Intellihot iN199 Neuron Drop In Tankless Water Heater User Guide

Installation & Operation Manual
iN199

iN199 Neuron Drop In Tankless Water Heater

Thank you for purchasing this Intellihot unit.
This unit is designed for years of trouble-free operation, and I urge you to read and follow the instructions in this “Installation & Operation Manual.”
Our mission to create a better heating system began in the winter of 2005 when a tank water heater broke down and flooded my basement. By combining the principles of a diesel engine’s robustness, robotics intelligence, and marine environment durability, we  set out to design a unit from the ground up that would outperform and outlast all others.
Quickly, our goal grew from not just making a better water heater, but creating an intelligent water heating and delivery system. Innovation is our hallmark, and simplicity, efficiency, and durability are at the core of every lntellihot product.
Our products are proudly engineered and built in Galesburg, Illinois. lntellihot has helped commercial customers throughout the nation save thousands of dollars while eliminating downtime. Our talented team of dedicated professionals is ready to assist you and help your business succeed.
I thank you for purchasing our lntellihot products.

Sincerely,
Sri Deivasigamani
CEO, lntellihot Inc.

WARNING
If the information in these instructions is not followed exactly, a re or explosion could result causing property damage, personal injury, or death.
— Do not store or use gasoline or other flammable vapors and liquids 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’sinstructions.
• 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.

This product complies with ANSIZ21.10.3 (2011) / CSA 4.3 Gas Water Heater. For use as potable water heating.

DANGER
To avoid product damage, personal injury, or even possible death, carefully read, understand, andfollow all the instructions in this Installation &Operation Manual before installing this product. Improper installation, adjustment, alteration, or maintenance can cause injury, loss of life, and/or property damage. This water heater should be installed and serviced by a qualified technician. The lack of proper service can result in a dangerous condition.
Due to Intellihot’s policy of continuous product improvement and technology, the design, technical specifications, or both in this manual are subject to change without notice.
This manual contains safety information, installation instructions, and maintenance procedures. It must be left with the homeowner or placed near the water heater in a noncombustible location. The customer should retain this manual for future reference.

Contact Information
Call us, your dealer, first if you have any questions about this product. We can help answer questions about installation, operation, or if there are damaged or missing parts when unpacking this unit from the shipping box.

General Information

1.1 Item s Shipped With Water Heater
The items shown in the illustration are shipped loose with the water heater.

1.2 Serial Number Locations
The unit’s serial number is located on the left side of the unit.
Provide this serial number when inquiring about service or warranty solutions.
Unit Serial Number: __
Heat Engine (ASME) Serial Number (iN199A/iN251 only): ____
Date of Installation: / / __

Safety

2.1 Safety Signal Words
DANGER
Indicates an imminently hazardous situation which, if not avoided, results in death or serious injury. This signal word is limited to the most extreme situations.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, might result in minor or moderate injury.
NOTICE
Indicates that equipment or property damage can result if instructions are not followed.
SAFETY INSTRUCTIONS
Safety instructions (or equivalent) signs indicate specific safety-related instructions or procedures.
Note: Contains additional information important to a procedure.
2.2 Installation Warnings

WARNING
DO NOT use this water heater for any purpose other than heating water.
Read, understand, and follow the Installation & Operation Manual, including all warnings and precautions, before operating this water heater. If you do not follow these instructions exactly, a fire or explosion can result, causing property damage, personal injury, or loss of life.
Follow all local codes and the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the USA or the Natural Gas and Propane Installation Code in Canada (CSA B149.1).
This water heater must be installed by a licensed plumber, gas fitter, or professional service technician. Installation by unqualified person(s) voids the warranty. This water heater is designed for operations at outlet temperature(s) not in excess of 190°F (88°C).

DANGER
A. This water heater does not have a pilot light. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner manually.
B. BEFORE OPERATING, smell all around the water heater area for gas. Be sure to smell near the floor because some gas is heavier than air and settles on the floor.
WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.
• Do not touch any electric 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 or police department.

C. Use only your hand to turn the manual gas shut-off valve. Never use tools. If the manual gas shut-off valve does not turn by hand, don’t try to repair it. Call a qualified service technician. Force or attempted repair can result in a fire or explosion.

WARNING

DO NOT use or store flammable liquids around the water heater, including gasoline, oils, spray paints, etc.
DO NOT operate this water heater unless it is properly vented to the outside (the exhaust vent piping must be connected from the unit directly to the outside). Improper venting can cause a build-up of carbon monoxide, which can result in brain damage or  death. Exhaust gases must be completely expelled out of the building.
This water heater is factory preset for NATURAL GAS but can be field-converted for use with propane. For propane conversion, refer to the Propane (LPG) Conversion section of this manual. Connecting the water heater to any other gas supply can result in property damage, serious injury, or even death.
This water heater is suitable for use in potable water heating applications. The cold and hot water fittings on the top of the water heater MUST NOT be connected to any heating system.
The water heater temperature is factory set to 120°F (49°C). Hot water temperatures above 125°F can cause severe burns instantly or death from scalds. If the proposed water heater outlet temperature is to be set above 125°F, installation of a thermostatically controlled (or temperature-limiting) mixing valve is recommended for all hot water going to faucets to avoid the risk of scalding. Examples include commercial applications where 140°F (60°C) is often needed or if the space heating temperature required is higher than the domestic hot water. Always check the temperature of the hot water before bathing, showering, washing, etc.
Protect against snow and debris accumulation around the vent terminations. Regularly inspect the exhaust vent pipe and the air intake pipe to ensure they remain clear from obstructions at all times.
CAUTION
Make sure you know the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the water heater is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the water heater checked by a qualified technician before resuming operation.
If the water quality is known to have high acidity, high hardness, or both, water treatment is recommended. Consult the local water authority.
SAFETY INSTRUCTIONS

DO NOT use this appliance if any part has been under water.
DO NOT reverse the cold water and gas connections as this damages the gas valve.
DO NOT over tighten fittings as damage might occur, causing internal leakage.
Locate the appliance in an area where leakage within the unit or at its connections does not result in damage to the surrounding area. The manufacturer is not responsible for any damage resulting from leaking if adequate drainage is not provided.

Technical Specifications

3.1 Specifications Chart

**Technical Data| ****iN199 Specification| ****iN199A Specification*
---|---|---
Type| Indoor, Floor-Mounted
Fuel| Preset for natural gas but convertible to propane
Minimum Input (BTUs/hour)| 30,000
Maximum Input (BTUs/hour)| 199,950
Maximum Output (BTUs/hour)| 195,950
Thermal Efficiency| 98%
Turn Down Ratio (TDR)| 6.7:1
Water Inlet / Outlet Connection| 1-1/2″ NPT
Gas Inlet Connection| 1-1/2″ NPT (3/4″ w/nipple)
Condensate Drain Connection| 3/4″ PVC
Maximum Condensate Flow Rate (GPM)| 1.4
Unit dimensions H X W X D (inches)| 67.5 X 20 X 20 (15.6 cu. ft)
Service Clearances| 4″ on the back, 6″ on the top, 12″ on the front, and 6″ on the sides
Unit weight (lbs)| 273
Shipping Crate Dimensions H X W X D / Weight| 27 X 29.5 X 85 (Inches) / 373 (LBS)
Venting Type| Direct Vent (2 pipe – air intake and exhaust gas outlet), Power Vent (1 pipe – exhaust gas only)
Venting Materials (USA)| Sch. 40 PVC, Sch. 80 CPVC, Polypropylene, Stainless Steel (AL29-4C)
Venting Materials  (Canada)| Type BH Gas Vent Classes: II A (PVC), II B (CPVC), II C (Polypropylene), I (AL294C SS)
Venting Size (Diameter)| 3″
Max 3″ Vent Length – Single Pipe/Power Vent| 195′
Max 3″ Vent Length – Two Pipe / Direct Vent| 95′ *

