Gas Tankless Water Heater
TM
Suitable for combination potable water heating and
space heating. Please refer to local codes for space-
heating compliance.
On-Demand Water Heater
Installation Manual and Owner’s Guide
If you have any questions, please
call or write to:
In the United States
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free: 1-877-737-2840
In Canada
599 Hill Street West
Fergus, ON N1M 2X1
1-888-479-8324
- Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Donottrytolightanyappliance.
• Donottouchanyelectricswitch,donot
use any phone in your building.
• Immediatelycallyourgassupplierfrom
a neighbor's phone. Follow the gas
supplier's instructions.
• Ifyoucannotreachyourgassupplier,call
the fire department.
- Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
WARNING
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
ANSI Z21.10.3 ・ CSA 4.3
540
model only
R
DR
Keep this manual near the water heater for future reference whenever maintenance, adjustment, or
service is required.
FEATURING
• ENDLESS HOT WATER
• ON-DEMAND USAGE
• COMPACT, SPACE SAVING
• ENERGY CONSERVATION
• COMPUTERIZED SAFETY
• NO PILOT LIGHT
• Complies with SCAQMD Rule
1146.2 for natural gas Low NOx
Emissions of 14 ng/J or 20 ppm.
• EASY-LINK SYSTEM
• MULTI-UNIT SYSTEM
(540 model only)
Models
• 240Indoor
• 340Indoor
• 540Indoor
• 240Outdoor
(USAOnly)
• 340Outdoor
(USAOnly)
• 540Outdoor
(USAonly)
2 Page
Contents
CONTENTS
Installation Manual
SPECIFICATIONS .............................................4
INTRODUCTION ..........................................5
SAFETY GUIDELINES.....................................6
SAFETY DEFINITION ....................................6
GENERAL ......................................................6
INSTALLATION ................................................7
GENERAL ......................................................7
CLEARANCES ...............................................9
INCLUDED ACCESSORIES ............................9
OPTIONAL ITEMS ........................................ 9
WARNING FOR INSTALLATIONS ...............11
HIGH-ALTITUDE INSTALLATIONS .............12
VENTING INSTRUCTIONS .........................13
General .....................................................13
Combustion air supply ..............................14
Exhaust vent (ABS,PVC,CPVC, or
polypropylene vent) .................................18
DIP switch settings for vent length
(ABS,PVC,CPVC, or polypropylene vent) ...19
Exhaust vent (Stainless steel vent) ...........22
DIP switch settings for vent length
(Stainless steel vent) .................................22
Common venting system ..........................24
Vent termination clearances ....................26
Clearances for sidewall terminations .......27
Clearances for rooftop terminations ........28
GAS SUPPLY AND GAS PIPE SIZING ......... 29
General .....................................................29
Gas connections .......................................29
Natural Gas supply piping .........................30
Propane (LP) supply piping ....................... 30
WATER CONNECTIONS .............................31
Pressure relief valve .................................31
CONDENSATE DRAIN ................................32
Condensate drain connections .................32
ELECTRICAL CONNECTIONS .....................34
TEMPERATURE REMOTE CONTROLLER .....35
Included accessories .................................35
Installation ................................................35
EASY-LINK SYSTEM .........................................37
Easy link connection procedures ..............37
MULTI-UNIT SYSTEM ......................................39
APPLICATIONS ..............................................40
Space heating applications ......................... 40
Recirculation ...............................................40
Dual-purpose hot water heating ................... 41
INITIAL OPERATION .....................................42
Owner's Guide
OPERATING SAFETY .....................................44
NORMAL OPERATION ..................................46
BUILT-IN CONTROLLER
AND REMOTE CONTROLLER ..................46
GENERAL ....................................................46
OUTLET WATER TEMPERATURE
SETTING ..................................................... 47
TEMPERATURE TABLE OF CONTROLLER .47
ADDITIONAL FEATURES ...................... ......48
Information mode ....................................48
Unit conversion mode ..............................48
TEMPERATURE SETTINGS ON THE PCB ........49
FLOW .......................................................... 49
FREEZE PROTECTION SYSTEM ................. 50
MAINTENANCE AND SERVICE ................. 51
Measuring inlet gas pressure ...................51
UNIT DRAINING AND FILTER CLEANING .......51
TROUBLESHOOTING .....................................52
GENERAL ....................................................52
ERROR CODES ...........................................53
General .......................................................53
Single unit installation ..............................54
Easy-Link System ....................................... 54
Fault analysis error code ..........................55
COMPONENTS DIAGRAM ............................57
PARTS LIST .................................................... 61
OUTPUT TEMPERATURE CHART ..................64
3 Page
Installaon Manual
Installation Manual
CONGRATULATIONS
Congratulations and thank you for choosing our tankless water heater.
Before use, we recommend that you read through this installation
manual carefully. Keep this manual for future reference.
If you need an additional manual, contact the manufacturer or your
local distributor. When you call, please tell us the product name and
the serial number of your unit written on the rating plate of the water
heater.
4 Page
Specicaons
Installaon Manual
SPECIFICATIONS
*40 psi or above is recommended for maximum flow.
**Water heater Category — water heaters of other than direct vent type, for outdoor installation, are divided into four
categories based on static pressure produced in the vent and flue loss.
Category I - a water heater that operates with a non-positive vent static pressure and with a vent gas temperature
that avoids excessive condensate production in the vent.
Category II - a water heater that operates with a non-positive vent static pressure and with a vent gas temperature
that may cause excessive condensate production in the vent.
Category III - a water heater that operates with a positive vent static pressure and with a vent gas temperature that
avoids excessive condensate production in the vent.
Category IV - a water heater that operates with a positive vent static pressure and with a vent gas temperature that
may cause excessive condensate production in the vent.
NOTE:
• Check the rating plate to ensure that this product matches your specifications.
• The manufacturer reserves the right to discontinue, or change at any time, specifications or designs
without notice and without incurring obligation.
Model
240
Indoor
240
Outdoor
340
Indoor
340
Outdoor
540
Indoor
540
Outdoor
Natural Gas Input
(Operating Range)
BTU/h
Min.: 15,000
Max.: 160,000
Min.: 15,000
Max.: 180,000
Min.: 15,000
Max.: 199,000
Propane Input
(Operating Range)
BTU/h
Min.: 13,000
Max.: 160,000
Min.: 13,000
Max.: 180,000
Min.: 13,000
Max.: 199,000
Gas Connection 3/4" NPT
Water Connections
3/4" NPT
Water Pressure* psi (MPa) 15 - 150 (0.1 - 1)
Natural gas
Inlet Pressure
" W.C.
(kPa)
Min. 4.0 (1.00)
Max. 10.5 (2.61)
Propane
Inlet Pressure
" W.C.
(kPa)
Min. 8.0 (1.99)
Max. 14.0 (3.48)
Weight lbs. (kg)
58 (26.3) 58 (26.2) 58 (26.3) 58 (26.2) 59 (26.8) 59 (26.9)
Dimensions
inch
H 22.4 x W 17.7 x D 10.7
H 570 x W 450 x D 272
mm
Ignition Electric Ignition
Electric
Supply
VAC/Hz 120/60
Consumption
Operation W/A 72.7 / 0.61 78.2 / 0.65 89.0 / 0.74
Standby W/A 3.1 / 0.03 3.1 / 0.03 4.2 / 0.04
Freeze-
Protection
W/A 174 / 1.5 174 / 1.5 175 / 1.5
Water heater category**
Category
IV
N/A
Category
IV
N/A
Category
IV
N/A
5 Page
INTRODUCTION
• This manual provides information necessary for the installation, operation, and maintenance
of the water heater.
