Rheem RTGH-L199I ThermaForce Super High Efficiency User Manual

INSTALLATION AND OPERATING INSTRUCTIONS

WARNING: If the information in this manual is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other ammable 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 re department.

Installation and service must be performed by a qualied

installer, service

agency or the gas supplier.

HIGH EFFICIENCY CONDENSING

TANKLESS WATER HEATER

199,000 Btu/hr Model

(Natural Gas or Propane)

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

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, qualied,

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

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

WARNING

If the information in this

manual is not followed

exactly, a re or explosion

may result causing property

damage, personal injury, or

loss of life.

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

NOTE

Points out installation,

maintenance and operation

details that will result in

enhanced e󰀩ciency, longevity

and proper operation of your

unit.

DANGER

Points out an imminently

hazardous situation which

must be avoided in order to

prevent serious injury or

death.

BEST PRACTICES

Points out recommendations

for better installation.

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

SPECIFICATION 199,000 BTU

Input (Natural Gas or Propane*) - MBH 28.5-199

U.E.F 0.9

DHW Flow Rate - GPM (LPM) 35°F (19°C) Temp Rise 10.1 (38)

45°F (25°C) Temp Rise 7.9 (30)

67°F (36°C) Temp Rise 5.4 (20)

Dimensions - in/mm 17.7 x 29.8 x 10.9 (450 x 757 x 277)

Weight (empty) - lbs/Kg 68 / 31

Installation Type Indoor only wall-hung

Venting Type Forced Draft Direct Vent

Electronic Ignition

Water Pressure - psig 40 - 150

Min Gas Pressure (Nat. Gas or Propane*) - inch w.c. 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 0.19 / 0.72

Ambient Temperature – Low (°F/°C) 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 re 100 watts

Materials Casing Painted steel and plastic

Heat Exchangers Copper tubes in AL block

Venting

Canada venting must meet ULC S636

Intake & Exhaust 2" or 3" PVC, CPVC,

Polypropylene

Venting Clearances 0" to combustibles

Safety Devices Flame Proving module, Flue

Gas Temperature Sensor,

Protective fuse

Certied design ANSI Z21.10.3 • CSA 4.3

Freeze Protection Yes

 *UnitsshipconguredforNaturalGas(NG)withaPropane(LP)conversionkitincluded.ConvertinganLPunitbacktoNGrequiresthecertiedNGconversionkitthat

can be ordered separately.

SPECIFICATIONS

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

BURN

HOT

DANGER

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.

WARNING

CAUTION

WATER HEATER INSTALLATION GUIDELINES

ADJUSTABLE TEMPERATURE SETTING

Hotter water increases the risk of scald injury. Before changing the temperature setting, see

instruction manual.

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.

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.

TIME/TEMPERATURE RELATIONSHIP IN SCALDS

WATER TEMPERATURE TIME TO PRODUCE A SERIOUS BURNTIME 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

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

CONTENTS

1.0 INSTALLATION ..........................................1-1

1.1 GENERAL........................................................1-1

1.2 CODE REQUIREMENTS ............................................1-3

1.3 LOCATION .......................................................1-3

1.3.1 Mobile Home Installations ........................................1-4

1.3.2 Removing/installing the front panel .................................1-5

1.4 EXHAUST VENTING AND AIR INTAKE .................................1-6

1.4.1 Applications ..................................................1-10

1.4.2 Exhaust Vent Material ..........................................1-10

1.4.3 Vent Travel ...................................................1-10

1.4.4 Venting Passage Through Ceiling and Floor .........................1-12

1.4.5 Rooftop Vent Termination........................................1-12

1.4.6 Sidewall Vent Termination .......................................1-14

1.4.7 “Direct Vent” Combustion Air Intake Piping ..........................1-18

1.4.8 “Indoor Air” Combustion Air Intake .................................1-19

1.4.9 Closet Installations .............................................1-19

1.5 CONDENSATE REMOVAL..........................................1-20

1.5.1 Condensate Trap ..............................................1-20

1.5.2 Installing the Condensate Trap....................................1-20

1.5.3 Further Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.6 WATER AND SPACE HEATING APPLICATION ..........................1-22

1.7 DOMESTIC HOT WATER SYSTEM ...................................1-24

1.7.1 Domestic Hot Water System .....................................1-25

1.7.2 Domestic Hot Water Piping ......................................1-26

1.7.3 Tankless Domestic Hot Water with a Storage Tank ....................1-27

1.8 GAS PIPING .....................................................1-29

1.9 ELECTRICAL CONNECTIONS ......................................1-30

1.9.1 120VAC Line Voltage Hook-up....................................1-30

1.9.2 Accessing Controller Terminal Strip ................................1-30

1.9.3 Power Quality and Electrical Protection ............................1-30

2.0

UNIT SYSTEM OPERATION .....................................2-1

2.1 GENERAL........................................................2-1

2.2 CONTROL .......................................................2-2

2.3 INSTALLER INTERFACE ............................................2-2

2.3.1 Turning Appliance ON/OFF .......................................2-2

2.3.2 Programming Mode.............................................2-3

2.4 TANKLESS DOMESTIC HOT WATER MODES ...........................2-4

2.4.1 Tankless Domestic Hot Water - Standard and ECO Comfort Modes ........2-4

2.5 SEQUENCE OF OPERATION ........................................2-5

2.6 ACCESSING THE INFORMATION MENU ...............................2-6

2.7 RESETTING THE MAINTENANCE COUNTER ...........................2-8

3.0 STARTUP & COMMISSIONING ..............................3-1

3.1 LIGHTING & SHUTTING DOWN THE UNIT .............................3-1

3.2 PRIOR TO START-UP ..............................................3-2

3.2.1 Pre-Ignition Checks .............................................3-2

3.2.2TestIgnitionSafetyShuto󰀨 .......................................3-2

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

3.3 COMMISSIONING .................................................3-2

3.4 FUEL CONVERSION ...............................................3-4

3.4.1 Gaining access to combustion chamber, burner removal instructions .......3-5

4.0 MAINTENANCE..........................................4-1

4.1 WATER HEATER MAINTENANCE.....................................4-1

4.1.1 General Care ..................................................4-1

4.1.2 Inspection.....................................................4-1

4.1.3 Venting .......................................................4-1

4.1.4 Condensate Trap ...............................................4-1

4.1.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.6 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.7 Gas Piping ....................................................4-2

4.1.8 Control Module.................................................4-2

4.1.9 Freeze Protection...............................................4-2

4.1.10 Relief Valve - Maintenance and Testing .............................4-2

4.1.11 Domestic Hot Water System......................................4-2

4.1.12 DHW Coil cleaning instructions...................................4-3

4.1.13 DHW Filter cleaning instructions ..................................4-4

4.1.14 Fan removal instructions ........................................4-4

4.1.15 Fan installation instructions ......................................4-4

4.1.16 Cleaning the Condensate Trap....................................4-5

4.1.17 Reset the Maintenance Counter...................................4-7

4.1.18 Winterization..................................................4-7

5.0 TROUBLESHOOTING .....................................5-1

5.1 PRELIMINARY CHECKS ............................................5-1

5.2 ELECTRONIC COMPONENTS .......................................5-2

5.2.1 Temperature Sensors............................................5-2

5.2.2 Cabinet Sensors................................................5-2

5.2.3 Flue Gas Temperature Sensor .....................................5-3

5.2.4 Domestic Hot Water Flow Sensor ..................................5-3

5.2.5 Domestic Hot Water Sensor.......................................5-3

5.2.6 Domestic Hot Water Bypass Valve..................................5-4

5.2.7 Domestic Cold Water Sensor ......................................5-4

5.2.8 Fan/Blower ....................................................5-4

5.3 FAULTS AND NOTIFICATIONS .......................................5-5

5.3.1 Fault Codes ...................................................5-5

5.3.2NoticationCodes ..............................................5-9

5.4 OTHER FAULTS ..................................................5-10

5.4.1 No domestic hot water (DHW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.2 Domestic hot water does not reach the correct temperature .............5-11

5.4.3 Burner ignites loudly............................................5-11

5.4.4 Burner resonates ..............................................5-11

6.0 REPLACEMENTS KITS ....................................6-1

7.0 WIRING DIAGRAMS ......................................6-2

INSTALLATION & COMMISSIONING REPORT..............................6-4

SERVICE RECORD ...................................................6-5

NOTES ............................................................6-6

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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uorinatedhydrocarbonscanreducethelifeofaunit.Cleaners,

bleaches,airfresheners,refrigerants,aerosolpropellants,dry-cleaninguids,

de-greasers and paint-removers all contain vapors that can form corrosive

acidcompoundswhenburnedinagasame.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nd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ue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ow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.