• Venting Note: From the maximum length above, deduct 5 ft. per 90° elbow and 2 ft. per 45° elbow.
  Ignition| Electronic Spark Ignition
  Temperature Range| 100°F – 190°F
  Temperature Stability| +/- 4°F (when on demand)
  Installation Location Ambient Temperature| 40°F – 130°F
  Safety| Flame Rod, Thermal Fuse, Overheat Prevention Device, Fan Speed Monitor, Flue Temperature Monitor, Blocked Vent Detector, Dual Flame Sensing
  Water Pressure Min / Max (PSI)| 30/150| 30/160

  ---

NG/LP- Min. Static Gas Pressure (Full Fire)

| NG = 2.5” WC LP= 8” WC (set Gas regulator to 8” WC for NG 11” WC for LP)
NG/LP – Maximum Static Gas Pressure| 14” WC (set Gas regulator to 8” WC for NG 11” WC for LP)
Gas Pressure for Adjustments| 8″ WC for Natural Gas, 11″ WC for Propane
Electrical| 120V AC, 60 Hz
Power Consumption| Max 9.5 Amps, 16W (Standby)
Internal Water Volume (gallons)| 1
Features and Approvals| iN199|
Cascading| Masterless, 4-Unit, Automatic Rotation
Common Venting| Yes, Up to 4 Units
Heat Exchanger| Expandable, Stainless 316L
Appliance Certification to ANSI Z21.10.3| ETL (Z21.10.3 / CSA 4.3)| ETL (Z21.10.3 / CSA 4.3), ASME HLW
SCAQMD (Pending)| Ultra Low Nox (under 20 PPM)
Performance| Specification|
Hot Water Output (45°F Rise) (GPM)| 8.7
Hot Water Output (70°F Rise) (GPM)| 5.6
Hot Water Output (90°F Rise) (GPM)| 4.4
Hot Water Output (100°F Rise) (GPM)| 3.9
Hot Water Output (140°F Rise) (GPM)| 2.8
Warranty| Heat Engine Coil – 6 years, All Other Parts – 1 year
Note: Due to continuous product improvements, the design and technical specifications are subject to change without notice.

3.2 Nomenclature

3.3 High Elevation Installations
For operation at elevations above 2,000 feet, the hot water delivery capacity should be reduced by 4% for each 1,000 feet above sea level.
Clearance Requirements
For the water heater to operate properly and efficiently, the clearances specified in the table below are recommended.

Service Clearances: If multiple units are installed, complete the electrical connections first before making all other connections (gas, water, supply air, exhaust, and condensate). This enables the 1″ side to side clearances mentioned in 3.1 Specifications Chart.

1
Top| 6″ (15 cm)| 2″ (51 cm)| 6″ (15 cm)
Back| 5/8″ (16 mm)| 5/8″ (16 mm)| 4″ (10 cm)
Sides| 1″ (25 mm)| 1/2″ (13 mm)| 6″ (15 mm)
Front| 2″ (5 cm)| 2″ (5 cm)| 21″ (53 cm)
Bottom| 0″ (0 mm)| 0″ (0 mm)| 0″ (0 mm)

1 Service clearances are recommended dimensions to allow for normal service of the unit.

3.4 Connection Specifications

Connections

Description| Specification 2
Gas Supply Inlet Connection| 3/4″ NPT
Water Supply Inlet Connection| 1-1/2″ NPT
Heated Water Outlet Connection| 1-1/2″ NPT
Exhaust Gas Vent1| 3” Polypropylene
Air Intake Inlet1| 3″ Polypropylene
Condensate Drain Connection| 3/4″
Power Supply| 120V AC Power

1 Use the 3” adapter provided when using PVC or CPVC pipe.
2 Using sizes other than specified can cause damage to the water heater and will void the warranty.
3.5 Exhaust Gas Standards

CO 2 and CO Standards

Description| CO 2 Range (%)| Max. CO Level Particles Per Million (ppm)
Natural Gas
High Fire| 9.1% to 9.3%| < 200 ppm
Low Fire| 9.1% to 9.3%| < 60 ppm
Propane Gas
High Fire| 10.1% to 10.5%| < 200 ppm
Low Fire| 10.1% to 10.5%| < 60 ppm

3.6 Overall Dimensions

3.7 Configuration Options

NOTES:

1. This schematic is a suggested piping diagram. Any additional requirements from local codes and ordinances shall supersede this diagram.
2. Units are not to be installed in a closed loop system. Our gas fired units are HLW stamped.
3.  For pipe sizes and gas pressure requirements, please refer to the operation and installation manual.
4. Gas pressure regulators to be installed for each unit. Follow manufacturer’s installation instructions.
5. Water hammer arrestor comes installed in the units.
6.  Y-strainer to be installed according to manufacturer’s instructions, horizontal or vertical preferred.
7. Temperature and pressure relief valve (shipped with the unit) to be installed on the top hot water port.
8. Expansion tank to be sized based on the gallons of water in the plumbing system and to be installed per manufacturer’s instruction.

System with no storage tank and without mixing valve.

NOTES:

1. This schematic is a suggested piping diagram. Any additional requirements from local codes and ordinances shall supersede this diagram.
2. Units are not to be installed in a closed loop system. Our gas fired units are HLW stamped.
3.  For pipe sizes and gas pressure requirements, please refer to the operation and installation manual.
4. Gas pressure regulators to be installed for each unit. Follow manufacturer’s installation instructions.
5. Water hammer arrestor comes installed in the units.
6. Y-strainer to be installed according to manufacturer’s instructions, horizontal or vertical preferred.
7. Temperature and pressure relief valve (shipped with the unit) to be installed on the top hot water port.
8.  Expansion tank to be sized based on the gallons of water in the plumbing system and to be installed per manufacturer’s instruction.

Two iN199s with mixing valve but no storage tank.

NOTES:

1. This schematic is a suggested piping diagram. Any additional requirements from local codes and ordinances shall supersede this diagram.
2. Units are not to be installed in a closed loop system. Our gas fired units are HLW stamped.
3. For pipe sizes and gas pressure requirements, please refer to the operation and installation manual.
4.  Gas pressure regulators to be installed for each unit. Follow manufacturer’s installation instructions.
5. Water hammer arrestor comes installed in the units.
6.  Y-strainer to be installed according to manufacturer’s instructions, horizontal or vertical preferred.
7. Temperature and pressure relief valve (shipped with the unit) to be installed on the top hot water port.
8. Expansion tank to be sized based on the gallons of water in the plumbing system and to be installed per manufacturer’s instruction.

Three iN199s with mixing valve but no storage tank.

NOTES:

1. This schematic is a suggested piping diagram. Any additional requirements from local codes and ordinances shall supersede this diagram.
2. Units are not to be installed in a closed loop system. Our gas fired units are HLW stamped.
3. For pipe sizes and gas pressure requirements, please refer to the operation and installation manual.
4. Gas pressure regulators to be installed for each unit. Follow manufacturer’s installation instructions.
5. Water hammer arrestor to be installed within 5 ft of the wall unit on the hot water supply. Water hammer arrestor comes installed in Neuron.
6. Y-strainer is built into the wall unit and accessible for service from the outside.
7. Temperature and pressure relief valve (shipped with the unit) to be installed on the hot water supply.
8. Expansion tank to be sized based on the gallons of water in the plumbing system and to be installed per manufacturer’s instruction.
9. Venting materials for the unit should be CPVC, approved polypropylene, or AL29-4C stainless steel.
10. Adjust circuit setter and/or booster set temperature so that required fixture temperature is obtained on high temperature circuit.

Quick Reference Installation Guide

4.1 Install the Water Heater
When installing the water heater, follow all local building codes and the current edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the USA, or National Gas and Propane Installation Code (CAN/CGA B149.1) in Canada.

Note: For water heater installations in Massachusetts, refer to section “16. Serviceable Parts” on page 60.

1. Select an installation location.
   For an interior or exterior location, refer to section “5.
   Preparation Before Installation” on page 13.

2.  Check the quality of the water to determine if additional treatment is beneficial to the function and efficiency of the water heater. For additional information, refer to section “5.
   Preparation Before Installation” on page 13.

3. Make all necessary gas connections.
   For additional information, refer to section “6. Gas Connection” on page 14.

4. Make all necessary venting connections.
   For additional information, refer to section “7. Air Intake Inlet and Exhaust Gas Outlet Pipe Connections” on page 19.