• The model description is listed on the rating plate which is attached to the side panel of the
water heater.
• Please read all installation instructions completely before installing this product.
• If you have any problems or questions regarding this equipment, consult the manufacturer or
its local representative.
• This equipment is an on-demand, tankless water heater designed to efficiently supply endless
hot water for your needs when properly sized and installed.
• These high efficiency models have a built-in secondary heat exchanger that absorbs latent
heat from the exhaust gas.
• The 240 Indoor, 340 Indoor, and 540 Indoor models are only to be installed indoors. The 240
Outdoor, 340 Outdoor, and 540 Outdoor models are only to be installed outdoors.
• The principle behind tankless water heaters is simple:
Exhaust
Secondary
heat exchanger
Intake port
Condensate
drain port
Cold water inlet
Gas
Hot water outlet
Computer board
Fan motor
Gas valves
Igniter
Thermistor
Thermistor
Bypass valve
Primary
heat exchanger
Exhaust thermistor
Water control valve
Thermistor
Flow sensor
Burners
1
2
3
4
5
4
6
7
7
7
8
4
4
7
*This diagram illustrates tankless water heater design concepts only and does not accurately represent
the water heater’s physical description.
1. A hot water fixture is turned on.
2. Water flows through the heater.
3. The water flow sensor detects the water flow.
4. The computer initiates the fan motor and gas valve to let gas flow through the heater and sends a
signal to the igniter to create an ignition spark.
5. The gas ignites and flames appear within the burner chamber.
6. Water is heated as it flows through the heat exchanger.
7. Using thermistors to measure temperatures throughout the water heater, the computer modulates
the gas and water valves to ensure proper output water temperature and hot water outflows.
8. When the fixture is turned off, the unit shuts down.
Introducon
Installaon Manual
6 Page
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the current edition of the National
Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas, Propane Installation Code in
Canada.
2. Properly ground the unit in accordance with all local codes or in the absence of local codes, with the
National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canadian Electrical Code
Part 1 in Canada.
3. Carefully plan where you intend to install the water heater. Please ensure:
• Your water heater will have enough combustion air and proper ventilation.
• Locate your heater where water leakage will not damage surrounding areas. (Please refer to p. 8.)
4. Check the rating plate for the correct GAS TYPE, GAS PRESSURE, WATER PRESSURE and ELECTRIC
RATING.
*If this unit does not match your requirements, do not install and consult with the manufacturer.
5. If any problem should occur, turn off all hot water taps and turn off the gas. Then call a trained
technician, the gas company, or the manufacturer.
Safety Guidelines
Installaon Manual
SAFETY GUIDELINES
SAFETY DEFINITION
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
Indicates an imminently hazardous situation which, if not avoided, could result
in minor or moderate injury.
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
DANGER
Indicates information considered important but not hazard related.
NOTICE
WARNING
• Water temperatures over 125 °F (52 °C) can cause severe burns instantly or death from
scalding. The water temperature is set at 120 °F (50 °C) from the factory to minimize any
scalding risk. Before bathing or showering always check the water temperature.
• Do not store or use gasoline or other flammables, vapors, or liquids in the vicinity of this
appliance.
• Do not reverse the water and/or gas connections as this will damage the gas valves and
can cause severe injury or death. Follow the diagram on p. 31 when installing your water
heater.
• Should overheating occur or the gas supply fails to shut off, turn off the manual gas control
valve to the appliance.
• Do not use this appliance if any part has been in contact with or been immersed in water.
Immediately call a qualified installer or service agency to replace a flooded water heater.
Do not attempt to repair the unit. It must be replaced.
• Do not disconnect the electrical supply if the ambient temperature will drop below
freezing. The Freeze Protection System only works if the unit has electrical power. The
warranty will not be covered if the heat exchanger is damaged due to freezing. Refer to
the section on the Freeze Protection System on p. 50 for more information.
• Failure to observe these warnings could result in severe personal injury or death.
7 Page
INSTALLATION
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the current edition of the National
Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas, Propane Installation Code
in Canada.
2. All gas water heaters require careful and correct installation to ensure safe and efficient operation.
This manual must be followed exactly. Read the “Safety Guidelines” Section.
3. The manifold gas pressure is preset at the factory. It is computer controlled and should not need
adjustment.
4. Maintain proper space for servicing. Install the unit so that it can be connected or removed easily.
Refer to the "Clearances" Section on p. 9 for proper clearances.
5. The water heater must be installed in a location where the proper amount of combustion air will
be available to it at all times without obstructions, or the indoor heater may be direct vented.
6. Electrical service to the water heater requires a means of disconnection. This will allow power to
the water heater to be shut off for servicing and safety purposes.
7. Do not install the unit where the exhaust vent is pointing into any opening in a building or where
the noise may disturb your neighbors. Make sure the vent termination meets the required
clearance from any doorway or opening to prevent exhaust from entering a building. (Refer to pp.
11, 26 and 27.) Check local code requirements prior to installation.
8. Carefully plan the installation location of the heater and vent terminations. Contaminants such as
aerosols, lint, and fine powders (including flour) can clog the air intake and reduce the operation
of the fan. This, in turn, can cause improper combustion and reduce the life of the water heater.
Regularly ensure that the area around the water heater, vent termination, and air intake is free of
dust, debris, and other contaminants. In environments with a high level of contaminants (laundry
facilities, hair salons, pet salons, chemical plants, commercial kitchens, etc.), direct venting is
required.
9. The 240 Indoor, 340 Indoor, and 540 Indoor are to be installed indoors only. These units are
equipped with a thermistor and hi-limit switch for the exhaust gas, detecting excess temperatures
within the flue and enabling the unit to safely stop operations if needed. These components are
always monitoring exhaust gas conditions in order to prevent heat damage to ABS, PVC, CPVC,
or polypropylene (Plastic) venting if ABS, PVC, CPVC, or polypropylene is used. If the exhaust
gas temperature exceeds 140 °F (60 °C), these components will enable the unit to safely stop
operations. These components are not installed on the outdoor models since the exhaust vent
is built-in.
• If the water heater is used as a direct-vent appliance, the unit requires 3 in (76 mm) or 4 in
(102 mm) combustion air supply pipe. The intake pipe must be sealed airtight. Refer to pp.
13 to 28 for more detail.
• Terminating the venting through a sidewall is recommended for the direct-vent system.
• Running the exhaust vent and the intake pipe parallel is recommended.
• Terminating the exhaust and intake on the same wall/surface is recommended. Terminating in
the same pressure zone allows for pressure balancing, which prevents nuisance shutdowns.
• Only install the water heater in a heated area where below freezing temperatures cannot
occur. The warranty does not cover damage caused by freezing.
• The water heater must be securely mounted to a wall or other suitable structure.
