps: 1. Confirm power to the unit: check that control module display is on (e.g.,
display is lit). 2. Check that unit is not in a safety lockout. 3. Ensure that wiring is secure and properly terminated. 4. Check that gas is reaching the unit. 5. Confirm that the domestic water system pressure is a minimum 40 psig.

TROUBLESHOOTING

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TANKLESS WATER HEATER 199

5.2 ELECTRONIC COMPONENTS
This section details the method for troubleshooting the non-standard electronic components on the unit.

Figure 38: Heat exchanger Temperature Sensor S0
Cabinet sensors

5.2.1 Temperature Sensors
The resistance of the temperature sensors varies inversely with temperature. To test, measure the temperature of the sensed environment and compare with the value derived from the measurement of the resistance (obtained by connecting a good quality test meter capable of measuring up to 5,000 K (5,000,000) at the controller end of the sensor lead).
To obtain a resistance reading, remove power to the unit. For the water sensors, remove the wire leads by disconnecting their respective Molex connectors. Place multi-meter probes into the sensor’s male Molex connector socket. Do not apply voltage to the sensor as damage may result.
12K temperature sensors are supplied with the unit. See Table 14 for resistance values.

SENSOR TYPE

PURPOSE

S0

NTC 12K

Heat Exchanger Temperature

S3

NTC 12K

Domestic Hot Water

S4

NTC 12K

Domestic Cold Water

S5

NTC 12K

Flue Gas Temperature

PTC1 PTC2

PTC

Cabinet Temperature

Table 13: Temperature Sensors

LOCATION
Left side of Heat Exchanger
DHW Supply Pipe DCW Supply Pipe Top of rear Flue passage Left and right Side top of inner cabinet

Figure 39: PTC Cabinet Temperature Sensors

5.2.2 Cabinet Sensors
The Cabinet temperature sensors ensure that the unit shuts down if the temperature inside the cabinet is above normal.
The Cabinet temperature sensors are located on the left and right side at the top of the cabinet. To remove the sensors, unclip the wiring harness and unscrew from the top cabinet.

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

F / C

– ohm

F / C

– ohm

5F / -15C

76,020

77F / 25C

12,000

14F / -10C

58,880

86F / 30C

9,805

23F / -5C

45,950

95F / 35C

8,055

32F / 0C

36,130

104F / 40C

6,653

41F / 5C

28,600

113F / 45C

5,522

50F / 10C

22,800

122F / 50C

4,609

59F / 15C

18,300

131F / 55C

3,863

68F / 20C

14,770

140F / 60C

3,253

Table 14: Temperature Sensor Resistance Values ­ 12K sensors.

TEMPERATURE RESISTANCE

F / C

– ohm

149F / 65C

2,752

158F / 70C

2,337

167F / 75C

1,994

176F / 80C

1,707

185F / 85C

1,467

194F / 90C

1,266

203F / 95C

1,096

212F / 100C

952

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TANKLESS WATER HEATER 199

Figure 40: Flue gas Temperature Sensor S5

5.2.3 Flue Gas Temperature Sensor
This sensor ensures that the unit shuts down safely if the flue temperature is above normal. High flue temperatures can be an indication that the heat exchanger requires cleaning. The flue gas temperature sensor is located at the top of the rear flue passage, below the top panel. To remove the sensor, unclip from the wiring harness and unscrew from the rear flue passage.
5.2.4 Domestic Hot Water Flow Sensor
The unit is equipped with a flow sensor to measure water flow through the domestic hot water circuit in the water heater. The flow sensor consists of two parts, the mechanical turbine in the cold water inlet and the external inductive sensor surface mounted on the outside of the cold water inlet. The minimum flow required to activate the water heater is 0.5 GPM or 2 L/min. To service or replace the mechanical turbine:
1. Disconnect power to the unit. 2. Turn off the cold and hot water valves below the unit, release the water
pressure and then drain the domestic hot water circuit. Leave the drain valves open.
5.2.5 Domestic Hot Water Sensor
The unit is equipped with a domestic hot water temperature sensor. The sensor is surface mounted on the hot water outlet pipe.

Figure 41: Domestic Water Flow Sensor

Figure 42: Domestic Hot Water Temperature Sensor S3

TROUBLESHOOTING

5-3

Figure 43: Bypass Valve

TANKLESS WATER HEATER 199
5.2.6 Domestic Hot Water Bypass Valve
This unit is equipped with a domestic hot water bypass valve which allows cold water to bypass the heat exchanger to temper the domestic hot water temperature. 1. To service or replace the bypass valve: 2. Turn off the unit and disconnect power. 3. Close the DHW hot and cold isolation valves. 4. Place a bucket under the drain and drain the DHW water from the unit. 5. Disconnect and remove the bypass tube. 6. Remove the retaining clip under the unit at the DHW filter. 7. Disconnect the bypass valve from the heat exchanger using two wrenches.
5.2.7 Domestic Cold Water Sensor
The Combi boiler is equipped with a domestic Cold water temperature sensor. The sensor is surface-mounted on the Cold water inlet pipe.
5.2.8 Fan/Blower
Control and power to the fan is provided via a single wiring harness to the controller.

Figure 44: Domestic Cold Water Temperature Sensor S4

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5.3 FAULTS AND NOTIFICATIONS

5.3.1 Fault Codes
During operation the controller can detect unusual situations and can take action to avoid damage to the heat exchanger or other unsafe operations. During these situations, the controller limits the temperature and power output of the burner, or temporarily disables operation entirely.
These warnings are shown flashing and visible on the main display, and displayed only when an unusual reading is currently detected. Fault Codes can be reset by touching the wrench for 2 seconds after the cause of the fault has been resolved.