5. Make all necessary water connections.
   For additional information, refer to section “8. Water Connections” on page

7. Make all necessary electrical connections. For additional information, refer to “9. Electrical Power” on page 30.
   Note: For additional electrical protection, a surge protector is recommended. Damage caused by power surges is not covered by the warranty.

8. If necessary, convert the water heater from the factory preset of using natural gas to using propane. Refer to section “11. Natural Gas to Propane Conversion” on page 34 for the instructions.

9. As part of the propane conversion process, the CO2 and CO₂ values must be adjusted. This process is also required when installing the water heater at altitudes over 8,000 feet. This procedure should be completed only by a qualified technician. To check, adjust, or both the CO2 and CO levels, refer to “10. Adjusting CO2 Level” on page 31.

10. If connecting multiple units together, refer to “13.
    Connecting Multiple Units” on page 47.

11. Fill out the Warranty Card and return it to Intellihot. For a copy of the card, go to “19. Product Warranty Registration” on page 71.

4.2 Pre-Startup Instructions

1. Recheck the hot and cold water lines, the gas line, condensate drain line, the fresh air inlet, and exhaust vent to make sure they are properly connected.
   

2. Open the gas supply valve, cold water valve, and hot water valve.

Note: Individual regulators not shown for clarity.

3. Before beginning this procedure, be sure power to the unit is off. Open several faucets and fixtures to allow for the maximum water flow rate.

4. Slowly open the outlet isolation water valve.

5. Slowly open the inlet isolation water valve.

6. Allow water to run for 10 minutes to purge all the air from the system

7. Slowly close the outlet isolation valve.

8. Purge air from the pump by opening its bleed screw.

9. Open the T&P valve to eliminate any residual air from the system. Purge for 5 minutes

10. Turn ON the power switch at the electrical junction box and turn ON the ON/OFF switch inside the front cabinet door. The water heater’s display panel should turn ON.

11. Slowly reopen the outlet isolation valve to allow maximum flow of water.

12.  Ensure the unit is operational and running at high fire with all individual engines operational.

13. Let the unit run a high fire for 15 minutes.

14. Turn off all the open faucets.

15. Follow the instructions in this manual and on the unit’s display screen. For additional information, refer to section “12. Operation” on page 36.

16. If multiple units are being installed, follow these instructions for each unit.

Preparation Before Installation

5.1 Selecting an Indoor Installation Site
NOTE:
a. When installing the water heater, follow all local building codes and the current edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the USA, or National Gas and Propane Installation Code (CAN/CGA B149.1) in Canada when installing this product.
b. For water heater installations in Massachusetts, refer to section “16. Serviceable Parts” on page 60.

1. Select an interior location for the installation. Each installation is unique; therefore, take the time to find the best location for the water heater.
   a. Install the water heater near locations that use hot water, such as bathroom, kitchen, or laundry room faucets.
   b. Select a location that minimizes the length of the water pipe.
   c. If the distances are long or if the faucet or appliance requires “instant” hot water, we recommend running a recirculation line back to the water heater from the farthest fixture.
   d. Insulate the hot water supply and recirculation lines.
   e. Select a location away from foot traffic and away from areas where dust, debris, chemical agents, or other combustible materials could accumulate.
   f. Allow sufficient space for service and maintenance access to all gas, water, and drain connections.
   g. Make sure the location meets all building code requirements.

2.  Minimize the distance that the exhaust gas outlet and air intake inlet must travel to an exterior wall.
   a. The exhaust vent outlet must not be located next to a walkway, near soffit vents, crawl space vents, or other areas where condensate (water vapor) could cause damage or create a hazard. Refer to section “7.7 Venting Clearance Specifications” on page 25 for additional information.
   b. The fresh air inlet vent must be separated from the exhaust vent per guidelines in section “7. Air Intake Inlet and Exhaust Gas Outlet Pipe Connections” on page 19. c. Contaminated or dirty air drawn into the intake pipe can damage the water heater. The warranty does not cover damage caused by airborne contaminants.

3. Locate the unit close to a drain and near gas and water connections.
   The water heater produces a significant amount of condensate during normal operation and should be located near a suitable drain where damage from a possible leak is minimal. Installing the water heater in a location without a drain voids the warranty and the manufacturer is not responsible for any resulting water damages that might occur. For additional information, refer to section “8.4 Condensate Drain Line” on page 29.

4. Locate the water heater and all the water pipes in an area where the ambient temperature always remains above freezing.
   a. When the water heater is connected to an electrical power supply, it automatically prevents the water from freezing inside the unit.
   b. The unit’s freeze protection system does not prevent the water in the external piping from freezing.
   NOTICE
   In cold climates, if there is a power failure, the unit’s freeze protection system does not operate and can result in water freezing inside the heat engine. To prevent damage to the water heater, turn OFF the gas supply and inlet water valve. Drain the unit completely. Damage caused by freezing water is not covered by the warranty.

5.  Select an appropriate location for the combustion air and exhaust pipes to exit the building, as shown in section “7.7 Venting Clearance Specifications”.

6. Check the water quality.
   a. Proper maintenance of the water heater is required to ensure that the water meets EPA quality standards. Refer to section “18. Warranty” on page 69 for quality standard requirements and additional information.
   b. If you suspect that your water is contaminated in any way, discontinue use of the water heater and contact an authorized technician or licensed professional.
   c. If the incoming water is known to have a high mineral content or “hardness” (see warranty section), treatment is recommended upstream from the water heater.

Gas Connection

WARNING
FIRE AND EXPLOSION HAZARD
To avoid serious injury or even death, the gas line installation and the gas line inlet pressure test must be done by a licensed professional.
Always match the water heater with the type of gas supplied to the unit (natural gas or propane). The water heater is factory preset for natural gas.
Make sure the gas line pressures are within normal limits. Pressures outside normal limits can result in poor performance and hazardous operating conditions.

6.1 Quick Reference Installation Instructions

1. Determine fuel source; natural gas or propane as shown in “6.2 Fuel Source” on page 14.
2. Measure gas pressure as shown in “6.3 Gas Pressure Requirements” on page 14.
3. Install a gas pressure regulator and vent line if gas pressure is above maximum recommendations as shown in “6.4 Gas Pressure Regulator” on page 14.
4. Measure the length of the supply line as shown in “6.5 Length of Gas Supply Line” on page 15.
5. Select the proper gas piping material as shown in “6.6 Gas Piping Material” on page 15.
6. Select the proper gas piping diameter as shown in “6.7 Determine Correct Gas Pipe Diameter” on page 15.
7. Install a drip leg on the gas piping as shown in “6.8 Gas Pipe Drip Leg and Shut-off Valve” on page 15.
8.  Install a manual shut-off valve as shown in “6.8 Gas Pipe Drip Leg and Shut-off Valve” on page 15.
9. Test all gas line connections for leaks.

NOTICE
Do not fire (operate) the water heater until all connections have been completed and the heat exchanger is filled with water.
6.2 Fuel Source

1. Natural gas is the factory preset.
   

2. To convert the unit to propane, refer to section “11. Natural Gas to Propane Conversion” on page 34.
   

6.3 Gas Pressure Requirements
iN series water heaters are designed to operate at gas pressures as low as 2.5” Water Column (WC) (at maximum firing rate). Gas inlet pressures to each unit should not exceed 14” WC under any condition (whether the unit is firing or not firing).

Natural Gas Static Gas Pressure

Parameters| Specifications
Minimum Static Gas Pressure| 2.5″ WC (non-corrugated, black iron)
Recommended Gas Pressure| 8″ WC
Maximum Static Gas Pressure| 14″ WC

6.4 Gas Pressure Regulator

1. If the gas inlet pressure is higher than recommended, install a gas pressure regulator to lower gas pressure to an acceptable level.
2. The gas pressure regulator must have the same or higher minimum to maximum modulation range as the iN model it is regulating. For example, an iN199 gas pressure regulator should have a modulation range of 30,000 BTU/h to 199,950 BTU/h.
3. When multiple units are connected, use a dedicated gas pressure regulator for each unit.
4. Regulators should be mounted with a minimum of 12″ of straight length pipe on either side.
5. To convert the unit to propane, refer to “11. Natural Gas to Propane Conversion” on page 34.