10. The 240 Outdoor, 340 Outdoor, and 540 Outdoor models must only be installed outdoors and only
in an area with mild, temperate climates. The Outdoor model shall be wall-mounted or mounted
on a stand. Locate the Outdoor model in an open, unroofed area and maintain the following
minimum clearances: There is a 3 in. (76 mm) clearance from the left and right sides of the unit
to combustible and non-combustible surfaces.
Installaon
Installaon Manual
8 Page
Installaon
Installaon Manual
• Installation and service must be performed by a qualified installer (for example, a
licensed plumber or gas fitter). Otherwise, the warranty will be void.
• The installer (licensed professional) is responsible for the correct installation of the
water heater and for compliance with all national, state/provincial, and local codes.
• The manufacturer does not recommend installing the water heater in a pit or
location where gas and water can accumulate.
• Do not have the vent terminal pointing toward any operating window, door, or
opening into a building.
• Do not install next to any source of airborne debris, such as a clothes dryer, that
can cause debris to be trapped inside the combustion chamber, unless the system is
direct-vented.
• Do not install the unit where water, debris, or flammable vapors may get into the flue
terminal or the air intake line.
• The manufacturer does not recommend installing the water heater in an attic due
to safety issues. If you install the water heater in an attic:
• Make sure the unit will have enough combustion air and proper ventilation.
Failure to do so could lead to carbon monoxide poisoning or death.
• Keep the area around the water heater clean. When dust collects on the flame
sensor, the water heater will shut down on an error code.
• Place the unit where it will allow easy access for service and maintenance.
• A drain pan, or other means of protection against water damage, is
recommended to be installed under the water heater in case of leaks.
• Failure to observe these warnings could result in severe personal injury, death,
and/or property damage.
WARNING
• The warranty will not cover damage caused by water quality.
• Only potable water can be used with this water heater. Do not introduce pool
or spa water, or any chemically treated water into the water heater.
• Water hardness levels must not exceed 7 grains per gallon (120 ppm) for
single family domestic applications or more than 4 grains per gallon (70 ppm)
for all other types of applications. Water hardness leads to scale formation
and may affect/damage the water heater. Hard water scaling must be avoided
or controlled by proper water treatment.
• Water pH levels must be between 6.5 and 8.5.
• Well water must be treated.
• The manufacturer recommends direct venting when the water heater is installed
in beauty salons, dry cleaners or any other locations in which such chemicals
are present in the air. Some chemicals used in beauty salons or dry cleaners may
affect the flame sensor. In such cases, the water heater may not work properly.
• Although the water heater is designed to operate with minimal sound, the
manufacturer does not recommend installing the unit on a wall adjacent to a
bedroom, or a room that is intended for quiet study or meditation, etc.
• Locate your heater close to a drain where water leakage will not do damage to
surrounding areas. As with any water heating appliance, the potential for leakage
at some time in the life of the product does exist. The manufacturer will not be
responsible for any water damage that may occur. If you install a drain pan under
the unit, ensure that it will not restrict the combustion air flow.
NOTICE
9 Page
CLEARANCES
Installaon
Installaon Manual
Model Top Bottom Front Back Sides
240 Indoor
340 Indoor
540 Indoor
12 in.
(305 mm)
12 in.
(305 mm)
4 in.*
(102 mm)
0.5 in.
(13 mm)
3 in.
(76 mm)
240 Outdoor
340 Outdoor
540 Outdoor
36 in.
(914 mm)
12 in.
(305 mm)
24 in.
(610 mm)
0.5 in.
(13 mm)
3 in.
(76 mm)
*24 inches recommended for maintenance.
OPTIONAL ITEMS
Back
Side
Front
Side
Top
Boom
#
Model
240
Indoor
240
Outdoor
340
Indoor
340
Outdoor
540
Indoor
540
Outdoor
1.
Temperature remote
controller
✓ ✓ ✓
2.
Pipe cover
✓ ✓ ✓ ✓ ✓ ✓
3.
Neutralizer kit
✓ ✓ ✓ ✓ ✓ ✓
4.
Sidewall vent
terminator (Hood)
and Wall thimble
✓ ✓ ✓
5.
3" PVC concentric
termination
✓ ✓ ✓
6.
Non-return valve
✓ ✓ ✓
7.
PVC Adapter
✓ ✓ ✓
INCLUDED ACCESSORIES
Check that these items below are included with the water heater.
Installation manual
and owner’s guide
Temperature remote controller kit*
Outdoor models only
Bird screen
Indoor models only
Communication cable
540 model only
Qty: 1
Qty: 1
Qty: 1
*Refer to p. 10 and 35.
Qty: 2
100209924
(TM-RE42)
Maintain all clearances around the water
heater. Failure to do so could create a fire
hazard, potentially leading to death, serious
injury, and/or property damage.
WARNING
10 Page
Installaon
Installaon Manual
3. Neutralizer kit: 100112159 (TH-NT01)
The neutralizer assembly neutralizes the condensate (acidic water) that forms in the
secondary heat exchanger of the water heater.
It connects to the condensate drain port of the water heater by using connectors
included with the neutralizer kit. (Refer to pp. 32 and 33.)
1. Temperature remote controller:
100209924 (TM-RE42)
The temperature remote controllers have
three functions. It allows the output
temperature from the water heater to be
adjusted and it also works as a diagnostic
tool and it provides a concise error code
whenever there is a problem with the unit. See the
Troubleshooting Section (pp.53 to 56) for information
on possible error codes.
5. 3" PVC concentric termination: 100112163 (TH-CVPVC33)
Used when terminating direct-vent (sealed combustion)
systems, with Indoor models that require a 3 in. (76 mm) intake
and a 3 in. (76 mm) exhaust.
2. Pipe cover:
100112718 (TH-PC03)
The pipe cover protects
the plumbing pipes to
the water heater from
unexpected adjustments.
This pipe cover is fixed
to the bottom of the
water heater, which hides the plumbing and
improves the visual aspects of the whole
installation for the water heater.
4. Sidewall vent terminator (Hood) and Wall thimble:
These are used when venting out through the wall. These terminations are special stainless steel
vents for gas appliances and are UL listed as Category II, III and IV. For different wall thicknesses, there
are two ranges of lengths available. (Refer to the NovaVent brochure for details.) Install these vent
terminations in accordance with their installation instructions and any applicable local codes.
Wall Thimble
Terminator Hood
6. Non-return valve: 100113130
7. PVC Adapter: 100113129
It is a must-have item for common venting system. It prevents
the escape of combustion gas through non-operating appliances.
(Refer to p. 24 and 25.)
This adapter transitions from the Non-return valve
outlet to 4" schedule 40 PVC pipe.
This concentric termination provides the convenience of only having to make one penetration through a
sidewall instead of two separate penetrations for the intake and exhaust piping. The termination includes
a bird screen, restricting small animals, pests, and foreign objects from entering into the vent system.
Covering wall thicknesses Part#
Terminator Hood 100112419
Wall Thimble 4 - 7 in (102 - 178 mm) 100112732
Wall Thimble 5 - 10 in (123 - 254 mm) 100112733
Termination + Thimble 4 - 7 in (102 - 178 mm) 100112424
Termination + Thimble 5 - 10 in (123 - 254 mm) 100112425
11 Page
Installaon
Installaon Manual
WARNING FOR INSTALLATIONS
FOR YOUR SAFETY, READ BEFORE INSTALLATION:
Do not install the heater where water, debris or
flammable vapors may get into the flue terminal.