CAUTION

Care must be taken to

properly size the unit for

its intended use. Prolonged

full-re run time, over-

sizing or under-sizing,

and incorrect ow rates

through the unit can lead

to increased maintenance

costs, equipment stress and

premature failure.

WARNING

Do not use this unit if any

part has been under water.

Immediately call a qualied

service technician to inspect

the unit and to replace any

part of the control system and

any gas control that has been

under water.

DANGER

Should overheating occur

or the gas supply fails to

shut o󰀨, do not turn o󰀨 or

disconnect the electrical

supply to the pump. Instead

shut o󰀨 the gas supply at

a location external to the

appliance.

INSTALLATION AND OPERATION INSTRUCTIONS

TANKLESS WATER HEATER 199

This page is intentionally left blank.

1-1

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

17.7in

[450mm]

3.1in

[79mm]

29.8in

[757mm]

4.3in

[109mm]

FRONT

1.0 INSTALLATION

1.1 GENERAL

ThisHighE󰀩ciency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 m

(140,000 ft

) for natural gas or 5680 L

(1500 US gallons) for propane. The products are fully condensing units with

variable input ranges (see specication 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

ndasuitablelocationfortheunit.See also Section 1.3 Location.

Figure 1a: Dimensions / Connections for Tankless Water HeaterTankless Water Heater

10.9in

[278mm]

SIDE

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.

INSTALLATION AND OPERATION INSTRUCTIONS

1-2

TANKLESS WATER HEATER 199

4.7in

[120mm]

4.7in

[120mm]

TOP

B (ALTERNATE)

4.5in

[114mm]

B (ALTERNATE)

6.7in

[170mm]

BOTTOM

3.7in

[95mm]

2.6in

[65mm]

2in

[50mm]

Figure 1b: Dimensions / Connections for Tankless Water HeaterTankless Water Heater

DESCRIPTION TANKLESS WATER HEATERTANKLESS WATER HEATER

A Exhaust Outlet 2" Schedule 40 PVC

B Combustion Air inlet 2" Schedule 40 PVC

Cold Domestic Water

Connection&inletlter

3/4" Male NPT

Hot Domestic Water

Connection

3/4" Male NPT

E Gas Inlet 3/4" Male NPT

F Condensate Outlet 3/4" Hose

Table 1: Connections

16in

[406mm]

BRACKET

1-3

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

1.2 CODE REQUIREMENTS

TThe Tankless Water Heaterhe Tankless Water Heater is is certied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

TheThe unit is designed and approved for indoor installation. Its venting options

provideexibility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

uorinated hydrocarbons can reduce the life of a water heater. Cleaners,

bleaches,airfresheners,refrigerants,aerosolpropellants,dry-cleaninguids,

de-greasers and paint-removers contain vapors that can form corrosive acid

compoundswhenburnedinagasame.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

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a󰀨ectingpotentialmountingsites:

• Ensureminimumclearancerequirementsforcombustiblematerials(see

Table 2)aresatised.

• 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.

WARNING

- Keep the unit area free

and clear of combustible

materials, gasoline, and other

ammable vapors and liquids.

- C

ombustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air

directly next to outdoor pools

and spas.

- T

he 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.

INSTALLATION AND OPERATION INSTRUCTIONS

1-4

TANKLESS WATER HEATER 199

SURFACE

DISTANCE FROM

COMBUSTIBLE

SURFACES

RECOMMENDED DISTANCE

FOR INSTALLATION AND

SERVICE

Front 2" 24"

Rear 0" 0"

Left Side 1.5"

6"(labelsmaybedi󰀩culttoreadwith

reduced clearance)

Right Side 4"

6"(labelsmaybedi󰀩culttoreadwith

reduced clearance)

Top 2" 24"

Bottom 8" 24"

Table 2: Clearance from the unit cabinet

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.

FOR BRACKET USE TWO ¼” X 1¾” LAG

SCREWS WITH FLAT WASHERS INTO

STUDS. FOR METAL MOUNTING SYSTEM

USE ¼” BOLTS WITH FLAT WASHERS.

FOR BRACKET USE TWO ¼” X 1¾” LAG

SCREWS WITH FLAT WASHERS INTO

STUDS. FOR METAL MOUNTING SYSTEM

USE ¼” BOLTS WITH FLAT WASHERS.

UNIT

MOUNT BRACKET TO WALL,

HOOK UNIT OVER TOP.

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.

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 - DO NOT MOUNT THIS UNIT

TO A HOLLOW SHEET ROCK TO A HOLLOW SHEET ROCK

WALL USING ANCHORS. The WALL USING ANCHORS. The

wall mounting bracket must wall mounting bracket must

be bolted to wall studs or a be bolted to wall studs or a

solid wall structure to support solid wall structure to support

the combined weight of the the combined weight of the

unit which can exceed 150 unit which can exceed 150

lbs. (68kg) once installed.lbs. (68kg) once installed.

- Take precautions to avoid

injury during the installation

of this unit.

1-5

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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.

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)

CAUTION

The front panel has a rubber

seal around the inner edge

sometimes making it very sti󰀨

to slide o󰀨 so please ensure

the unit is secured to the wall

correctly before attempting

this procedure!

WARNING

This is a room sealed cover

and therefor extremely

important that it is tted

correctly, failure to do so can

result in ue gas spillage and

carbon monoxide emissions,

causing severe personal

injury or death.

Figure 3: Loosen screws Figure 4: Frontpanel upward

Figure 5: Positioning the frontpanel

INSTALLATION AND OPERATION INSTRUCTIONS

1-6

TANKLESS WATER HEATER 199

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a󰀨ect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.

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.

Tankless

Water Heater

FLUE GAS

EXHAUST TO

OUTDOORS

Figure 6: Basic exhaust vent assembly

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 nished 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

ue gas spillage and carbon

monoxide emissions, causing

severe personal injury or

death. Failure to comply will

result in severe personal

injury or death.

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 re,

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.

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.

1-7

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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 side-

wallexhaustventterminationislessthanseven(7)feetabovenishedgrade

in the area of the venting, including but not limited to decks and porches, the

followingrequirementsshallbesatised.

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ttershallobservethatahard-wiredcarbonmonoxide

detectorwithanalarmandbatterybackupisinstalledontheoorlevelwherethe

gasequipmentistobeinstalled.Inaddition,theinstallingplumberorgastter

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

qualied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oor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-certied.

3.SIGNAGE.Ametalorplasticidentication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, gas-

fueled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.

NOTE

For the State of

Massachusetts, use only

plastic piping, ttings

and vent terminations as

specied 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

INSTALLATION AND OPERATION INSTRUCTIONS

1-8

TANKLESS WATER HEATER 199

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 side-

wall,horizontallyvented,gas-fueledequipmentdoesnotprovidethepartsfor

ventingtheuegases,butidenties“specialventingsystems,”thefollowing

requirementsshallbesatised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.