6.4.1 Venting of Gas Supply Regulators
Make sure the gas supply regulator is properly vented by following all local codes and the gas regulator manufacturer’s recommendations.

1. The vent pipe must be at least the same size as the regulator vent.
2. When multiple units are connected, each regulator must have a separate vent line.
3. Vent lines must not be connected together or connected with any other appliance requiring external venting.
4. When selecting the size, the pipe diameter must be increased by one size for every 20 feet of pipe.
   • Each 90° elbow is equivalent to approximately:
   4.5 feet for nominal pipe sizes of up to 1-1/2″ 10.5 feet for nominal pipe sizes of up to 4″.
   • Each 45° elbow is equivalent to approximately:
   2 feet for nominal pipe sizes of up to 1-1/2″ 5 feet for nominal pipe sizes of up to 4″.

6.5 Length of Gas Supply Line

1. Make sure the length supply line is correctly sized.
   a. Measure the length of the gas supply line from the gas meter to the water heater or other appliances requiring gas. The diameter of the pipe must be in relation to the length.
   b. The total length of gas piping, as well as fitting pressure drop, must be considered when sizing the gas piping. Total equivalent length should be calculated from the meter or source location to the last heater connected.
   c. Gas pipe size should be selected on the total equivalent length. The gas volume for cfh (cubic foot per hour) flow is the input divided by the calorific value of the fuel to be supplied.
   d. Use the “6.10 Gas Pipe Sizing Tables” on page 17 or refer to the gas line manufacturers sizing information to determine the correct diameter for the supply pipe.
   e. The diameter of the gas lines vary according to the specific installation requirements.

6.6 Gas Piping Material

1. All gas piping and components must comply with NFPA local codes, and utility requirements minimum. Only gas approved fittings, valves, or pipe should be utilized.
2. Standard industry practice for gas piping is Schedule 40 iron pipe and fittings. All high and low gas pressure piping systems must comply with local utility and building codes.
3. Assembled piping should be clean of all scale, debris, metal particles, or foreign material.
4. The piping must be supported from the floor, ceiling, or walls and by the water heater itself.

6.7 Determine Correct Gas Pipe Diameter
Note: The water heater should be the first appliance to be connected to the gas supply line.

1. Determine the gas requirement of the water heater(s) and other appliances requiring gas.
2.  Size the pipe diameter according to the COMBINED total maximum BTUH volume for all the appliances as if they were all operating at the same time. Use the “6.10 Gas Pipe Sizing Tables” on page 17.

3.  Select the proper header pipe according to the number of units being connected together, as shown in the chart.
   Header Sizing for Multiple iN Units

   Number of Heaters| 1| 2| 3| 4
   Sch 40 Iron Pipe| 1″| 1″| 1.5″| 1.5″

4. The maximum pressure drop from the source to the final water heater must not exceed 0.3” WC.
5. The maximum gas flow rate required is the sum of the maximum inputs of each unit divided by the heat of combustion of the fuel supplied at the location (approximately 1,030 BTU per cubic foot for natural gas or 2,520 BTU per cubic foot for propane).
   Note: Consult the fuel supplier or utility to confirm that sufficient volume and normal pressure is provided to the building at the discharge side of the gas meter or supply pipe.

6.8 Gas Pipe Drip Leg and Shut-off Valve

1. Install a gas pipe drip leg on each water heater to prevent dirt, condensation, or debris from entering the gas inlet.
   

2. Local codes might require multiple units to have a full size drip leg on the main gas supply line and one on each unit.

3. The drip leg should have a removable clean-out cap.

4. The gas pipe must not be supported by the drip leg.

5. Follow local building codes when selecting and installing a shut-off valve.

6. Local codes might require multiple units to have a shut-off valve on the main gas supply line and one on each unit.

DANGER
The drip leg is required to protect the gas valve from debris and metal shavings. If the local plumbing code does not allow drip leg, an alternative mechanism such as filter shall be installed to protect the gas valve. The warranty does not cover if the gas valve is stuck open due to missing drip leg (or not including alternative method).

6.9 Connecting Gas Line to Unit
Note: Always clean the inside of the gas line of any dirt or debris before connecting the piping to the unit.

1. Install a flanged steel coupling and gasket with a short piece of 3/4″ NPT black pipe.

2. Install a manual shut-off valve as described in “6.8 Gas Pipe Drip Leg and Shut-off Valve” on page 15.
   Note: Wye-Strainer not shown for clarity.

3. Install a drip leg as described in “6.8 Gas Pipe Drip Leg and Shut-off Valve” on page 15.

4. Continue installing pipe to reach the main gas supply connection.

5.  Test all gas pipe connections.
   a. All the gas pipe connections should be tested as prescribed in NFPA 54.
   b. In multiple unit applications, each unit should be isolated before testing any piping system as pressure might exceed the allowable pressure of 14.0” WC.

NOTICE
Do not fire (operate) the water heater until all connections have been completed and the heat exchanger is filled with water.

6.10 Gas Pipe Sizing Tables
This information is for reference only. Refer to gas pipe manufacturer specifications for actual delivery capacity. Contact the local gas supplier for actual BTU/ft3 rating. This data is copied from the National Fire Protection Association Article 54 (NFPA 54).

Pipe Sizes and BTU/h Capacity (NATURAL GAS). Use this table for static gas pressure LESS THAN 5” WC

Length including fittings (feet)| 3⁄4″| 1″| 1-1/4″| 1-1/2″| 2″| 2-1/2″| 3″| 4″
10| 360,000| 678,000| 1,390,000| 2,090,000| 4,020,000| 6,400,000| 11,300,000| 23,100,000
20| 247,000| 466,000| 957,000| 1,430,000| 2,760,000| 4,400,000| 7,780,000| 15,900,000
30| 199,000| 374,000| 768,000| 1,150,000| 2,220,000| 3,530,000| 6,250,000| 12,700,000
40| –| 320,000| 657,000| 985,000| 1,900,000| 3,020,000| 5,350,000| 10,900,000
50| –| 284,000| 583,000| 873,000| 1,680,000| 2,680,000| 4,740,000| 9,660,000
60| –| 257,000| 528,000| 791,000| 1,520,000| 2,430,000| 4,290,000| 8,760,000
70| –| 237,000| 486,000| 728,000| 1,400,000| 2,230,000| 3,950,000| 8,050,000
80| –| 220,000| 452,000| 677,000| 1,300,000| 2,080,000| 3,670,000| 7,490,000
90| –| 207,000| 424,000| 635,000| 1,220,000| 1,950,000| 3,450,000| 7,030,000
100| –| –| 400,000| 600,000| 1,160,000| 1,840,000| 3,260,000| 6,640,000
125| –| –| 355,000| 532,000| 1,020,000| 1,630,000| 2,890,000| 5,890,000
150| –| –| 322,000| 482,000| 928,000| 1,480,000| 2,610,000| 5,330,000
175| –| –| 296,000| 443,000| 854,000| 1,360,000| 2,410,000| 4,910,000
200| –| –| 275,000| 412,000| 794,000| 1,270,000| 2,240,000| 4,560,000
Note: BTU/h capacities are based on specific gravity of 0.6, pressure drop of 0.5” WC.
Pipe Sizes and BTU/h Capacity (NATURAL GAS). Use this table for static gas pressure GREATER THAN 5” WC