This may cause damage to the heater and void the
warranty.
Do not have the vent terminal pointing toward
any opening into a building. Do not locate your
heater in a pit or location where gas and water
can accumulate.
Do not install this water heater under an
overhang less than 3 ft (914 mm) from its top
or eaves. The area under an overhang must be
open to three sides (Outdoor model only).
Do not install next to a dryer or any source
of airborne debris that can be trapped inside
the combustion chamber, unless the system is
direct-vented.
Prohibited
Prohibited
3 ft
(914 mm)
Water heater vent terminator must be at least 2
ft (610 mm) away from an inside corner for both
outdoor installation and direct-vent installation.
Inside
Corner
2 ft
(610 mm)
USA: 1 (30 cm) min.
Canada: 3 (91 cm) min.
USA: 1 (30 cm) min.
Canada: 3 (91 cm) min.
USA: 1 (30 cm) min.
Canada: 3 (91 cm) min.
USA: 12 in. (30 cm) above grade and
above ancipated snow level
Canada: 12 in. (30 cm) above grade
Ancipated snow level
Ensure that you meet the minimum clearances
shown below for a direct vent termination:
12 Page
HIGH-ALTITUDE INSTALLATIONS
WARNING
• Adjust the appropriate DIP switches according to model and elevation as
shown below. DO NOT adjust the other DIP switches.
• Turn off the power supply to the water heater before changing the DIP
switch settings.
• Failure to observe these warnings could lead to carbon monoxide poisoning
or death.
Check the elevation where your water heater is installed. Set DIP switches shown in the table below
depending on the altitude.
Installaon
Installaon Manual
NOTE: The dark squares indicate the correct DIP switch positions.
540 model computer board
Lower bank of DIP switches
Bank of DIP switches
240 and 340 models computer board
Indoor models
0 to 2,000 ft
(0 to 610 m)
(DEFAULT)
2,000 to
3,000 ft
(611 to 914 m)
3,000 to
5,000 ft
(915 to 1,524 m)
5,000 to
7,500 ft
(1,525 to 2,286 m
7,500 to
10,100 ft
(2,287 to 3,078 m)
240 and 340 models
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : OFF
No. 5 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : ON
No. 5 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : OFF
No. 5 : ON
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : ON
No. 5 : ON
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : ON
No. 4 : ON
No. 5 : ON
540 model
(Lower bank of
DIP switches)
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : OFF
No. 4 : OFF
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : ON
No. 4 : OFF
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : OFF
No. 4 : ON
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : ON
No. 4 : ON
OFF
ON
1 2 3 4 5 6
No. 2 : ON
No. 3 : ON
No. 4 : ON
Altitude
DIP switches
Installation altitude
The maximum certified
or allowable installed
altitude is 10,100 ft
(3,078 m) for indoor
models and 6,000 ft
(1,829 m) for outdoor
models.
Outdoor models
0 to 2,000 ft
(0 to 610 m)
(DEFAULT)
2,000 to
4,000 ft
(611 to 1,219 m)
4,000 to
6,000 ft
(1,220 to 1,829 m)
240 and
340 models
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : OFF
No. 5 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : OFF
No. 4 : OFF
No. 5 : ON
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 3 : ON
No. 4 : OFF
No. 5 : ON
540 model
(Lower bank of
DIP switches)
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : OFF
No. 4 : OFF
OFF
ON
1 2 3 4 5 6
No. 2 : OFF
No. 3 : OFF
No. 4 : ON
OFF
ON
1 2 3 4 5 6
No. 2 : ON
No. 3 : OFF
No. 4 : ON
Altitude
DIP switches
13 Page
Installaon
Installaon Manual
VENTING INSTRUCTIONS
Indoor models
-General-
WARNING
• Improper venting of this appliance can result in excessive levels of carbon
monoxide which can result in severe personal injury or death.
• Improper installation can cause nausea or asphyxiation, severe injury or death
from carbon monoxide and flue gases poisoning. Improper installation will void
product warranty.
• When installing the vent system, all applicable national and local codes must be
followed. If you install thimbles, fire stops or other protective devices and they
penetrate any combustible or noncombustible construction, be sure to follow
all applicable national and local codes.
The Indoor model must be vented in accordance with “Venting of Equipment" in the current edition of the
National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 8 of the B149.1 Natural
Gas and Propane Installation Code in Canada, as well as applicable local building codes.
The use of venting materials approved for Category III/IV appliances is recommended whenever possible.
However, the Indoor model may also be vented with plastic pipe materials such as ABS, PVC (solid core),
CPVC (solid core), or polypropylene. For details, please refer to the Exhaust Vent (ABS, PVC, CPVC, or
Polypropylene Vent) Section on p. 18. Vent installations in Canada which utilize plastic vent systems must
use venting that complies with ULC S636.
General rules for venting water heaters:
• Place the water heater as close as possible to the vent termination.
• The vent collar of the water heater must be fastened directly to an unobstructed vent pipe.
• Do not weld the vent pipe to the water heater’s vent collar.
• Do not cut or alter the vent collar of the unit.
• The vent must be easily removable from the top of the water heater for normal service and inspection of
the unit.
• The water heater vent must not be connected to any other gas appliance or vent stack except an approved
common-venting system. Refer to pp. 24 and 25.
• Avoid using an oversized vent pipe or using extremely long runs of the pipe unless it is part of an approved
common vent system.
• Air supply pipe can be made of ABS, PVC (solid core), CPVC (solid core), polypropylene, corrugated stainless
steel, or Category lll / IV stainless steel. Regarding exhaust pipe, refer to pp.18 to 23.
• Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenylsulfone) in nonmetallic
venting systems is prohibited. Covering non-metallic vent pipe and fittings with thermal insulation is
prohibited.
• Sidewall venting is recommended for the Indoor model. Vertical venting (roof termination) is acceptable.
• The manufacturer recommends running the exhaust vent and the intake pipe as parallel as possible.
• For rooftop venting, a rain cap or other form of termination that prevents rain water from entering into
the water heater must be installed.
• Do not terminate vent into a chimney. If the vent must go through the chimney, the vent must run all the
way through the chimney with approved vent pipe.
• The water heater shall not be connected to a chimney flue serving a separate appliance, designed to burn
solid fuel.
General rules for vent terminations:
• Avoid locating the water heater vent termination near any air intake devices. These fans can pick up the
exhaust flue products from the water heater and return them to the building. This can create a health
hazard.
• Locate the vent termination so that it cannot be blocked by any debris, at any time. Most codes require
that the termination be at least 12 in (305 mm) above grade and anticipated snow level, but the installer
may determine if it should be higher depending on the job site condition and applicable codes.
• A proper sidewall termination is recommended when the water heater is vented through a sidewall.
• Regarding the clearances from the exhaust termination to the air inlet or opening, refer to pp. 26 to 28.
14 Page
-Combuson air supply-
This gas water heater requires an adequate source of clean air for combustion and
ventilation. Without sufficient air, your water heater may not operate properly and
may emit excessive and abnormal amounts of carbon monoxide which may result in
carbon monoxide poisoning or death.
WARNING
• The guidelines in this section apply to installations within the United States. All
U.S. installations must conform to the National Fuel Gas Code, ANSI Z223.1/NFPA
54 (current edition) and local codes.