1-9

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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deciencies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replace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ame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,replacedampersandanyothergas-

burning 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.

NOTE

The ue gas temperature

sensor reports the current

ue gas exhaust temperature

to the unit’s controller. If

necessary, the controller

will reduce the input of the

tankless water heater to

meet the ue gas exhaust

temperature requirements of

PVC material. The controller

locks out the unit if this

temperature is exceeded, and

displays F003.

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 ue

serving a separate appliance

designed to burn solid fuel.

- The air intake tting can be

moved to the left or to the

right of the exhaust tting.

INSTALLATION AND OPERATION INSTRUCTIONS

1-10

TANKLESS WATER HEATER 199

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 tting to us for evaluation and written approval.

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tting

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’).

WARNING

- Do not mix venting materials

from di󰀨erent 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.

Figure 7: Inlet and outlet vent

connections. Note the ue

exhaust test port.

NOTE

For the State of

Massachusetts, use only

plastic piping, ttings

and vent terminations as

specied 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

1-11

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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.

65'65'*

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 APPROXIMATE DERATE

199,000

10 - 16%10 - 16%

Follow all installation instructions supplied by the pipe and tting

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rst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.

BEST PRACTICES

To reduce the possibility of

expansion noise, allow a 1/4"

gap around the exhaust and

air intake piping.

NOTE

The bird screen is optional

for exhaust piping in cold

weather climates.

WARNING

ombustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air

directly next to outdoor pools

and spas.

Figure 8

INSTALLATION AND OPERATION INSTRUCTIONS

1-12

TANKLESS WATER HEATER 199

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ring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llthe

condensate trap before testing.

1.4.4 Venting Passage Through Ceiling and Floor

• Conrmmaterialmeetslocalcodesincludingre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inltration;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)

WARNING

Condensate can cause

corrosion of metal roong

components and other

roong materials. Check

with the builder or roong

contractor to ensure that

materials are resistant to

acidic condensate. pH levels

can be as low as 3.0

[18" (457 mm) Canada] MIN.

NOTE: THE BIRD SCREEN

IS OPTIONAL IN COLD

WEATHER CLIMATES

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.

Figure 10: Rooftop vent terminal congurations

Figure 9: Rooftop vent terminal

congurations

1-13

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

• Optionalbirdscreenmaybeplacedinaterminationtting.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ashing.

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 OPERATION INSTRUCTIONS

1-14

TANKLESS WATER HEATER 199

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 bemust 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conguredasinFigure 13,togainrequiredclearance.

• Usea45°elbowontheexhaustterminationtolaunchtheplumeupando󰀨

the sidewall, for protection of wall.

• Optionalbirdscreenmaybeplacedinaterminationtting.Leaveunglued,

and hold in place with a short nipple to allow easy access for cleaning.

SNOW + 12"

[305mm]

MIN.

SNOW + 12"

[305mm]

MIN.

SNOW + 12"

[305mm]

MIN.

WARNING

- You must maintain at least

the minimum separation of

exhaust vent termination from

unit’s intake air as illustrated

in gures 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.

- You must not cover non-

metallic vent pipe and ttings

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.

WARNING

The vent for this appliance

must not terminate:

1. Over public walkways in

the US. In Canada 7’ above

public walkways.

2. Near so󰀩t 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 conguration

Figure 14Figure 14: Prohibited installation

1-15

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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proleterminationkit-Part#P-741

• 3"PVClowproleterminationkit-Part#P-742

Vent on Left or Right Side

Figure 15: Sidewall vent termination - multiple vent piping conguration

[305mm]

[152mm]

12" [305mm] MIN.

[915mm]

Figure 16 PVC low prole termination acceptable orientations

INSTALLATION AND OPERATION INSTRUCTIONS

1-16

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InnouePPs-#ICWT242(Termination)

#ICTCR24 (2 Pipe Adapter)

• 3"CentrothermInnoue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

Figure 18: Horizontal Polypropylene Concentric Termination - Single Kit

1-17

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

Vent terminal clearance minimums are as follows:

CANADIAN

INSTALLATIONS

1, 3

INSTALLATIONS

2, 3

A=Clearanceabovegrade,

veranda, porch, deck, or balcony

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

B=Clearancetowindowordoor

that may be opened

36 in (91 cm) for appliances

over 100,000 Btuh (30kW)

12 in (30 cm)

C=Clearancetopermanently

closed window

* (Recommend minimum 1

ft (30 cm))

* (Recommend minimum 1

ft (30 cm))

D=Verticalclearanceto

ventilatedso󰀩tlocatedabove

the terminal within a horizontal

distance of 2 ft (61 cm) from the

center line of the terminal.

* (Recommend minimum 2

ft (61 cm))

* (Recommend minimum 2

ft (61 cm))

E=Clearancetounventilated

so󰀩t

*(Recommend minimum 1 ft

(30 cm))

* (Recommend minimum 1

ft (30 cm))

F=Clearancetooutsidecorner * (Recommend minimum 4

ft (122 cm))

* (Recommend minimum 4

ft (122 cm))

G=Clearancetoinsidecorner * (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

vent outlet

3 ft (91 cm) *

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

6 ft (1.83 m) 3 ft (91 cm) above if within

10 ft (3 m) horizontally

L=Clearanceabovepaved

sidewalk or paved driveway

located on public property

7 ft (2.13 m) † Vents cannot be located

above public walkways

or other areas where

condensate or vapor can

cause a nuisance or hazard.

M=Clearanceunderveranda,

porch deck, or balcony

12 in (30 cm) ‡ *

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di󰀨erent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oor.

* 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speciedintheNationalFuelGasCode,ANSIZ223.1/NFPA54,and/ortheNaturalGasandPropane

Installation Code, CSA B149.1

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 congured 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 shut-

down.

INSTALLATION AND OPERATION INSTRUCTIONS

1-18

TANKLESS WATER HEATER 199

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.

Tankless

Water Heater

FLUE GAS

EXHAUST TO

OUTDOORS

COMBUSTION

AIR FROM

OUTDOORS

ALTERNATIVE

COMBUSTION AIR

CONNECTION

“DIRECT VENT”

INSTALLATION

CHECK AIR INTAKE

OUTSIDE TO MAKE SURE

IT IS CLEAR OF

OBSTRUCTIONS

FLUE GAS

EXHAUST TO

OUTDOORS

COMBUSTION

AIR FROM

OUTDOORS

ALTERNATIVE

COMBUSTION AIR

CONNECTION

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 counter-

clockwise to remove from top

of cabinet.

- Reinstall plug and

combustion air connection

in the desired locations then

rotate 1/8

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.

Figure 20: Direct vent combustion air intake

1-19

INSTALLATION AND OPERATING 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 35'Actual(Equivalent=Actualx1.4)

Table 4: Maximum intake piping length.

* The input rate will derate as intake length increases. See table below for

approximate derate at 2" maximum intake length.

MAXIMUM FIRING RATE APPROXIMATE DERATE

199,000 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tting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conguration

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conned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 OPERATION INSTRUCTIONS

1-20

TANKLESS WATER HEATER 199

1.5 CONDENSATE REMOVAL

Thespeciedventcongurationpromotesthesafedrainageofmoisturefromthe

unitandexhaustventingwithoutowing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lled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.

Figure 21: Condensate trap installation

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 lled 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.

1-21

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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rellasnecessary.

Tankless

Water Heater

Figure 22: Condensate trap drainage

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.

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 e󰀨ective.

WARNING

If condensates are to be

discharged into building drain

piping materials that are subject

to corrosion, a neutralization

package must be used.