Length including fittings (feet)| 1/2″| 3⁄4″| 1″| 1-1/4″| 1-1/2″| 2″| 2-1/2″| 3″| 4″
10| 404,000| 949,000| 1,787,000| 3,669,000| 5,497,000| 10,588,000| 16,875,000| 29,832,000| 43,678,000
20| 286,000| 652,000| 1,228,000| 2,522,000| 3,778,000| 7,277,000| 11,598,000| 20,503,000| 30,020,000
30| 233,000| 524,000| 986,000| 2,025,000| 3,034,000| 5,844,000| 9,314,000| 16,465,000| 24,107,000
40| 202,000| 448,000| 844,000| 1,733,000| 2,597,000| 5,001,000| 7,971,000| 14,092,000| 20,632,000
50| –| 397,000| 748,000| 1,536,000| 2,302,000| 4,433,000| 7,065,000| 12,489,000| 18,286,000
60| –| 360,000| 678,000| 1,392,000| 2,085,000| 4,016,000| 6,401,000| 11,316,000| 16,569,000
70| –| 331,000| 624,000| 1,280,000| 1,919,000| 3,695,000| 5,889,000| 10,411,000| 15,243,000
80| –| 308,000| 580,000| 1,191,000| 1,785,000| 3,437,000| 5,479,000| 9,685,000| 14,181,000
90| –| 289,000| 544,000| 1,118,000| 1,675,000| 3,225,000| 5,140,000| 9,087,000| 13,305,000
100| –| 273,000| 514,000| 1,056,000| 1,582,000| 3,046,000| 4,856,000| 8,584,000| 12,568,000
125| –| 242,000| 456,000| 936,000| 1,402,000| 2,700,000| 4,303,000| 7,608,000| 11,139,000
150| –| 219,000| 413,000| 848,000| 1,270,000| 2,446,000| 3,899,000| 6,893,000| 10,093,000
175| –| 202,000| 380,000| 780,000| 1,169,000| 2,251,000| 3,587,000| 6,342,000| 9,285,000
200| –| –| 353,000| 726,000| 1,087,000| 2,094,000| 3,337,000| 5,900,000| 8,638,000
Note: For 1/2″ line, BTU/h capacities are based on specific gravity of 0.6, pressure drop of 4.6″ WC and 5.0″ WC. For all other line sizes, capacities are based on specific gravity of 0.6, pressure drop of 3.0″ WC.
Pipe sizes and BTU/h capacity (PROPANE). Use this table for static gas pressure GREATER THAN 5” WC.

Length including fittings (feet)| 1/2″| 3⁄4″| 1″| 1-1/4″| 1-1/2″| 2″| 2-1/2″| 3″| 4″
10| 409,000| 608,000| 1,150,000| 2,350,000| 3,520,000| 6,790,000| 10,800,000| 19,100,000| 39,000,000
20| 289,000| 418,000| 787,000| 1,620,000| 2,420,000| 4,660,000| 7,430,000| 13,100,000| 26,800,000
30| 236,000| 336,000| 632,000| 1,300,000| 1,940,000| 3,750,000| 5,970,000| 10,600,000| 21,500,000
40| 204,000| 287,000| 541,000| 1,110,000| 1,660,000| 3,210,000| 5,110,000| 9,030,000| 18,400,000
50| –| 255,000| 480,000| 985,000| 1,480,000| 2,840,000| 4,530,000| 8,000,000| 16,300,000
60| –| 231,000| 434,000| 892,000| 1,340,000| 2,570,000| 4,100,000| 7,250,000| 14,800,000
80| –| 212,000| 400,000| 821,000| 1,230,000| 2,370,000| 3,770,000| 6,670,000| 13,600,000
100| –| –| 372,000| 763,000| 1,140,000| 2,200,000| 3,510,000| 6,210,000| 12,700,000
125| –| –| 349,000| 716,000| 1,070,000| 2,070,000| 3,290,000| 5,820,000| 11,900,000
150| –| –| 330,000| 677,000| 1,010,000| 1,950,000| 3,110,000| 5,500,000| 11,200,000
175| –| –| 292,000| 600,000| 899,000| 1,730,000| 2,760,000| 4,880,000| 9,950,000
200| –| –| 265,000| 543,000| 814,000| 1,570,000| 2,500,000| 4,420,000| 9,010,000
Note: The line BTU/h capacities are based on specific gravity of 1.5, pressure drop of 0.5″ WC.

Air Intake Inlet and Exhaust Gas Outlet Pipe Connections

D ANGER
Improper venting of the water heater results in excessive levels of carbon monoxide, which can lead to severe personal injury or death. This water heater must be vented in accordance with the “Venting of Equipment” section of the latest edition of the ANSI Z223.1 / NFPA 54 (Natural Fuel Gas Code) in the USA, or in Canada refer to the “Venting Systems and Air Supply for Appliances” section in the latest version of CAN/CGA B149.1 (Natural Gas and Propane Installation Code), and all applicable local building codes. Vent installation should be performed only by a licensed professional.

WARNING
BREATHING HAZARD CARBON MONOXIDE GAS

• Do not operate flood-damaged water heaters.
• Install venting system according to the required codes and material manufacturers specifications.
• Do not obstruct fresh air intakes or exhaust outlets. Adequately support all vent system piping.
• Do not place vapor-emitting products near water heater or air intake.
• Place working carbon monoxide detectors outside each sleeping area.
• Do not operate the water heater before properly installing the exhaust outlet.
• Inspect the vent system and eliminate any possible area where condensation could create a blockage of intake or exhaust air.

Breathing concentrated levels of carbon monoxide, even for a short period, causes brain damage and can even lead to death.

Note: This water heater falls into the Category IV appliance.
7.1 Quick Reference Installation Guide

1. Select the desired type of venting system: Two Pipe Vent System (Direct) or Single Pipe Vent System (Power).
   • “7.3 Two Pipe Vent System (Direct Vent)” on page 20.
   • “7.4 Single Pipe Venting System” on page 22.

2. Select the desired termination of the air intake inlet and exhaust gas outlet pipe: outside wall or roof.
   • “7.3.3 Side Wall Air Intake Inlet and Exhaust Gas Outlet Pipe Termination” on page 21.
   • “7.3.4 Roof Air Intake Inlet and Exhaust Gas Outlet Pipe Termination” on page 22.

3. Determine the straight line distance and the number of elbows required to route the air intake inlet and exhaust gas outlet pipes to their termination point. See “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” on page 24.

4. Determine the diameter of pipe required to properly bring in intake air and vent exhaust gas.
   See “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” on page 24.

5. Verify that the location of the air intake inlet and exhaust gas outlet terminations are within state and local codes. See “7.7 Venting Clearance Specifications” on page 25.

6.  Select an approved material for the air intake inlet piping. See “7.8 Exhaust Gas Outlet Pipe Materials” on page 26.

7.  Select an approved material for the exhaust gas outlet piping. See “7.9 Air Intake Inlet Pipe Vent Materials” on page 26.

7.2 Typical Single Unit Air Intake Inlet and Exhaust Gas Outlet Pipe Installation

1. Select one of the follwing two venting configurations:
   • Two pipes (direct vent) configuration
   • One pipe (power vent) configuration

2. Select the desired termination location and make sure each pipe terminates according to all local and state codes.

3. Select the desired material for the air intake inlet and exhaust gas outlet pipes.
   CAUTION
   This water heater has a factory preset control to limit the exhaust gas temperature to 149°F (65°C) when the PVC is selected in the “Flue Type” programming section. As a result, the water heater can be vented with Schedule 40 PVC. If the incoming (or  recirculation return) water temperature does not exceed 150°F (66°C), the exhaust gas temperature does not exceed 149°F (65°C).
   WARNING
   When the unit is set for CPVC (polypropylene pipe), flue temperatures can reach 190°F (88°C). PVC pipe melts at temperatures above 149°F (65°C) and could therefore result in a fire. Make sure the setting and the type of material being used for the flue are compatible.
   For this application, use Schedule 80 CPVC or Approved Polypropylene in the USA or Type BH Special Gas Vent Class IIB (CPCV) or Class IC (Polypropylene) that conforms to ULC-S636 in Canada.
   SAFETY INSTRUCTIONS
   On multiple unit installations, the air intake inlet and exhaust gas outlet piping from each water heater must be connected into the properly-sized common piping. Use the table in “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” on page 24 to determine the diameter of the common connecting piping between each individual water heater.

4. Determine the length and corresponding diameter for the air inlet pipe and route the pipe to the desired termination location.
   a. For termination of the pipe to the outside, continue installing the required pipe to a suitable outside location.
   Glue all connections, making sure the joints are sealed airtight.
   b. Install suitable pipe support hangers every 4 to 5 feet, or as local building codes require.

c. To configure the unit for power vent, insert a 3′ section of 3″ pipe.
5. Determine the length and corresponding diameter for the exhaust gas outlet pipe and route it to a suitable outside location.
a. Glue all connections, making sure the joints are sealed airtight.
b. Install all horizontal exhaust gas outlet piping with a minimum 2 degree (1/4″ per foot) slope back toward the water heater. This allows any condensate that accumulates in the exhaust gas outlet pipe to properly drain back into the unit.
c. Install suitable pipe support hangers every 4 to 5 feet, or as local building codes require.
SAFETY INSTRUCTIONS
Do not connect any other appliance vents to the water heater inlet or outlet pipes.