• Canadian requirements differ from the guidelines in this section. In Canada,
follow the requirements of B149.1 (Natural Gas and Propane Installation Code,
current edition) as well as local and provincial codes. Contact your local code
enforcement agency for direction.
NOTICE
Before installing the water heater, you must determine the amount of air needed to supply this water
heater and any other gas appliances in the same area and provide adequate air for combuson and ven-
laon. Consult a qualied person if you’re unsure of the proper way to supply air to your water heater.
Check for Chemicals:
Air for combuson and venlaon must be clean and free of corrosive chemicals. If corrosive chemicals,
such as sulfur, ourine, or chlorine are present, the water heater must be direct vented. Failure due to
these corrosive chemicals is not covered by the warranty.
WARNING!
In all cases, ensure that corrosive chemicals are not present at the air intake. Presence of such chemicals
at the air intake could result in death, personal injury, or property damage. Examples of locaons that
require outside air due to chemicals include:
• Beauty salons
• Photo processing labs
• Indoor pools
• Laundry, hobby, or cra rooms
• Chemical storage areas
Products such as aerosol sprays, detergents, bleaches, cleaning solvents, gasoline, air fresheners, paint and
varnish removers, and refrigerants should not be stored or used near the water heater.
Does your installation space have sufficient combustion air?
Venlaon with outside air is recommended for all installaons. Even if the water heater is installed in a
large, open room inside the house, outdoor air is usually needed because modern homes are very ghtly
sealed and oen do not supply enough air to the water heater. However, when installed in a large indoor
space, it may be possible to provide enough air without outside venlaon. If you are unsure if your
installaon locaon has enough venlaon, contact your local gas ulity company or code ocials for a
safety inspecon or direct vent the water heater
The following instrucons will help determine if it may be possible to install the water heater without
outside venlaon.
CalculatetotalBTU/hrangofallappliances.
To calculate the combuson air and venlaon required, add up the total BTU/h rangs of all gas burn-
ing appliances (e.g., water heaters, furnaces, clothes dryers) in the same area. Do not include appliances
that are direct vented. Refer to the following example.
Installaon
Installaon Manual
15 Page
Your water heater’s BTU/h rating is on the rating plate. The BTU/h ratings should be on the other
appliances’ rating plates. If you have trouble determining the BTU/h ratings, contact the manufacturer
or have a qualified person determine the ventilation requirements.
NOTICE: If you are replacing your old water heater with one that has a higher BTU/h rang, the amount of
venlaon required may be greater.
Gas Burning Appliance BTU/hRang
Gas Water Heater 199,000
Furnace 75,000
Dryer 20,000
Total 294,000
Example:
Gas Burning Appliance BTU/hRang
Gas Water Heater
Total
Your
appliances:
Calculate the air volume of the room
Air requirements depend on the size of the room.
Room Volume (
3
) = Floor Area (
2
) X Ceiling Height ()
If there are large objects in the room (e.g., refrigerator, furnace, car), subtract their volume from the vol-
ume of the room to get a beer esmate of the air available.
Air Volume = Room Volume - Object Volume
NOTE: Adjoining rooms with permanently opened doorways can be counted as part of the calculaon.
Calculate required air volume
A water heater installed in an unconned ac, garage, or space requires that the space be at least 50
3
(1.42 m
3
) per 1,000 BTU/h of the total input for all gas burning appliances in the same area.
Required Air Volume (
3
) =Total Appliance Energy Rang (btu/h) X 50
3
/ 1000 (btu/h)
Example:
(294,000 / 1000) x 50 = 14,700
3
If the air volume of the room is less than the required air volume, you must direct vent the water heater
or provide permanent outside air openings that draw in sucient air. Go to “Install with outside venla-
on” if you want to provide combuson air with outside venlaon.
If the air volume of the room is greater than the required air volume, it may be possible to install the
water heater without outside venlaon. However, be sure to consider the eects of exhaust fans.
Exhaust fans can aect the amount of combuson air that is available in your home. Appliances such
as furnaces, whole house fans, and clothes dryers draw air out of your home. If they draw air out faster
than it can be replaced, your water heater may not have enough oxygen to re properly. Back-draing
may also result, which is when negave air pressure pulls air backwards through chimneys or appliance
vents. These events can cause unsasfactory water heater performance. The best soluon is to direct
vent the water heater or install an adequate number of make-up air vents. (See “Install with outside ven-
laon”.) For more informaon, consult a qualied technician or your local gas ulity.
Install with outside ventilation
Venlaon with outside air is recommended, and, for most installaons, is needed. There may be exisng
venlaon that is adequate, or you may need to add more venlaon.
Supplying outside air to the water heater typically requires two openings. One opening must be within 12 in
(305 mm) from the oor and the second opening must be within 12 in (305 mm) from the ceiling. Although a
single opening is not preferred, you may use a single opening to outside air if the minimum free area is sized
according to Table 1. Two openings must be used when venlang with air from another room.
The outside air can be taken from a crawl space or ac open to the outdoors and adequately venlated.
You may use vercal or horizontal ducts.
Installaon
Installaon Manual
16 Page
Determine type of ventilation
There are several types of venlaon that can be used. The various opons are listed below. See also the
illustraons on the next page.
1. Direct to outdoors
2. Vercal ducts
3. Horizontal ducts
4. Single opening (not recommended; must be at least 100 in
2
(6.5 cm
2
) . Not appropriate for conned
spaces smaller than 50
3
(1.42 m
3
) per 1,000 BTU/h or when geng air from another room.)
5. From a larger room inside the house (not recommended – refer to "Calculate the air volume of the room"
above to determine if the combined volume of the rooms may be adequate).
Determine minimum free area required for each vent opening
The size of the vent openings depends on the total BTU/h rang of all appliances in the space (use your calculaon
from “Before beginning”) and the type of vent used. Table 1 provides the minimum free area for each vent opening
depending on the type of venlaon.
Calculate minimum size of vent openings and ducts
The vent cross-seconal area needed to provide the free area depends on the covering on the vent openings. Typical
vents use louvers or grilles to protect the opening. The louver or grill itself blocks some of the free area, so the open-
ing may need to be larger to meet the minimum free area requirements.
Use the following formula to calculate the required cross-seconal area:
Cross-seconal area = minimum free area required ÷ percent free area of covering (in decimals – e.g., 60 % = 0.6)
For example, an installaon area that requires openings with 100 in
2
(645 cm
2
) of free area would need
134 in
2
(865 cm
2
) openings if using metal louvers rated at 75% free area (100 in
2
÷ 0.75 = 134 in
2
).
If you do not know the % free area for your louver or grill, use the following values:
• For wood louvers or grilles: 25%
• For metal louvers or grilles: 75%
Follow these rules to ensure that vents and ducts provide adequate air ow:
• Each vent opening must be no smaller than 100 in
2
(645 cm
2
).
• Ducts must have the same cross-seconal area as free area of the opening.
• Rectangular ducts must have a minimum dimension of no less than 3 in (76 mm).
• All screens must have mesh ¼” or larger.
• Moveable louvers must be locked open or interconnected with the equipment so that they open automa-
cally during operaon.
• Keep louvers and grills clean and free of debris or other obstrucons.