Tankless

Water Heater

Figure 23: Condensate neutralization tank

INSTALLATION AND OPERATION INSTRUCTIONS

1-22

TANKLESS WATER HEATER 199

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.

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.

1-23

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199



Tankless

Water Heater

Non-ferrous pump (sized for combined head loss of water heater and air

handler)

Check valve (may be built into pump)

Potable water expansion tank

Mixing valve

Figure 24: DHW and Air Handler Piping

NOTE

Connection to space-heating

circuit through potable water

system as shown may be

prohibited by local code.

INSTALLATION AND OPERATION INSTRUCTIONS

1-24

TANKLESS WATER HEATER 199

1.7 DOMESTIC HOT WATER SYSTEM

BURN

HOT

DANGER

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.

WARNING

CAUTION

WATER HEATER INSTALLATION GUIDELINES

ADJUSTABLE TEMPERATURE SETTING

Hotter water increases the risk of scald injury. Before changing the temperature setting, see

instruction manual.

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.

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.

1-25

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

1.7.1 Domestic Hot Water System

ThisTanklessWaterHeaterhasacopperpipingcircuitfore󰀩cientlygenerating

DomesticHotWater.Whenafaucetisopenedtodrawhotwater,waterowis

detectedwithaowsensorandtheunitres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bu󰀨er,

eliminatingthe“coldwatersandwiche󰀨ect”whenturningonando󰀨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e󰀩ciencies.

When installing and maintaining the water heater, you must consider water

quality.Waterconditionsoutsideofthelevelsspeciedbelowmaydamagethe

water heater.

DESCRIPTION MAX MIN

Water Pressure 150 PSI 40 PSI

Programmable Water Temperature 149°F (65°C) 105°F (40°C)

Minimum DHW Flow Rate to Initiate Operation N/A 0.5 GPM

pH 8.5 6.5

Total Dissolved Solids (TDS) 500 mg/L

Total Hardness 250 mg/L 14.6 gr/

gal

Aluminum 0.2 mg/L 0.05 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

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 ow 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

specications in the table 5.

INSTALLATION AND OPERATION INSTRUCTIONS

1-26

TANKLESS WATER HEATER 199

Graph 1: Water Heater Pressure Drop

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eldpipingontotheboiler.Useonewrenchto

holdtheboilertting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ushing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ows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ltertopreventcontaminantsfromfoulingthe

owsensorandheatexchanger.Seemaintenancesection4.1.12forcleaning

procedure.

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

tting with a second wrench

while tightening eld piping may

lead to boiler damage.

NOTE

See Domestic Hot Water

Warnings on page 1-25.

Figure 25: Overview of piping

connections



Tankless

Water Heater

DHW DCW

1-27

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

DOMESTIC HOT WATER

DELIVERY

@ 67°F / 37.2°C temperature

rise

199,000 Btu/hr199,000 Btu/hr 5.4 GPM

CAUTION

A eld 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.

Aquastat

Combi Boiler

Tankless

Water Heater

Tankless

Water Heater

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

schematic guide.

1.7.3 Tankless Domestic Hot Water with a Storage

Tank

The Tankless Water HeaterTankless 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re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.

INSTALLATION AND OPERATION INSTRUCTIONS

1-28

TANKLESS WATER HEATER 199

Controller Manual for required parameter changes.

See the Tankless Water Heater

Figure 27: Typical DHW Recirculation piping – concept drawing. This drawing is only a

simple schematic guide

1-29

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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.

Conrm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eldpipingontotheboiler.Useonewrenchto

holdtheboilertting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 1/2" IPS 3/4" IPS 1" IPS

199,000 Btu/hr (Natural Gas) 10' 40' 150'

199,000 Btu/hr (Propane) 30' 125' 400'

Table 6: Maximum Pipe Length (ft)

Gaspipingmusthaveasedimenttrapaheadoftheunit’sgasvalve(see Figure

29). Amanualshuto󰀨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shuto󰀨valveduringanypressuretestingequaltoorlessthan½

psi (3.5 kPa).

• Disconnecttheboilerandgasshuto󰀨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ring

rates with the modulating series units, but will always be close to 0" w.c.

CHECK LOCAL CODE FOR

SIZE REQUIREMENTS

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

ring 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 retrot

situations where existing

regulators may have an over-

sized orice and/or worn seats,

causing pressure “creep” and

high lock up pressures.

WARNING

Failure to support the boiler

tting with a second wrench

while tightening eld piping

may lead to boiler damage.

Figure 28: Gas Valve

WARNING

Do not check for gas leaks

with an open ame, 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 29: Gas Piping

INSTALLATION AND OPERATION INSTRUCTIONS

1-30

TANKLESS WATER HEATER 199

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.

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.

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/o󰀨switchwithinsightoftheunit.

1.9.2 Accessing Controller Terminal Strip

Pulloutonthetwocontrolmoduleretainingtabsthenipdownthecontrolto

access the terminal strip.

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.

Figure 30: Pullling out the tray

2-1

UNIT SYSTEM OPERATION

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ame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.

BURN

HOT

DANGER

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.

INSTALLATION AND OPERATION INSTRUCTIONS

2-2

TANKLESS WATER HEATER 199

2.2 CONTROL

ICON FUNCTION

Numerical Display Main Display

Plus & Minus TemperatureAdjustment

Flame Burner ON Indicator

Dot Power ON Indicator

Faucet DHW Indicator

Wrench Service / Reset

Return Arrow Enter / Save

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o󰀨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.

Controller turn on

A G HF

2-3

UNIT SYSTEM OPERATION

TANKLESS WATER HEATER 199

2.3.2 Programming Mode

There are two parameters available in the User Setup Menu.

Thecontrollerhasve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.

DHW menu B

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

• 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.

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 e󰀩cient operation,

this setting should be set

as low as practical for the

consumer’s needs.

INSTALLATION AND OPERATION INSTRUCTIONS

2-4

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.

• 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.

2-5

UNIT SYSTEM OPERATION

TANKLESS WATER HEATER 199

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 forfordomestichotwaterheatingfromtheinternalow

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ame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o󰀨.(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

SERVICE

DISPLAY

DESCRIPTION

OFF - The unit is OFF. Press the space above the dot for 2

seconds to turn on the unit

(blank) (blank) No Call for Hot Water - Standby

XXX

Unit water temperature exceeds target, call still present

XXX 2 Self-test – When power is applied to the unit the

controller enters a self diagnostic mode for 5 seconds

XXX 3 Fan Pre-purge and Post-purge

XXX 4 Trial for Ignition and Flame Proving

XXX + Heating – DHW

XXX 7 Burner on for DHW Comfort mode

XXX

Freeze Protection mode

Table 8: Operating Display and Service Display Codes.

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.

INSTALLATION AND OPERATION INSTRUCTIONS

2-6

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.

2-7

UNIT SYSTEM OPERATION

TANKLESS WATER HEATER 199

See below for a description of the codes:

Table 9: Information Menu

Notethatdisplayparametersmaydi󰀨erdependingontheconguration.Wherethereisno

DHW sensor, the display reading can be ignored.

INSTALLATION AND OPERATION INSTRUCTIONS

2-8

TANKLESS WATER HEATER 199

2.7 RESETTING THE MAINTENANCE

COUNTER

Inspectionoftheunitmustbeperformedannuallybyaqualied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noticationcodewillbedisplayed.

Toresetthemaintenancecounterandclearamaintenancenotication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.

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.

2-9

UNIT SYSTEM OPERATION

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.

INSTALLATION AND OPERATION INSTRUCTIONS

2-10

TANKLESS WATER HEATER 199

INSTALLATION AND OPERATION INSTRUCTIONS

2-10

TANKLESS WATER HEATER 199

Thefollowingnoticationswillbedisplayedasthetimeformaintenance

approaches.