5. If multiple units are installed, make sure the diameter of the connecting exhaust gas outlet pipe is properly sized for the number of units being installed.

7.3 Two Pipe Vent System (Direct Vent)
7.3.1 Single Unit Configurations
The water heater can be directly vented without any modification using a 3-inch diameter pipe.
The following diagrams represent some typical direct venting configurations and are included to assist in designing the vent system. Possible configurations are not limited to the following diagrams.

7.3.2 Multiple Units Configurations
When more than one unit is installed, refer to “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” on page 24.
Connecting multiple units together requires proper sizing of the air intake inlet and exhaust gas outlet pipes. Up to four water heaters can be cascaded together. Units which share a common vent must be connected together in a cascading configuration, as described in “13. Connecting Multiple Units” on page 47. The following diagrams represent some typical direct venting configurations and are included to assist in designing the vent system. Possible configurations are not limited to the following diagrams.

7.3.3 Side Wall Air Intake Inlet and Exhaust Gas Outlet Pipe Termination

1. Terminate the air intake inlet pipe with a 90° elbow (angled down). Use a flange and PVC screen (not supplied).
2. Terminate the exhaust gas outlet pipe on the exterior wall at least 12″ above ground and at least 18″ away from the air intake inlet pipe, or as required by local building codes. In areas of high snow fall, protect the vent terminations from blockage. Use a flange and PVC guard.
   Separation Distance| Status
   ---|---
   0 – 17.9″| Not Allowed
   18″ – 36″| Allowed
   36.1″ – 71.9″| Not Allowed
   72″ or greater| Allowed
3. To avoid moisture and frost build-up to openings on adjacent structures, use 45° elbows, 90° elbows, or tees for the vent termination to direct the exhaust gas fumes away from the building.

7.3.4 Roof Air Intake Inlet and Exhaust Gas Outlet Pipe Termination
With this installation method, the terminations must extend at least 12 inches over maximum potential snow levels, or as required by local building codes. In areas of high snow fall, protect the vent terminations from blockage. Terminate the air intake inlet pipe with a 90° elbow (angled down). A suitable roof flashing and vent cap (not supplied) should be installed.

Note: The distance between any exhaust gas outlet and air intake inlet pipe should be between 18 and 36 inches apart. If this minimum specification cannot be met, the air intake inlet and exhaust gas outlet pipes should be 72 inches apart or more.

7.4 Single Pipe Venting System
7.4.1 Single Unit
The following illustrations represent some typical venting configurations and are included to assist in designing the vent system. Possible configurations are not limited to these designs.

7.4.2 Multiple Units
When installing multiple units, refer to “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” on page 24. Connecting multiple units together requires proper sizing of the air intake inlet and exhaust gas outlet pipes. Up to four water heaters can be cascaded together. Units which share a common vent must be connected together in a cascading configuration, as described in “13. Connecting Multiple Units” on page 47

7.5 Combustion Air Requirements
When using the single exhaust gas outlet pipe or vent method, the following table outlines the required opening sizes for the combustion and ventilation air coming into the room and the required CFM requirements per water heater:
SAFETY INSTRUCTIONS
Do not operate the unit in an area that draws in outside air contaminated with high levels of dust, sawdust, aerosols such as paint, or other airborne contaminants.
If necessary, purchase and install appropriate air screens and follow a regular cleaning program to ensure an adequate supply of clean, outside combustion air.

Required Combustion & Ventilation Air Opening Sizes (sq. in) Per Heater Per Boiler Room:

**Model| ****Input| ****Air Type| ****Required CFM| Air is drawn directly from outside into the mechanical room| Air is drawn from another interior space inside the building
Through two openings*, direct or vertical| Through one opening**| Through two horizontal ducts*
iN199| 199,950| Combustion Air| 36| 50| 63| 100| 200
Ventilation Air| 36| 50| 100| 200
Where two openings are used, one must be within 12 inches of the floor and the other opening must be within 12 inches of the ceiling of the mechanical room.
**Where one opening is required, it must be located within 12 inches of the ceiling.

7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length
The iN199 comes factory installed with 3-inch polypropylene (PP) venting. The following chart outlines the maximum length of venting allowable for each model.
A vent system’s length is calculated by adding the length of all straight runs used (both horizontal and vertical) and then adding the equivalent lengths of each turn (90° or 45° elbow) used in the system.

SAFETY INSTRUCTIONS
A vent system’s length must not exceed the maximum length outlined in the chart below.

Maximum Pipe Length in Feet

Number of Units

| ****

Venting Type

| Diameter, Model, and Length in Feet
3”Diameter| 4” Diameter| 6” Diameter
iN199| iN199| iN199
1| 1 pipe| 195| 250| 250
2 pipe| 95| 125| 125
2| 1 pipe| 55| 228| 250
2 pipe| 28| 114| 125
3| 1 pipe| | 110| 250
2 pipe| | 55| 125
4| 1 pipe| | | 250
2 pipe| | | 125
Note:
•   1 Pipe – Only exhaust-out pipe is connected and the combustion air intake is from within the room. For example, one iN199 with a 3″ diameter, the maximum exhaust pipe length for 1 pipe is 195 feet.
•   2 Pipe – Both the combustion air intake and the exhaust pipe are connected. In this case, the table specifies the maximum length per pipe. For example, one iN199 with 3″ diameter, 95 feet maximum is allowed for combustion air intake pipe and exhaust-out pipe. The 95 feet maximum is per pipe.
•   Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.
•   If Multiple units are common-vented, then the units must be cascaded. Refer to section “7.5 Combustion Air Requirements” on this page for how to do combustion with common-vented units.

7.7 Venting Clearance Specifications

Venting Clearance Specifications

Item

| ****

Description

| Clearance Distance
USA 1| Canada 2
A| Clearances above grade, veranda, porch, deck, or balcony| 1 foot| 1 foot
B| Clearances to window or door that can be opened| 1 foot| 3 feet
C| Clearances to permanently closed window| |
D| Vertical clearance to a ventilated soffit, eves, or overhang| |
E| Clearances to unventilated soffit, eves, or overhang| |
F| Clearances to outside corner| |
G| Clearances to inside corner| |
H| Clearances to each side of centerline extended from meter/regulator| | 3 feet within a height 15 feet above meter/ regulator assembly
I| Clearances to gas meter regulator vent outlet| | 3 feet
J| Clearances to non-mechanical air supply inlet or combustion air inlet to any other appliance| 1 foot| 3 feet
K| Clearances to mechanical air supply inlet| 3 feet above if within 10 feet horizontally| 6 feet
L| Clearances above paved sidewalk or paved driveway on public property| | 7 feet
M| Clearances under veranda, porch, deck, or balcony| | 1 foot
*Per local/gas supplier codes. Use clearances in accordance with local building codes and local gas supplier.
** For single vent pipe/direct 4 feet (1.2 m) below or to the side of opening and 1 foot above opening.
1 In accordance with Z223.1
2 In accordance with CSA B149.1

Note:
The vent for this appliance shall not terminate:

• Over public walkways
• Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage
• Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment

7.8 Exhaust Gas Outlet Pipe Materials
SAFETY INSTRUCTIONS

For Canadian installations, plastic exhaust gas outlet piping must comply with CAN/CGA B149.1 and be certified to the Standard For Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products.
All units come factory installed with 3-inch polypropylene (PP) venting. A polypropylene-to-PVC adapter is included with each unit to enable the use of PVC exhaust gas outlet pipe. The maximum allowable venting distances are the same regardless of vent material selected.
The materials listed in the tables below outline the acceptable exhaust gas outlet pipe materials:

United States Exhaust Gas Outlet Pipe Standards

Material| **Description***

Exhaust Gas Outlet Pipe

| PVC Schedule 40 (ASTM D1785)
CPVC Schedule 80
Approved Polypropylene
AL29-4C Stainless Steel
Canadian Exhaust Gas Outlet Pipe Standards
Material| Description (approved to ULC-S636)**

Exhaust Gas Outlet Pipe

| Type BH Special Gas Vent Class IIA (PVC)
Type BH Special Gas Vent Class IIB (CPVC)
Type BH Special Gas Vent Class IIC (Polypropylene)
Type BH Special Gas Vent Class I (AL29-4C Stainless Steel)
*Note: Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel (polyphenylsulfone) in nonmetallic venting systems is prohibited. Covering nonmetallic vent pipe and fittings with thermal insulation is prohibited.
**Note: The components (pipe, fittings, primers, and glues) must be from a single manufacturer; do not interchange. Follow the vent manufacturer’s certified instructions.