Check that air source is clean and free of chemicals
Air for combuson and venlaon must be clean and free of corrosive or ammable chemicals. A failure due to cor-
rosive chemicals in the air is not covered by the warranty. Combuson air must be free of acid-forming chemicals such
as sulfur, uorine, and chlorine. Be sure that air at the vent inlets is free of such chemicals.
See graphics on next page.
Table 1
Minimum Free Area of Permanent Openings for Venlaon and Combuson Air Supply – Air from outdoor or
indoor spaces.
Based on the total BTU/h input rang for all gas burning appliances within a conned space.
Opening Source Minimum Free Area
Direct to outdoors*
1 in
2
(6.5 cm
2
) per 4,000 BTU/hr (see Figure 1, 2)
Vercal ducts
1 in
2
(6.5 cm
2
) per 4,000 BTU/hr (see Figure 3)
Horizontal ducts
1 in
2
(6.5 cm
2
) per 2,000 BTU/hr (see Figure 4)
Single Opening
1 in
2
(6.5 cm
2
) per 3,000 BTU/hr (see Figure 5)
Two permanent openings
to another room**
1 in
2
(6.5 cm
2
) per 1,000 Btu/hr (see Figure 6)
Opening: 100 in
2
(645 cm
2
) MIn
Minimum dimension of air openings:
no less than 3 in (76 mm)
*These openings connect directly with the outdoors through a venlated ac, a venlated crawl space, or through
an outside wall.
**United States: For direcon on combining spaces in dierent stories within the structure, refer to the current edi-
on of the Naonal Fuel Gas Code ANSI Z223.1/NFPA 54. In Canada, contact your local code enforcement agency for
direcon.
Installaon
Installaon Manual
17 Page
Combusonairsupplyopons
Gable vent
to outdoors
Install above
insulaon
Outlet air to
ac 1 in
2
(6.5 cm
2
)
per 4,000 btu/h
Inlet air from
the crawl space
Open foundaon vent
Confined
Space
Alternate
Air Inlet
1 in
2
(6.5 cm
2
)
per 4,000 btu/h
Figure 1 - Direct to outdoors openings
Figure 3 - Vercal duct openings
Outlet air to
ac 1 in
2
(6.5 cm
2
)
per 4,000 btu/h
Inlet air duct
1 in
2
(6.5 cm
2
)
per 4,000 btu/h
Confined
Space
12” (305 mm)
maximum
Gable vent
to outdoors
Install above
insulaon
Figure 5 - SIngle opening
Confined
Space
1 in
2
(6.5 cm
2
)
per 3,000 btu/h
Alternave
Opening
Locaon
Figure 6 - Two permanent openings
Two permanent
Openings
1 in
2
per
1,000 btu/h
12” (305 mm)
maximum
12” (305 mm)
maximum
Confined
Space
Figure 4 - Horizontal duct openings
1 in
2
(6.5 cm
2
)
per 2,000 btu/h
Confined
Space
Outlet
Inlet
Outdoor
Air Ducts
1 in
2
(6.5 cm
2
)
per 2,000 btu/h
Figure 2 - Direct to outdoors openings
Two permanent openings
Two permanent
Openings
1 in
2
(6.5 cm
2
)
per 4,000 btu/h
12” (305 mm)
maximum
12” (305 mm)
maximum
Confined
Space
Installaon
Installaon Manual
18 Page
-Exhaust vent (ABS, PVC, CPVC, or polypropylene vent)-
The Indoor models can be vented with ABS, PVC, CPVC, or polypropylene (temperature rated up to
149 °F). Vent material certified to ULC S636 standards is recommended in the USA. In Canada, plastic
venting must be certified to ULC S636 standards.
• The maximum length of exhaust vent piping must not exceed 70 ft (21.3 m) for 3” venting, which
depends on the elevation where the water heater is installed, and 100 ft (30.5 m) for 4” venting
(deducting 5 ft (1.5 m) for each elbow used in the venting system). Do not use more than 5
elbows. See the table below.
• When the horizontal vent run exceeds 5 ft (1.5 m), support the vent run at 3 ft (0.9 m) intervals
with overhead hangers.
Installaon
Installaon Manual
Item Material United States Canada
Exhaust pipe and
Fittings
Schedule 40 PVC ANSI/ASTM D1785
ULC S636 Certified
Materials Only
PVC-DWV ANSI/ASTM D2665
Schedule 40 CPVC ANSI/ASTM F441
Schedule 40 ABS-DWV ANSI/ASTM D2661
Polypropylene UL-1738
Pipe Cement/Primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
ABS ANSI/ASTM D2235
Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenylsulfone) in
non-metallic venting systems is prohibited.
Covering non-metallic vent pipe and fittings with thermal insulation is prohibited.
Diameter Max. No. of Elbows Max. Vertical and Horizontal (Total) Vent Length
3 in. (76 mm) 5 70 ft (21.3 m)
4 in. (102 mm) 5 100 ft (30.5 m)
*For each elbow added, deduct 5 ft. (1.5 m) from max. vent length.
No. of Elbows
Max. Vertical or Horizontal (Total) Vent Length
3" (76 mm) venting
4" (102 mm)
venting
0 to 3,000 ft
(0 to 914 m)
3,001 to 6,000 ft
(915 to 1,829 m)
6,001 to 10,100 ft
(1,830 to 3,078 m)
0 to 10,100 ft
(0 to 3,078 m)
0 70 ft (21.3 m) 40 ft (12.2 m) 25 ft (7.6 m) 100 ft (30.5 m)
1 65 ft (19.8 m) 35 ft (10.7 m) 20 ft (6.1 m) 95 ft (29.0 m)
2 60 ft (18.3 m) 30 ft (9.1 m) 15 ft (4.6 m) 90 ft (27.4 m)
3 55 ft (16.8 m) 25 ft (7.6 m) 10 ft (3.0 m) 85 ft (25.9 m)
4 50 ft (15.2 m) 20 ft (6.1 m) N/A 80 ft (24.4 m)
5 45 ft (13.7 m) N/A N/A 75 ft (22.9 m)
Excludes vent terminators, termination elbows, or rain caps.
For details on the vent connection, refer to pp. 20 and p. 21.
19 Page
Installaon
Installaon Manual
-DIP switch settings for vent length-
Typicalinstallaonsusing PVC, CPVC, ABS, or polypropylene vent
WARNING
• Adjust the appropriate DIP switches according to model and vent length as
shown below. DO NOT adjust the other DIP switches.
• Turn off the power supply to the water heater before changing the DIP
switch settings.
• Failure to observe these warnings could lead to carbon monoxide poisoning
or death.
<Two-pipe,direct-ventinstallaon>
VercalInstallaon
Roof ashing
Roof
Fire stop
HorizontalInstallaon
Wall
Connect between exhaust vent collar and piping.
See the instrucons below.
Hanger
Hanger
For details of the optional items, refer to the Installation manual for each optional item.
Set DIP switches shown in the table below depending on the vent diameter and length.