FAULT CODE F000 F002
F003
F004

DESCRIPTION Heat exchanger temperature sensor fault. High heat exchanger temperature during DHW demand.
High flue temperature.
No flame detected during four ignition trials.

POSSIBLE CAUSE / SOLUTION
· Verify wire harness connections at heat exchanger temperature sensor and control module are tight.
· Replace heat exchanger temperature sensor.
· Verify the unit has been converted to propane if operating on propane
· Verify combustion readings at low and high fire are within specifications.
· Clean heat exchanger DHW coil. · Clean fire side of heat exchanger.
· Verify the unit has been converted to propane if operating on propane.
· Verify combustion readings at low and high fire are within specifications.
· Clean fire side of heat exchanger. · Clean heat exchanger central heating and DHW coils.
· Verify external gas shutoff valve is open. · Verify gas inlet pressure is at least 4″ during igntion
trial.
· Verify condensate drain is not blocked. · Check vent and combustion air piping for blockage. · Verify internal and power supply grounding. · Verify ground spring is in contact with burner head
screw.
· Verify ignitor to ignition module connection is tight. · Check ignitor condition and clean/replace as
necessary.
· Verify operation of the backflow flapper in the fan outlet.
· Verify ignitor is not in contact with burner and gap is correct.
· Replace ignition module if unit lights but flame icon doesn’t illuminate.
· Replace ignition module if spark is not present and 110VAC is present on ignition module black and gray wires.
· Replace control module if spark is not present and 110VAC is not present on ignition module black and gray wires.
· Replace gas valve if gas inlet pressure does not drop during trial for ignition and 24VDC is present at gas valve harness.
· Replace control module if gas inlet pressure does not drop during trial for ignition and 24 VDC is not present at gas valve harness.

TROUBLESHOOTING

5-5

F005
F006 F007 F008 F009 F010 F011 F012
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TANKLESS WATER HEATER 199

No flame detected during operation.
Flame detected when burner is off. Low flame signal. Incorrect fan speed Control module internal fault. Heat exchanger temperature sensor open.
Heat exchanger temperature sensor short. Flue temperature sensor open.

· Verify condensate drain is not blocked. · Check vent and combustion air piping for blockage. · Check for flue gas recirculation. · If vent termination is subject to high winds,
reconfigure/relocate as necessary. · Verify gas inlet pressure is at least 4″ at both low and
high fire. · Verify low and high fire combustion readings are within
specifications. · Check ignitor condition and clean/replace as
necessary.
· Verify good internal and power supply grounding. · Verify flame goes out at conclusion of demand, if not
replace gas valve.
· Replace ignition module. · Replace control module.
· Verify ignitor to ignition module connection is tight. · Check ignitor condition and clean/replace as
necessary.
· Verify low and high fire combustion readings are within specifications.
· Verify wire harness connections at fan and control module are tight.
· Replace fan. · Replace control module.
· Remove all field wiring from unit then reset fault. · Check field wiring for voltage backfeed if F009 fault
does not return.
· Replace control module if F009 fault code returns.
· Verify wire harness connections at heat exchanger temperature sensor and control module are tight.
· Check resistance of each heat exchanger temperature sensor (center pin is common), replace sensor if open circuit is found.
· Check resistance of each heat exchanger temperature sensor (center pin is common) at control module harness connector, repair wire harness if open circuit is found.
· Check resistance of each heat exchanger temperature sensor (center pin is common), replace sensor if short circuit is found.
· Check resistance of each heat exchanger temperature sensor (center pin is common) at control module harness connector, repair wire harness if short circuit is found.
· Verify wire harness connections at flue temperature sensor and control module are tight.
· Check resistance of flue temperature sensor, replace sensor if open circuit is found.
· Check resistance of flue temperature sensor at control module harness connector, repair wire harness if open circuit is found.

INSTALLATION AND OPERATION INSTRUCTIONS

F013
F014 F015 F016 F017
F018 F019 F021 F028 F029

TANKLESS WATER HEATER 199

DHW inlet temperature sensor open/ short
Heat exchanger temperature sensor mounting fault. High cabinet temperature DHW outlet temperature sensor mounting fault DHW bypass valve fault
Flue/Combustion Air blockage. Boiler Memory Module (BMM) fault.
Critical parameter changed Reset button fault Gas valve fault.

· Verify wire harness connections at DHW inlet temperature sensor and control module are tight.
· Check resistance of DHW inlet temperature sensor, replace sensor if open/short circuit is found
· Check resistance of DHW inlet temperature sensor at control module harness connector, repair wire harness if open/short circuit is found
· Heat exchanger temperature is not changing while unit is fired.
· Verify heat exchanger temperature sensor is properly mounted on the heat exchanger.
· Check heat exchanger for flue gas leakage · Check vent pipe for flue gas leakage
· DHW outlet temperature is not changing while unit is fired
· Verify DHW outlet temperature sensor is properly mounted on the DHW outlet pipe
· Verify wire harness connections at DHW bypass valve and control module are tight
· Check resistance of DHW bypass valve at control module harness connector:
Green – Pur

References

• National Institute for Occupational Safety & Health | NIOSH | CDC
• licensing.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp

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