SAFETY
INSTRUCTIONS
Do not use cellular foam core pipe to vent exhaust gases.
This water heater has a built-in exhaust gas outlet temperature control that limits the exhaust gas temperature to a maximum of 149°F (65°C) for PVC pipe. In commercial applications which require higher water temperatures, exhaust gas temperature can reach 190°F (88°C) and require materials such as polypropylene (PP), stainless steel (SS), or CPVC.
If the temperature approaches the upper limit, the burner turns off automatically to protect the vent pipe. After the exhaust gas temperature has dropped to a normal operating level, the unit automatically restarts.
If the inlet/return water temperature exceeds 150°F (66°C), do not use PVC pipe. Follow the display prompts to set the maximum water temperature for the exhaust-gas outlet pipe material being used.

7.9 Air Intake Inlet Pipe Vent Materials
The air intake inlet pipe can be of any plastic or metal vent material available. ABS, PVC, polypropylene, galvanized steel, and/or flexible corrugated ducting are all examples. When using a corrugated material, ensure there is no inadvertent crimping or blockage to the air intake inlet pipe.
Refer to the tables below for a list of approved materials.

United States Vent Pipe Standards

Material| Description

Vent Pipe

| PVC Schedule 40
CPVC Schedule 80
Approved Polypropylene
Canadian Vent Pipe Standards

Material| Description

Vent Pipe

| Type BH Special Gas Vent Class IIA (PVC)
Type BH Special Gas Vent Class IIB (CPVC)
Type BH Special Gas Vent Class IIC (Polypropylene)

Note: In addition to these charts, it is recommended to consult the most recent edition of ANSI Z223.1/NFPA 54 or CAN/ CGA B149.1, as well as all applicable local codes and regulations when selecting vent pipe materials.

7.10 Recommended Exhaust-Gas Outlet Pipe Transitions

Water Connections

Note: For flow rate changes faster than 10 gpm (gallons per minute) in one second, a water hammer arrester must be installed to prevent damage to the water heater.
8.1 Quick Reference Installation Instructions

1. Install the hot water pipe and the pressure relief valve (furnished with the water heater) as per “8.2 Hot Water Connection” on page 28.
   NOTICE
   When tightening any fittings to the connections on the water heater, do not overtighten these joints and damage the unit.

2. Install the cold water pipe as per “8.3 Cold Water Connection” on page 29.

3. Install a condensate drain line as per “8.4 Condensate Drain Line” on page 29.

4. After installation is complete, fill and test the water heater for proper flow and inspect for leaks.

5. Run the hot water for a few minutes and then clean the inlet water strainer located on the cold water inlet fitting. This strainer must be cleaned periodically to maintain proper water flow.

8.2 Hot Water Connection
Install and connect the hot water lines. Keep the hot water pipes as short as possible to deliver hot water to the fixtures quickly. If an optional hot water storage tank is required, connect the hot water lines to this tank also.
Since each installation is different, it is up to the installer to route the water lines using the most efficient routing. The drawings shown here are suggestions indicating the items needed for the installation.

CAUTION
To prevent adverse health issues, only materials (pipes, fittings, valves, solder, etc.) that are approved for use in potable water systems should be used.

1. Connect a 1-1/2″ NPT coupler to the water heater’s hot water connection.

2. Install a 1-1/2″ union connection.

3. iN199 supplied with a 150 pressure relief valve. iN199A supplied with a T&P valve. Install the supplied 3/4″ 1relief valve, as required by your local code into the port on the outlet pipe of the unit.

4. Following local building codes, install a 1-1/2″ manual shut-off valve with 1-1/2″ NPT fittings.
   Note: Wye-Strainer and gas regulator not shown for clarity. WARNING
   To prevent serious personal injury, do not install any shut-off device between the water heater and the pressure relief valve. This valve is designed to release abnormally high pressure within the water heater in the event of a system problem.
   NOTICE
   The pressure relief valve must be rated at 150 psi, the maximum btu/h output of the unit, and comply with all local building codes and standards. Do not install any restrictions or other valves before the pressure relief valve.

5. Install and route a discharge pipe from the pressure relief valve to within six inches of the floor and directed away from walkways or other appliances.
   a. Route the relief valve to within six inches of the floor to prevent injury in the event of a discharge.
   b. The diameter of the pipe from the relief valve must be equal to the outlet size of the relief valve.
   c. Do not use reducers in the outlet pipe.
   d. Do not install any valves, restrictions, elbows, or other blockages in the outlet pipe.
   e. For multiple unit installations, the outlet pipes must not be connected together. Each pipe must be separately routed to a suitable drain.

6. Connect the unit to the building’s hot water pipes. If multiple water heaters are being installed, the diameter of both the main cold water pipes and the main hot water pipes need to be sized by an engineering professional.

7. To conserve energy, insulate all hot water pipes and recirculation pipes.
   Do not insulate the pressure relief valve.

8.  With the unit OFF, open a nearby hot water faucet and allow the water to flow through the unit until all the trapped air is exhausted from the water pipes and from the water heater.

9. Leak-test the water piping. Repair any leaks immediately.

8.3 Cold Water Connection
Install and connect the cold water pipes.
Note: If the incoming water is known to have a high mineral  content or “hardness” (see “18. Warranty” on page69), treatment is recommended upstream from the water heater.
When the water heater is installed in a closed loop recirculation system, and if the cold water supply pipe has a back flow preventer, then an expansion tank should be installed to allow for water expansion as per the diagrams in “3.7 Configuration Options” on page 9.

CAUTION
To prevent adverse health issues, only materials (pipes, fittings, valves, solder, etc.) that are approved for use in potable water systems should be used.

1. Connect a 1-1/2″ NPT coupler to the water heater’s cold water connection.

2. Install a 1-1/2″ union connection.
   Note: Wye-Strainer not shown for clarity.

3.  Following local building codes, install a 1-1/2″ manual shut-off valve with 1-1/2″ NPT fittings.

4. Connect the unit to the building’s cold water pipes. If multiple water heaters are being installed, the diameter of the main cold water pipe needs to be sized by an engineering professional.
   Note: Isolation valve kits can be used if incoming water treatment is anticipated (such as a water softener) due to hardness levels or heavy usage of the unit.

5. With the unit OFF, open a nearby cold water faucet and allow the water to flow through the unit until all the trapped air is exhausted from the water pipes and from the water heater.

6. Leak-test the water pipes. Repair any leaks immediately.

8.4 Condensate Drain Line
Due to its efficient design, the water heater produces condensate (water) as a normal by-product of heating the water.
This condensate is acidic, with a pH level between 3 and 4.
Local building codes might require an in-line neutralizer to be installed (not included) to treat this water. The maximum condensate flow rate is 1.4 GPH.

1. Install a 3/4″ flexible hose to the hose connection on the water heater.
   Note: If a floor drain is used to remove the discharge, route the drain line over or into the drain. The line should freely drain. The line termination should not be immersed in water.

2. Follow applicable local codes and if required, install in-line neutralizer to treat the acidic condensate. Follow all the installation instructions included with the neutralizer.