MAINTENANCE COUNTER NOTIFICATION CODE

80 n120 - Maintenance recommended

100 n121-Maintenancerequired,limitedDHWoutput

120 n122-Maintenancerequired,noDHWoutput

Thenoticationcodewillbedisplayedfor30secondsandthewrenchwillash.

Pressthewrenchbuttontoseethenotication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brieydisplayedontherightscreentoindicatethechangehasbeen

stored.

3-1

STARTUP AND COMMISSIONING

TANKLESS WATER HEATER 199

3.0 STARTUP & COMMISSIONING

3.1 LIGHTING & SHUTTING DOWN THE UNIT

(LP)

INSTALLATION AND OPERATION INSTRUCTIONS

3-2

TANKLESS WATER HEATER 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-2

TANKLESS WATER HEATER 199

3.2 PRIOR TO START-UP

3.2.1 Pre-Ignition Checks

1. Fill the condensation trap. Ensure the venting system is complete and seal-

tested.Conrm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uehas

been done.

Conrm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o󰀨,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 minimum 4" w.c. and

maximum 14" w.cmaximum 14" w.c. Check that there are no gas leaks.

4. Performanal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shuto󰀨deviceby

shuttingo󰀨themanualgasvalveimmediatelyoutsidetheunitcase.Ensurethat

theunithasshuto󰀨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oriceinstalledandisnoteld

adjustable.Alowcaloricvaluenaturalgasorice(SeeTable10)isavailablefor

locationswherethenaturalgascaloricvaluefallsbelowtheexpectedrangeof

950-1100BTU/Ft3.Consultyourlocalfuelproviderforyourfuel’scaloricvalue.

Lowreiseldadjustableviathelowreadjustmentonthegasvalvebutmust

bedonewithcaution.Nomixtureadjustmentmaybeperformedunlessdoneby

aqualiedtechnicianusingaproperlyfunctioningandcalibratedcombustion

analyzer.

This unit can burn either natural gas or propane if equipped with the

correct specied orice. Examine the rating plate of the unit to ensure it

is congured 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

TO PROPANE

PROPANE TO

NATURAL GAS

LOW CALORIFIC

NATURAL GAS

199,000 Btu/hr P-081014 P-081024 P-081414

Table 10: Fuel conversion kits

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a󰀨ectedataltitude.

DANGER

- Fill trap with water before

unit is rst red to prevent

exhaust fumes from entering

room. Never operate the unit

unless the trap is lled 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.

3-3

STARTUP AND COMMISSIONING

TANKLESS WATER HEATER 199

Toverifytheproperoperationofthegasvalveintheeld,thefollowingprocedure

canbecarriedoutbyaqualiedtechnician(see diagrams on this page).

1. Turno󰀨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re.

2. Allowtheunittoignite/runagainstalargeload.Tomaintainhighre,press

theame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re.

NOTE:Allowtheunittooperateathighre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conrmfullmaximumratingplateinput.With

acombustionanalyzerprobeintheue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conrmthatthecorrectoriceand

venturi are installed. High Fire CO

issetbytheoriceinstalledandisnot

eldadjustable.Forareasoflowercaloricvaluenaturalgas,installthe

alternativeoricelistedinTable10.

4. SwitchtheunittolowrebypressingtheWrench button and Minus

buttonsatthesametime.Theunitwilldroptolowre.“L”willshowonthe

service display. Compare the readings with Table 11 - Low Fire.Ifadjustment

isnecessary,removethelowre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 CO

and counter-clockwise to reduce

. If the target cannot be met, even after a full turn, contact the factory.

Whennished,replacethelowrecap,andleavethemanualmodeby

pressing+AND-simultaneously.

5. Switcho󰀨the unit by pressing the space above the dot for two seconds. Turn

o󰀨thegasattheunit’smanualgasvalve.Removetheue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 31 Gas Valve Adjustment

Figure 32: Flue gas test port plug

WARNING

Check the rating plate of the

unit to ensure it is congured

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

re combustion by adjusting

the low re combustion

adjustment could lead to

unstable operation, failed

ignitions, or dangerous

operating conditions.

INSTALLATION AND OPERATION INSTRUCTIONS

3-4

TANKLESS WATER HEATER 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-4

TANKLESS WATER HEATER 199

3.4 FUEL CONVERSION

Theunitisfactoryre-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qualied

technician.

Fuelconversionrequireshardwareadjustments(oricereplacement)aswellas

measurementandpossibletuningofthelowre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

VALUE

(

)

AT HIGH FIRE WITH THE FRONT COVER OPEN¹

Max. CO

value 10.3% 11.0%

Min. CO

value 8.7% 9.8%

CO LIMIT

(

PPM

)

AT HIGH FIRE WITH THE FRONT COVER OPEN²

Max. CO limit < 150ppm <250ppm

VALUE

(

)

AT LOW FIRE WITH THE FRONT COVER OPEN

Max. CO

value =valueatHigh =valueatHigh–0.3%

Min. CO

value 8.7% 9.5%

Table 11: Acceptable High and Low Fire Combustion Values

¹HighFireCO2issetbytheoriceinstalledandisnoteld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.

Thefollowingproceduremustbecarriedoutbyaqualiedtechnician.

1. Ensurethatthegassupplyisturnedo󰀨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oriceandO-ring.

4. Insertthecorrectorice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.

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 re or

explosion, which may cause

property damage, personal

injury, or loss of life.

Figure 33: Orice and O-ring

PROPANE ORIFICE CHART

MODEL

ORIFICE

SIZE

199,000 Btu/hr 535

NATURAL GAS ORIFICE

CHART

MODEL

ORIFICE

SIZE

199,000 Btu/hr 660

WARNING

Ensure the part kit and

orice are correct for the

appliance model and fuel type

prior to performing the fuel

conversion.

3-5

STARTUP AND COMMISSIONING

TANKLESS WATER HEATER 199

Figure 34: Back Flow Valve

Figure 35: Blower and Gas Valve Assembly

WARNING

Each unit is equipped with

a back ow valve installed

at the outlet of the fan.

Inspect the back ow apper

annually.

3.4.1 Gaining access to combustion chamber, burner

removal instructions

DISASSEMBLY

1. Turno󰀨themainpowerswitchtotheunit.

2. Turno󰀨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o󰀨.

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.

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.

INSTALLATION AND OPERATION INSTRUCTIONS

3-6

TANKLESS WATER HEATER 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-6

TANKLESS WATER HEATER 199

REASSEMBLY

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ue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.

Figure 36: Tighten hex bolts in

cross pattern direction.

4-1

MAINTENANCE

TANKLESS WATER HEATER 199

4.0 MAINTENANCE

4.1 WATER HEATER MAINTENANCE

4.1.1 General Care

•

Keepcombustiblematerialsandammable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qualied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lters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-lledcompletelybeforeringtheunit.

• Check the pH level of the condensate discharge if using condensate

neutralization.

4.1.5 Burner

•

 Attherst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ltrationifthe

burnerrequirescleaningeveryyear.Inalternateyears,visuallyinspectburner

throughthesightglass.Ensuretheameisstableandwithoutexcessive

uttering.Normalame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.

3/16" / 4.5MM

Figure 37: Checking igniter gap using 251-001 Ignitor Gapping Tool

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.

WARNING

- Fill the trap with water

before the unit is rst red to

prevent exhaust fumes from

entering the room. Never

operate the unit unless the

trap is lled 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.

INSTALLATION AND OPERATION INSTRUCTIONS

4-2

TANKLESS WATER HEATER 199

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sti󰀨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.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ush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qualied

service personnel.