DIP switch settings : Two-pipe, Direct vent installations
Vent diameter
3" (76 mm) venting* 4" (102 mm) venting
5 to 20 ft
(1.5 to 6.1m)
(DEFAULT)
21 to 40 ft
(6.2 to 12.2 m)
41 to 70 ft
(12.3 to 21.3 m)
5 to 50 ft
(1.5 to 15.2m)
(DEFAULT)
51 to 100 ft
(15.3 to 30.5 m)
240/340
Indoor
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : OFF
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : O N
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : OFF
No. 7 : OFF
540 Indoor
(Upper bank
of
DIP switches)
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : OFF
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : O N
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : OFF
No. 4 : OFF
Vent
length
Model
*PVC concentric termination (100112163) installation is applied to the DIP switch settings of 3" (76 mm)
venting. (Refer to p. 10.)
240 340 Computer board
Bank of
DIP switches
540 Computer board
Upper bank of
DIP switches
Lower bank of
DIP switches
20 Page
Installaon
Installaon Manual
1. Connect 3" (76 mm) couplings directly on the exhaust
and intake vent collar of the water heater.
2. Connect 3" (76 mm) straight pipes to the couplings.
1. Connect 3"x 4" (76 x 102 mm) increasers directly
on the exhaust and intake vent collar of the water
heater.
2. Connect 4" (102 mm) straight pipes to the increasers.
<Howtoinstallintakeandexhaustventing(two-pipe,direct-vent)withtheindoormodels>
3"(76mm)ventconnecon 4"(102mm)ventconnecon
<Single-pipewithroom-airintakeinstallaon>
HorizontalInstallaon
VercalInstallaon
Roof
Connect between exhaust vent collar and piping.
See the instrucons below.
Roof
ashing
Elbow
Elbow
Fire stop
Wall
Hanger
For details of the optional items, refer to the Installation manual for each optional item.
DIP switch settings : Single vent pipe installations
Vent diameter
3" (76 mm) venting* 4" (102 mm) venting
5 to 45 ft
(1.5 to 13.7 m)
(DEFAULT)
46 to 70 ft
(13.8 to 21.3 m)
5 to 50 ft
(1.5 to 15.2 m)
(DEFAULT)
51 to 100 ft
(15.3 to 30.5 m)
240/340
Indoor
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : OFF
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : OFF
No. 7 : OFF
540 Indoor
(Upper bank
of
DIP switches)
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : OFF
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : OFF
No. 4 : OFF
Vent
length
Model
Set DIP switches shown in the table below depending on the vent diameter and length.
Exhaust vent collar
(Female)
3" (76 mm) coupling
(included)
For PVC venng only
Intake vent collar
(Female)
3"(76 mm)
straight pipe
3" (76 mm)
straight pipe
3" (76 mm) coupling
(included)
For PVC venng only
Exhaust vent collar
(Female)
Intake vent collar
(Female)
3"x 4"
(76 x 102 mm)
increaser
3"x 4"
(76 x 102 mm)
increaser
4" (102 mm)
straight pipe
4" (102 mm)
straight pipe
21 Page
Installaon
Installaon Manual
<Howtoinstallsingleventwiththeindoormodels>
CENTROTHERM PP VENTING (Polypropylene)
WARNING! Do not mix parts or fittings of different material types, and do not mix pipe, fittings, or
joining methods from different manufacturers. Combustion exhaust can contain carbon monoxide and
must be properly vented outside. Breathing abnormal amounts of carbon monoxide can result in seri-
ous injury or death.
Description
Centrotherm Part Number (Trade
Name InnoFlue)
4''/6'' (102 mm/152 mm) x 39" (990 mm) Concentric Wall
ICWS4639
4'' (102 mm) Twin Pipe to 4''/6'' (102 mm/152 mm) Concentric Adaptor
ICTC0446
4" (102 mm) x 87° Elbow
ISEL0487
100 mm to 4" (102 mm) Increaser
ISIA10004
4" (102 mm) x 12" (305 mm) Vent Length
ISVL041
4" (102 mm) x 24" (610 mm) Vent Length
ISVL042
4'' (102 mm) x 36'' (914 mm) Vent Length
ISVL043
4" (102 mm)x 72" (1,829 mm) Vent Length
ISVL046
4" (102 mm) Horizontal Drain Tee
ISHDT04
3''/5'' (76 mm/127 mm) x 13'' (330 mm) Concentric Wall Termination SS
ICWS3513
3'' (76 mm) Twin Pipe to 3''/5'' (76 mm/127 mm) Concentric Adaptor
ICTC0335
3" (76 mm) x 87 Elbow
ISEL0387
3" (76 mm) x 12" (305 mm) Vent Length
ISVL031
3" (76 mm) x 24" (610 mm) Vent Length
ISVL032
3" (76 mm) x 36'' (914 mm) Vent Length
ISVL033
3" (76 mm) x 72'' (1,829 mm) Vent Length
ISVL036
100 mm to 4" (102 mm) 110 mm
ISRA1003
3" (76 mm) Horizontal Drain Tee
ISHDT03
1. Connect a 3" (76 mm) elbow directly on the
intake vent collar of the water heater.
2. Connect a 3" (76 mm) coupling directly on the
exhaust vent collar of the water heater.
3. Connect a 3" (76 mm) straight pipe to the
coupling.
3"(76mm)ventconnecon
1. Connect a 3" (76 mm) elbow directly on the
intake vent collar of the water heater.
2. Connect a 3" x 4" (76 x 102 mm) increaser
directly on the exhaust vent collar of the
water heater.
3. Connect a 4" (102 mm) straight pipe to the
increaser.
4"(102mm)ventconnecon
Exhaust vent
collar
(Female)
3" (76 mm) elbow
with bird screen
Intake vent collar
(Female)
4" (102 mm)
straight pipe
3"x 4"
(76 x 102 mm)
increaser
Exhaust vent
collar
(Female)
Intake vent collar
(Female)
3"(76 mm)
straight pipe
3" (76 mm) coupling
(included)
For PVC venng only
3" (76 mm) elbow
with bird screen
22 Page
-Exhaust vent (Stainless steel vent)-
This is a Category IV appliance and must be vented accordingly. The vent system must be sealed airtight. All seams
and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive
tape having a minimum temperature rating of 160 °F (71 °C). For best results, a vent system should be as short and
straight as possible.
• The Indoor models are a Category IV appliance and must be vented accordingly with any 4” vent approved for use with
Category III/IV or Special BH type gas vent.
• The manufacturer recommends the NovaVent line. However, the following are also UL listed manufacturers: ProTech
Systems Inc. (FasNSeal), Metal-Fab Inc., and Heat-Fab Inc. (Saf-T Vent).
• Follow the vent pipe manufacturer’s instructions when installing the vent pipe.
• The maximum length of exhaust vent piping must not exceed 100 ft (30.5 m) (deducting 5 ft (1.5 m) for each elbow used in
the venting system). Do not use more than 5 elbows.
• When the horizontal vent run exceeds 5 ft (1.5 m), support the vent run at 3 ft (0.9 m) intervals with overhead hangers.
Installaon
Installaon Manual
Diameter Max. No. of Elbows Max. Vertical and Horizontal (Total) Vent Length*
4 in. (102 mm) 5 100 ft (30.5 m )
*For each elbow added, deduct 5 ft. (1.5 m) from max. vent length.
Excludes vent terminators, termination elbows, or rain caps.