Electrical Power

9.1 Electrical Recommendation s

WARNING
To avoid serious injury or even death, follow all applicable local, state, and national regulations, mandates, and building codes for guidelines to install the electrical power supply.
Electrical code requirements are different in the USA and Canada. Refer to and follow the local building codes, and the latest edition of the National Electrical Code (NFPA 70) in the USA, or the CGA C22.1 Canadian Electrical Code – Part 1. For a single iN199 water heater, the circuit breaker(s) should be at least 15 amps per circuit.
For multiple units, install an adequately sized circuit breaker. Installing a separate circuit breaker for each unit is recommended to isolate units during service or repair.

Note: For an electrical wiring schematic, refer to “15.2 Complete Wiring Diagram” on page 52 for additional information.
NOTICE
The electrical connections for the water heaters are polarity-sensitive. Before connecting the water heater to the power source, test the polarity of the electrical circuit.

9.2 Connection Instructions

1. On single-unit installations, make sure the electrical outlet being used is wired with at least 12-gauge wire and grounded with an appropriately sized circuit breaker. The electrical power required for the water heater is 120V AC at 60 Hz.
2. Remove the two cover screws and open the cover.

WARNING
To avoid serious injury or even death from electrical hazards, an additional ON/OFF electrical junction box should be installed near the water heater. This switch allows power to be removed from the water heater prior to service or in the case of an emergency.

3. Route a customer-supplied, appropriately-sized wire with ground from an electrical junction box with an ON/OFF switch through the back panel of the water heater. Route the wire through the cabinet to the junction box.

4. On the opposite side of the block from the factory-installed wiring, connect the white wire to the white terminal, the black wire to the black terminal, and the green ground wire to the green terminal (for each circuit).
   

5. If multiple units are being installed, refer to “13. Connecting Multiple Units” on page 47 for additional information.

Adjusting CO2 Level

10.1 General Information
This procedure is required:

1. Only during installation in a high-altitude location over 2,000 feet, or
2. When converting the unit from natural gas to propane.

This procedure should be completed only by a qualified technician.

DANGER
A concentration of carbon monoxide (CO) as small as 0.04% (400 parts per million) in the air can be fatal. When making High Fire and/or Low Fire adjustments, CO levels must be monitored using a flue gas analyzer and must not exceed 400 ppm of CO at any time during the operation.
Adjusting the “Low Fire screw” or the “High Fire screw” even in small increments can result in a significant increase in CO concentration. To avoid serious injury or death, DO NOT adjust the gas valve without monitoring the exhaust gases with a functional and calibrated flue gas analyzer.

CO 2 and CO Standards

Description| CO 2 Range (%)| Max. CO Level (ppm)
Natural Gas
High Fire| 9.1% to 9.3%| < 200 ppm
Low Fire| 9.1% to 9.3%| < 60 ppm
Propane
High Fire| 10.1% to 10.5%| < 200 ppm
Low Fire| 10.1% to 10.5%| < 60 ppm

NOTICE

1. The values listed in the table are for nominal conditions. Variables such as gas pressure, heating value of the gas, humidity, and temperature of combustion air can impact CO and CO2 values. Changes in these variables can result in different CO and CO2 values on the same water heater.
2. A qualified service technician must use a calibrated flue gas analyzer to adjust the gas valve to achieve the desired CO2 and CO values.
3.  Before any adjustments are made, the service technician must confirm the static gas pressure meets these minimum requirements: Natural Gas – 8″ WC; Propane – 11″ WC.
4. If units are cascaded and common-vented, these combustions must be done on only one unit at a time.

Turn off the valve to the hot water outlet of the other units and power off before doing combustion.

1. The values listed in the table are for nominal conditions.
   Variables such as gas pressure, heating value of the gas, humidity, and temperature of combustion air can impact CO and CO2 values. Changes in these variables can result in different CO and CO2 values on the same water heater.

2. A qualified service technician must use a calibrated flue gas analyzer to adjust the gas valve to achieve the desired CO2 and CO values.

3. Before any adjustments are made, the service technician must confirm the static gas pressure meets these minimum requirements: Natural Gas – 8″ WC; Propane – 11″ WC.

4.  If units are cascaded and common-vented, these combustions must be done on only one unit at a time.  Turn off the valve to the hot water outlet of the otherunits and power off before doing combustion.

10.2 Adjustment Procedure

1. Open or remove the front doors.

2. Locate the gas valve as shown in illustration.

3.  Remove the plug from the test port on the exhaust manifold.

4.  Insert a calibrated flue gas analyzer into the test port.

5. Follow the display screens.
   
   NOTICE
   Do NOT change the blower speed settings. This adjustment MUST be completed by factory personnel ONLY. Changing this setting VOIDS the warranty!

6. Create a hot water flow of at least 6.0 GPM as shown on the display screen.
   Note: If flow rate is inadequate, a pop-up message notifies you to increase the flow.

7. At a flow rate of 6.0 GPM, the heat engine starts.

8. Press HIGH FIRE on the display screen.

9. Allow three minutes of operation at High Fire.

10. Record “initial output” in Hire Fire Recorded Values table.

11. If the CO2 values are within appropriate range, proceed to Step 12, otherwise continue.
    a. Use a flat-blade screwdriver to turn the High Fire screw clockwise to decrease and counterclockwise to increase the CO2 value.
    b. Adjust in ¼ turn increments.
    c. Wait three minutes to stabilize flue gas readings and recheck values.
    d. Adjust until values fall with specified range.

12. After the desired values are achieved, record the new High Fire CO2 “adjusted values” in the table.
    CO 2 and CO Standards

    Description| CO 2 Range| Max. CO Level
    Natural Gas High Fire| 9.1% to 9.3%| < 200 ppm
    Propane High Fire| 10.1% to 10.5%| < 200 ppm
    High Fire Recorded Values

    Date / / ___
    Heat Engine| Initial Output| Adjusted Value
    CO2 Value %| |
    Max CO ppm| |

13. Press LOW FIRE on the display screen.

14. Record “initial output” in Low Fire Recorded Values table.
    CO 2 and CO Standards

    Description| CO 2 Range| Max. CO Level
    Natural Gas Low Fire| 9.1% to 9.3%| < 60 ppm
    Propane Low Fire| 10.1% to 10.5%| < 60 ppm
    Low Fire Recorded Values

    Date / / ___
    Heat Engine| Initial Output| Adjusted Value
    CO2 Value %| |
    Max CO ppm| |

15. Adjust the Low Fire screw while the burner operates at low fire using a 2mm hex wrench. Turn clockwise to increase CO2 and counterclockwise to decrease CO2.

16. After the desired values are achieved, record the new Low Fire CO2 “adjusted values” in the table.

17. After the heat engine is properly adjusted, turn off the water flow.

18. Remove the flue gas analyzer probe and plug the test port.

19. Press the back button to return to the main screen.

20. Check for gas leaks using a leak detector.

21. Install side panel covers. If converting to propane, proceed to section “11. Natural Gas to Propane Conversion” on page 34.

Natural Gas to Propane Conversion

A qualified service technician MUST make the required changes to convert the water heater from natural gas to propane.

11.1 General Information
Note: This conversion process also requires the CO2 levels to be adjusted. Refer to “11. Natural Gas to Propane Conversion” on page 3410. Adjusting CO2 Level” on page 31.
Before converting the unit for propane, verify the current gas inlet pressure meets the recommended pressure and record it in the space below.

Propane Static Gas Pressure

Parameters| Specifications
Minimum Static Gas Pressure| 8″ WC (non-corrugated, black iron)
Recommended Gas Pressure| 11″ WC
Maximum Static Gas Pressure| 14″ WC

Current Static Propane Gas Pressure WC
Date ____

11.2 Conversion Procedure

1. Follow these steps before repositioning the DIP switches.
   a. Turn the water heater OFF using the display screen.
   b. Place the circuit breaker for the water heater at the main electrical panel in the OFF position. Verify there is no power to the unit(s).

c. Open the front door and locate the main circuit board.
d. Locate DIP Switch 1 on the circuit board.

e. Move DIP switch downward into the Propane position.
f. Reset the circuit breaker to the ON position. Turn the water heater ON using the display screen.

2. Follow the display screens to check if the unit is now set to propane.
   

Revised 05‑2024
Part#: IGT‑MNL0060

Intellihot Inc. | www.intellihot.com | 2900 W. Main Street, Galesburg, IL 61401 | 877.835.1705 | [email protected]

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