Ifthereliefvalvedoesnotcompletelyseal,anduidcontinuestoleakfrom

thedischargepipe,performthetestagaintotryandushanydebristhatmay

be lodged in the valve. If repeated attempts fail to stop the leakage, contact a

licensedcontractororqualied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e󰀩ciency.FoulingoftheDHWcoilwill

CAUTION

The heat exchanger has a small

amount of combustion chamber

insulation (refractory) that

contains ceramic bers.

When exposed to extremely

high temperatures, the ceramic

bers, which contain crystalline

silica, can be converted into

cristobalite, classied 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 certied by

NIOSH, refer to the “NIOSH

Guide to the Selection

and Use of Particulate

Respirators Certied under

42 CFR 84”.

For current information,

contact NIOSH on 1-800-356-

4676 or on the web at

www.cdc.gov/niosh.

2. Wear long sleeved, loose

tting 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 rst aid guidelines:

• Eye contact - Irrigate and

wash immediately.

• Breathing in fumes - Provide

fresh air.

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TANKLESS WATER HEATER 199

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 MIN

Water Pressure 150 PSI 40 PSI

Programmable Water Temperature 149°F (65°C) 105°F (40°C)

Minimum DHW Flow Rate to Initiate Operation N/A 0.5 GPM

pH 8.5 6.5

Total Dissolved Solids (TDS) 500 mg/L

Total Hardness 250 mg/L

14.6 grains/gal

Aluminum 0.2 mg/L 0.05 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

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ushkit.

3. Turno󰀨theunitbytouchingtheareaabovethedotfor2seconds.

4. Openahotwaterfaucetuntiltheheatexchangerissu󰀩ciently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ush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ue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.

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.

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15. OpentheDHWcoldwaterisolationvalveandushoutthebypasslinefor

about 5 minutes.

16. Reconnectthewireharnesstotheue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lterduringannualmaintenanceasfollows:

1. Turno󰀨theunitanddisconnectpower.

2. Turno󰀨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lterfromtheunit’scoldwaterinlet.

5. Cleanthewaterlterunderrunningwater.Useasoftbrushifnecessary.

6. Reinstallthewaterlter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.

4.1.14 Fan removal instructions

1. Turno󰀨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orice

and O-ring, and keep in a safe place for re-installation later. Ensure you

protect the gas valve outlet from dust and debris.

Remove the 2 hex nuts connecting the fan to the burner housing, and

carefullyremovethefan.Youwillndagasketattachedtothefanoutletas

well as an internal check valve. Keep these items in a safe place for re-

installation.

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t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orice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.

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.

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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o󰀨thepowerandthegassupplytotheunit.

2. Remove the front cover, and allow the unit to cool down.

3. Removetheexiblehose(1)fromthecondensatetrapanddrain.

4. Detach the condensate trap cup (2) by rotating it to the left (counter-

clockwise) 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)

8. Clean the following components with water:

● the inside of condensate trap base

● plastic ball

● circlip

● condensate trap cup

● openingoftheuepipe

1 2

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TANKLESS WATER HEATER 199

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ue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).

2 ¼"

(60 mm)

13. Makesurethecondensatetrapcupis¾lled

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).

–

9 10

14. Slidetheexiblehoseontothecondensatetrapbaseandintothedrain(10)

DANGER

Make sure that the

condensate trap base is

returned to its original

position, rmly 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.

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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o󰀨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.

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5.0 TROUBLESHOOTING

The troubleshooting section is divided into four sections:

5.1 Preliminary Checks

5.2 Electronic Components

5.3 Faults and Notications

5.4 Other Faults

Often, you can identify and solve a problem through simple checks of the basics:

conrmingtheelectricalpowersupplyandgasow.Tohelpwithpreliminary

checks,theunit’scontrolmoduleo󰀨ers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 Notication 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rst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. Conrm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.

Conrmthatthedomesticwatersystempressureisaminimum40psig.

NOTE

This appliance is equipped

with a blocked vent shut-o󰀨

system that closes the gas

supply when it detects an

irregular venting condition.

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5.2 ELECTRONIC COMPONENTS

This section details the method for troubleshooting the non-standard electronic

components on the unit.

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KΩ(5,000,000Ω)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.

12KΩ temperature sensors are supplied with the unit. See Table 14 for resistance

values.

SENSOR TYPE PURPOSE LOCATION

NTC12KΩ

Heat Exchanger

Temperature

Left side of Heat Exchanger

S3 NTC12KΩ Domestic Hot Water DHW Supply Pipe

S4 NTC12KΩ Domestic Cold Water DCW Supply Pipe

S5 NTC12KΩ Flue Gas Temperature Top of rear Flue passage

PTC1

PTC2

PTC Cabinet Temperature

Left and right Side top of

inner cabinet

Table 13: 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 TEMPERATURE RESISTANCE

F / C Ω-ohm F / C Ω-ohm F / C Ω-ohm

5F / -15C 76,020 77F / 25C 12,000 149F / 65C 2,752

14F / -10C 58,880 86F / 30C 9,805 158F / 70C 2,337

23F / -5C 45,950 95F / 35C 8,055 167F / 75C 1,994

32F / 0C 36,130 104F / 40C 6,653 176F / 80C 1,707

41F / 5C 28,600 113F / 45C 5,522 185F / 85C 1,467

50F / 10C 22,800 122F / 50C 4,609 194F / 90C 1,266

59F / 15C 18,300 131F / 55C 3,863 203F / 95C 1,096

68F / 20C 14,770 140F / 60C 3,253 212F / 100C 952

Table 14: Temperature Sensor Resistance Values – 12KΩ sensors.

Figure 38: Heat exchanger

Temperature Sensor S0

Cabinet sensors

Figure 39: PTC Cabinet

Temperature Sensors

5-3

TROUBLESHOOTING

TANKLESS WATER HEATER 199

Figure 42: Domestic Hot Water

Temperature Sensor S3

5.2.3 Flue Gas Temperature Sensor

Thissensorensuresthattheunitshutsdownsafelyiftheuetemperature

isabovenormal.Highuetemperaturescanbeanindicationthattheheat

exchangerrequirescleaning.

Theuegastemperaturesensorislocatedatthetopoftherearuepassage,

below the top panel. To remove the sensor, unclip from the wiring harness and

unscrewfromtherearuepassage.

5.2.4 Domestic Hot Water Flow Sensor

Theunitisequippedwithaowsensortomeasurewaterowthroughthe

domestichotwatercircuitinthewaterheater.Theow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ow

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.

Turno󰀨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 40: Flue gas Temperature

Sensor S5

Figure 41: Domestic Water Flow

Sensor

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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o󰀨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lter.

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 43: Bypass Valve

Figure 44: Domestic Cold Water

Temperature Sensor S4

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TANKLESS WATER HEATER 199

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ashing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 DESCRIPTION POSSIBLE CAUSE / SOLUTION

F000 Heat exchanger temperature sensor

fault.

• Verify wire harness connections at heat exchanger

temperature sensor and control module are tight.

• Replace heat exchanger temperature sensor.

F002 High heat exchanger temperature during

DHW demand.

• Verify the unit has been converted to propane if

operating on propane

• Verifycombustionreadingsatlowandhighreare

withinspecications.

• Clean heat exchanger DHW coil.

• Cleanresideofheatexchanger.

F003 Highuetemperature.

• Verify the unit has been converted to propane if

operating on propane.

• Verifycombustionreadingsatlowandhighreare

withinspecications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

F004 Noamedetectedduringfourignition

trials.

• Verifyexternalgasshuto󰀨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backowapperinthefan

outlet.

• Verify ignitor is not in contact with burner and gap is

correct.

• Replaceignitionmoduleifunitlightsbutame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.

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TANKLESS WATER HEATER 199

F005 Noamedetectedduringoperation.

• Verify condensate drain is not blocked.

• Check vent and combustion air piping for blockage.

• Checkforuegasrecirculation.

• Ifventterminationissubjecttohighwinds,

recongure/relocateasnecessary.

• Verify gas inlet pressure is at least 4” at both low and

highre.

• Verifylowandhighrecombustionreadingsarewithin

specications.

• Check ignitor condition and clean/replace as

necessary.

F006

Flamedetectedwhenburneriso󰀨.Flamedetectedwhenburneriso󰀨.

• Verify good internal and power supply grounding.

• Verifyamegoesoutatconclusionofdemand,ifnot

replace gas valve.

• Replace ignition module.

• Replace control module.

F007 Lowamesignal.

• Verify ignitor to ignition module connection is tight.

• Check ignitor condition and clean/replace as

necessary.

• Verifylowandhighrecombustionreadingsarewithin

specications.

F008 Incorrect fan speed

• Verify wire harness connections at fan and control

module are tight.

• Replace fan.

• Replace control module.

F009 Control module internal fault.

• Removealleldwiringfromunitthenresetfault.

• CheckeldwiringforvoltagebackfeedifF009fault

does not return.

• Replace control module if F009 fault code returns.

F010 Heat exchanger temperature sensor

open.

• 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.

F011 Heat exchanger temperature sensor

short

•

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.

F012 Flue temperature sensor open.

• Verifywireharnessconnectionsatuetemperature

sensor and control module are tight.

• Checkresistanceofuetemperaturesensor,replace

sensor if open circuit is found.

• Checkresistanceofuetemperaturesensoratcontrol

module harness connector, repair wire harness if open

circuit is found.

5-7

TROUBLESHOOTING

TANKLESS WATER HEATER 199

F013 DHW inlet temperature sensor open/

short

• 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

F014 Heat exchanger temperature sensor

mounting fault.

• Heat exchanger temperature is not changing while unit

isred.

• Verify heat exchanger temperature sensor is properly

mounted on the heat exchanger.

F015 High cabinet temperature

• Checkheatexchangerforuegasleakage

• Checkventpipeforuegasleakage

F016 DHW outlet temperature sensor

mounting fault

• DHW outlet temperature is not changing while unit is

red

• Verify DHW outlet temperature sensor is properly

mounted on the DHW outlet pipe

F017 DHW bypass valve fault

• 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-Purple=30to40Ω

 Green-Blue=30to40Ω

 Green-Yellow=30to40Ω

 Green-Orange=30to40Ω

 Red-Black=5.5to6.5MΩ

 Red-Brown=17to21MΩ

• If any resistance value is outside of these ranges,

check and repair any wire harness open/short circuit

before replacing DHW bypass valve

F018 Flue/Combustion Air blockage.

• Check the vent and combustion air pipes for blockage.

• Verifyoperationofthebackowapperinthefan

outlet.

F019 Boiler Memory Module (BMM) fault.

• Verify wire harness connections at boiler memory

module and control module are tight.

• Verify wire harness continuity between boiler memory

module and control module .

• Replace boiler memory module.

F021 Critical parameter changed

• Factoryresetrequired

F028 Reset button fault

• Check the reset button for unintentional operation (e.g.

cleaning of the control panel).

• Replace the control module.

F029 Gas valve fault.

• Verify wire harness connections at gas valve and

control module are tight

• Replace gas valve if upper coil resistance is not 35 to

45Ω.

• Replace gas valve if lower coil resistance is not 20 to

30Ω.

• Check resistance of gas valve at control module

harness connector, repair wire harness if open/short

circuitisfoundorifresistanceisnotwithin60to70Ω

• Replace control module.

INSTALLATION AND OPERATION INSTRUCTIONS

5-8

TANKLESS WATER HEATER 199

F040 Cabinet temperature sensor open.

• Verify wire harness connections at cabinet

temperature sensors and control module are tight.

• Check resistance of cabinet temperature sensors,

replace sensor if open circuit is found.

• Check resistance of cabinet temperature sensors at

control module harness connector, repair wire harness

if open circuit is found.

F041

Cabinet temperature sensor short

•

Check resistance of cabinet temperature sensors,

replace sensor if short circuit is found.

• Check resistance of cabinet temperature sensors at

control module harness connector, repair wire harness

if short circuit is found.

F042 Cascade DHW not available

• Resolve any other lockouts in the cascade system

• Verify Leader cascade parameter settings are correct

• Verify Follower(s) cascade parameter settings are

correct

• Check cascade communication status in the

information menu of both Leader and Follower

-- (Blinking) Water presssure sensor fault

• Verify wire harness connections at water pressure

sensor and control module are tight

• Check resistance of water pressure sensor at control

module harness connector:

 Black-Orange=7.5to9.5KΩ

 Black-Yellow=7.5to9.5KΩ

• If any resistance value is outside of these ranges,

check and repair wire harness open/short circuit

before replacing water pressure sensor

5-9

TROUBLESHOOTING

TANKLESS WATER HEATER 199

5.3.2 Notication Codes

Duringoperationthecontrollercanalsodetectunusualsituationsanddisplayanotication,usuallywithoutsignicant

interruption of the normal operation of the appliance.

Thesenoticationsareshownonthemaindisplay,anddisplayonlywhenanunusualreadingiscurrentlydetected.

Once the error has been resolved, the operation will be restored

Note that these notications only appear on controllers installed with software versions after 1.80. The software

version of the controller will appear upon the controller’s initial start up.

NOTIFICATION

CODE

DESCRIPTION POSSIBLE CAUSE / SOLUTION

n030 DHW outlet temperature sensor

open/short

• Verify wire harness connections at DHW outlet temperature

sensor and control module are tight.

• Check resistance of DHW outlet temperature sensor, replace

sensor if open/short circuit is found.

• Check resistance of DHW outlet temperature sensor at control

module harness connector, repair wire harness if open/short circuit

is found.

n040 Cascade communication lost

• Verify Leader is powered on and cascade parameter settings are

correct.

• Verify Follower(s) cascade parameter settings are correct.

• Check cascade communication status in the information menu of

both Leader and Follower.

n041 Cascade system sensor open

• Verifysystemsensoreldwiringisterminatedatthechooseninput

(X13-3&4 or X13-4&5).

• Check resistance of system temperature sensor, replace sensor if

open circuit is found.

• Check resistance of system temperature sensor at control module

harnessconnector,repairsystemsensoreldwiringifopencircuit

is found.

n120 Maintenance recommended

• Maintenance is recommended based on hours of use.

n121 Maintenancerequired,limitedDHW

output

• Maintenanceisrequiredbasedonhoursofuse.

• DHW output will be limited until maintenance is performed.

n122 Maintenancerequired,noDHW

output

• Maintenanceisrequiredbasedonhoursofuse.

• DHW output is disabled until maintenance is performed.

n150 High heat exchanger temperature,

limited output

• Verify all air has been bled/purged from the heat exchanger

central heating coil.

• Replace internal pump if it is not operating during a central heating

demand.

• Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

n151 Highuetemperature,limited

output

• Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

INSTALLATION AND OPERATION INSTRUCTIONS

5-10

TANKLESS WATER HEATER 199

n152 Flue temperature sensor mounting

fault

• Fluetemperatureisnotchangingwhileunitisred.

• Verifyuetemperaturesensorisproperlymountedonthevent

pipe.

n201 Heat exchanger air purge function

activated

• Air trapped in the heat exchanger

• Closed boiler isolation valve

• Defective boiler pump

n202 Highuetemperature,burner

disabled

• Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger

• Clean heat exchanger central heating and DHW coils.

n245 Fluegasbackow,fanonlow

speed

• Verify vent and combustion air piping and terminations are

installed according to this manual.

• Verifyoperationofthebackowapperinthefanoutlet.

5.4 OTHER FAULTS

5.4.1 No domestic hot water (DHW)

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

The power LED is not shown. →Yes

↓No

• Check the power supply.

• Check the fuse (see electrical schematic).

Flow sensor does not work. →Yes

↓No

Replacetheowsensor.

Domestichotwaterow<0.5gpm →Yes

↓No

Increasethedomestichotwaterow.

Domestic hot water sensor S3 is

defective.

→Yes

↓No

Replace the domestic hot water sensor S3.

Noelectricityontheowsensor(5V

DC).

→Yes Check the wiring according to the schematic. CK THE

WIRING ACCORDING TO THE SCHEMATIC.

5-11

TROUBLESHOOTING

TANKLESS WATER HEATER 199

5.4.2 Domestic hot water does not reach the correct temperature

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

Domestichotwaterowistoohigh. →Yes

↓No

Reducethedomestichotwaterow.

Setting for domestic hot water

temperature is too low.

→Yes

↓No

Increase the domestic hot water temperature.

Insu󰀩cientheattransferduetocalciumor

contamination in the domestic hot water-sided

central heating unit.

→Yes

↓No

De-calcifyorushthedomestichotwater-sidedcentral

heating unit.

Theueisblocked.

→Yes Checktheue.

5.4.3 Burner ignites loudly

POSSIBLE CAUSES ANALYSIS SOLUTION

Inlet pressure is too high. →Yes

↓No

The gas pressure regulator may be defective. In that case,

contact the energy company.

Ignition distance is incorrect. →Yes

↓No

Replace the ignitor including the ignition cable.

Gas-air control is not correctly

adjusted.

→Yes Checkand/oradjustcombustionwithacalibrated

combustion analyzer.

5.4.4 Burner resonates

POSSIBLE CAUSES ANALYSIS SOLUTION

Gas inlet pressure lower than 4“ w.c.

or sometimes disappears.

→Yes

↓No

The gas pressure regulator may be defective. Contact the

energy company.

Thereisrecirculationofuegases. →Yes

↓No

Checktheueandairsupplyduct.

Gas-aircontrolisnotcorrectlyadjusted. →Yes

↓No

Checkand/oradjustcombustionwithacalibrated

combustion analyzer.

Burner seal is defective. →Yes

↓No

Replace the burner seal.

Burner is defective. →Yes Replace the burner.

INSTALLATION AND OPERATION INSTRUCTIONS

5-12

TANKLESS WATER HEATER 199

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6-1

REPLACEMENT KITS

TANKLESS WATER HEATER 199

6.0 REPLACEMENTS KITS

Replacement Kit Numbers Replacement Kit Description

P-081014 Conversion To Propane - Venturi 375

P-081024 Conversion To Natural Gas - Venturi 375

P-081414 Conversion To Low Caloric Gas - Venturi 375

P-081134 Replacement kit: Flue Temperature Sensor

P-081144 Replacement kit: Ignitor

P-081174 Replacement kit: EBM Fan

P-081234 Replacement kit: Gas Valve

P-081294 Replacement kit: Temperature Sensor Heat Exchanger

P-081304 Replacement kit: Condensate Trap Tankless Water Heater 199

P-081334 Replacement kit: Controller Box White

P-081384 Replacement kit: Burner 160 - 199

P-081444 Replacement kit: Flow Sensor (Clip only)

P-081454 Replacement kit: Maintenance Set Heat Exchanger

P-081494 Replacement kit: Bypass Wiring

P-081504 Replacement kit: Ignition Wiring

P-081534 Replacement kit: Sensor Wiring Tankless

P-081574 Replacement kit: Ignition Line Complete

P-081694 Replacement kit: Temperature Sensor Supply (Clip 22mm)

P-082424 Replacement kit: Bypass valve

P-081784 Replacement kit: Temperature Sensor DHW (Clip 15mm)

P-081794 Replacement kit: Controller Box Black

P-081814 Replacement kit: Strainer

INSTALLATION AND OPERATION INSTRUCTIONS

6-2

TANKLESS WATER HEATER 199

7.0 WIRING DIAGRAMS

Diagram 6.2-1: Schematic wiring diagram

6-3

DIAGRAMS

TANKLESS WATER HEATER 199

1415

12 11 10 9 8 7

5 4 3 2

Domestic hot water sensor S3

Domestic cold water sensor S4

Heat exchanger sensor S0

Flue sensor S5

BMM

Gasvalve

X15

(24V=)

X14

12 12345

X13

(24V =)

N/A

(24V =)

X11

(24V =)

N/A

X10

(24V =)

N/A

(120V ~)

Ignition unit

Burner controller

123456

Earth connections

heat exchanger

Power cord

Eart connections

burner controller

Fan

Ignition pin

Electronic bypass

valve

24V =

http://www.intergasverwarming.nl

(120V ~)

N/A

12345

(120V ~)

8 7

5 4 3 2

120V~ / 60Hz

Diagram 6.2-2: Electrical wiring diagram

INSTALLATION AND OPERATION INSTRUCTIONS

6-4

TANKLESS WATER HEATER 199

INSTALLATION & COMMISSIONING REPORT

Water Heater Details:

Model Number _____________________ Serial Number ______________________________________________

Date of Installation ______________ Address of installation __________________________________________

_____________________________________________________________________________________________

User contact information _______________________________________________________________________

Installer Information Company ___________________________________________________________________

Address ______________________________________________________________________________________

Phone/Fax/E mail ____________________________________________________________________________

Fuel

Natural Gas

Propane

Gas Supply Pressure (high re) _______ Inches w.c. Measured Rate of Input (high re) ____________ Btu/hr

Installation instructions have been followed and completed (Section 1 of Installation and Operating Instructions).

Check-out procedures have been followed and completed (Section 3 of Installation and Operating Instructions).

Leak testing completed

gas piping

venting system

Fan and combustion components

Air purge completed

Relief Valve correctly installed and piped

Relief valve “try lever” test performed

Condensatetraplled

Condensatedrainclearandfreeowing

Condensate Neutralization? Yes/No

IgnitionSafetyShuto󰀨testcompleted.Flamecurrentreading-Highre_______µA-Lowre_______µA

Owner advised and instructed in the safe operation and maintenance of the unit.

Information regarding the unit and installation received and left with owner

Combustion Readings - recommended, but optional (required for fuel

conversion):

_____________ % O

______________ % CO ____________ ppm

Fluetemperature_________Returnwatertemperature(measuresimultaneouslywithuetemp.)_______________

Commissioning has been completed as listed on this report - Installer Signature _____________________________

This installation & commissioning report should remain with the Water Heater for future reference during

maintenance and repair.

6-5

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

SERVICE RECORD

DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

INSTALLATION AND OPERATION INSTRUCTIONS

6-6

TANKLESS WATER HEATER 199

NOTES

6-7

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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INSTALLATION AND OPERATION INSTRUCTIONS

6-8

TANKLESS WATER HEATER 199

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6-9

INSTALLATION AND OPERATING INSTRUCTIONS

TANKLESS WATER HEATER 199

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84160404

Rheem Sales Co.

Montgomery, AL.

(833) 212-9276

IBC Technologies Inc.

8015 North Fraser Way

Burnaby, BC Canada V5J 5M8

(844) HEAT-IBC / (844) 432-8422

IBC Technologies USA Inc.

121 Walter A Gaines Way

Lawnside, NJ 08045

(856) 887-0544

Rheem RTGH-L199I ThermaForce Super High Efficiency Condensing Tankless Gas Water Heaters

Product's Documents

Installation and Operating Instructions

Specifications

Rheem RTGH-L199I Questions and Answers