No. of Elbows Max. Vertical or Horizontal Vent Length No. of Elbows Max. Vertical or Horizontal Vent Length
0 100 ft (30.5 m) 3 85 ft (25.9 m)
1 95 ft (29.0 m) 4 80 ft (24.4 m)
2 90 ft (27.4 m) 5 75 ft (22.9 m)
-DIP switch settings for vent length-
Typicalinstallaonsusingstainless steel vents
WARNING
• Adjust the appropriate DIP switches according to model and vent length as shown
below. DO NOT adjust the other DIP switches.
• Turn off the power supply to the water heater before changing the DIP switch settings.
• Failure to observe these warnings could lead to carbon monoxide poisoning or death.
DIP switch settings : Single pipe and Direct vent installations / Vent diameter : 4" (102 mm) venting
240 /340 Indoor 540 Indoor (Upper bank of DIP switches)
Vent length
5 to 50 ft (1.5 to 15.2m)
(DEFAULT)
51 to 100 ft (15.3 to 30.5 m)
5 to 50 ft (1.5 to 15.2m)
(DEFAULT)
51 to 100 ft (15.3 to 30.5 m)
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : O N
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : OFF
No. 7 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : O N
No. 4 : OFF
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : OFF
No. 4 : OFF
VercalInstallaon
Roof
Roof ashing
Fire stop
Rain cap
HorizontalInstallaon
Wall
Sidewall vent
terminaon
Hanger
Hanger
For details of the optional items, refer to the Installation manual for each optional item.
23 Page
<Howtoinstallstainlesssteelventwiththeindoormodels>
4"ventconneconfordirect-ventinstallaon
4" (102 mm)
stainless steel vent
straight pipe
Exhaust vent collar
of the Indoor
models (Female)
Intake vent
collar (Female)
4" (102 mm)
stainless
steel vent
straight pipe
Installaon
Installaon Manual
Exhaust vent collar
of the Indoor models
(Female)
4” (102 mm)
stainless steel vent
straight pipe
Intake vent
collar (Female)
4" (102 mm)elbow
with bird screen
1. Connect a 4" (102 mm) stainless steel vent straight pipes
directly on the exhaust vent collar of the water heater.
2. Connect a 4" (102 mm) elbow directly on the intake
vent collar of the water heater.
• Connect 4" (102 mm) stainless steel vent
straight pipes directly on the exhaust/intake
vent collar of the water heater.
4"ventconneconforsingleventinstallaon
WARNING
• Regarding the clearances from the exhaust terminal to the air inlet or opening, refer to pp. 26 to 28.
• Follow all vent system manufacturer’s instructions and all local codes.
• Use 4" (102 mm) Category III/IV approved or Special BH, single or double wall stainless steel
vent pipe.
• Do not mix parts or fittings of different material types, and do not mix pipe, fittings, or
joining methods from different manufacturers. Combustion exhaust can contain carbon
monoxide and must be properly vented outside. Breathing abnormal amounts of carbon
monoxide can result in serious injury or death.
Approved Category IV, Single Wall, Venting Suppliers and Part Numbers
Description
Heater
Vent
Kits
Z-FLEX®
Description
Heater
Vent
Kits
Z-FLEX®
Nova
VENT™
Z-VENT™
Nova
VENT™
Z-VENT™
4" (102 mm) Straight pipe
- 6" (152 mm) length
100112407 2NVP4.5 2SVEPWCF0406
4" (102 mm) 3-in-1 adaptor
(F-F adaptor, condensate drain,
& back-flow preventer)
100112585 2NVBFA4 2SVBFDPA04
4" (102 mm) Straight pipe
- 12" (305 mm) length
100112406 2NVP41 2SVEPWCF0401 4" (102 mm) F-F adaptor 100112399 2NVAFF4 2SVEEWCF0445
4" (102 mm) Straight pipe
- 24" (610 mm) length
100112404 2NVP42 2SVEPWCF0402
4" (102 mm) Backflow preventer
w/ F-F adaptor
100112416 2NVBFU4 2ZVB04
4" (102 mm) Straight pipe
- 36" (914 mm) length
100112403 2NVP43 2SVEPWCF0403
4" (102 mm) exhaust / 3" (76 mm)
intake DV concentric termination
- 5"-10" (127 - 254 mm)
adjustability
100112550 2NVHTC43S 2SVSHTC43S
4" (102 mm)Straight pipe
- 48" (1,219 mm) length
100112402 2NVP44 2SVEPWCF0404
4" (102 mm)exhaust / 3" (76 mm)
intake DV concentric termination
- 12"-18" (305 - 457 mm)
adjustability
100112551 2NVHTC43 2SVSHTC43
4" (102 mm) Adjustable straight pipe -
10"-18" (254 - 457 mm)
adjustability
100112405 2NVAL4 2SVSPA04
4" (102 mm) Sidewall termina-
tion, adjustable pipe
100187853 2NVBV4 n/a
4" (102 mm) 45 degree elbow 100112401 2NVE445 2SVEEWCF0445
4" (102 mm) Wall Thimble,
3"-6"(76 - 152 mm) wall thickness
100187852 2NVBT4 n/a
4" (102 mm) 90 degree elbow 100112400 2NVE490 2SVEEWCF0490
4" (102 mm) exhaust / 3" (76 mm)
intake concentric termination
- 5" to 10" (127 - 254 mm)
adjustability
100112550 2NVHTC43S 2SVSHTC43S
4" (102 mm) Sidewall termination
(4" (102 mm)Termination Hood)
100112419 2NVTH4 2SVSHTX04
4" (102 mm) exhaust / 3" (76 mm)
intake concentric termination
- 12" to 18" (305 - 457 mm)
adjustability
100112551 2NVHTC43 2SVSHTC43
4" (102 mm) Vent
termination tee
100112547 2NVTT4 2SVSTTF04
4" (102 mm) exhaust / 4" (102
mm) intake concentric termination
- 5" to 10" (127 - 254 mm)
adjustability
100112552 2NVHTC44S 2SVSHTC04S
4" (102 mm) Rain Cap 100112415 2NVRC4 2SVSRCF04
4" (102 mm) exhaust / 4" (102
mm) intake concentric termination
- 12" to 18" (305 - 457 mm)
adjustability
100112553 2NVHTC44S 2SVSHTC04
4" (102 mm) Extreme weather
rain cap
100112548 2NVWC4 2SVSHRC04 4" (102 mm) Flat roof flashing 100112412 2NVFF4 2SVSSCF04
4" (102 mm) Horizontal drain tee 100112414 2NVHD4 2SVEDWCF04 4" (102 mm) Angled roof flashing 100112411 2NVAF4 2SVSADJF04
4" (102 mm) Vertical drain tee 100112413 2NVVD4 2SVEVDP04 Storm collar 100112410 2NVSC4 2SVSLSF04
4" (102 mm) wall thimble length
4"-7" (102 - 178 mm)
wall thickness
100112732 2NVWT4 2SVSWTF04 Wall support 100112409 2NVSS41 2SVSWS04
4" (102 mm) wall thimble length
5"-10" (127 - 254 mm)
wall thickness
100112733 2NVWT4L 2SVSWTEF04 Firestop support 100112408 2NVFS4 2SVSFSSF04
24 Page
Typicalcommon-ventinstallaonexamples
-Common-venng system-
The Indoor model can be vented together using the same exhaust and intake venting.
• Up to 8 water heaters can be common-vented together.
• A non-return valve (100113130) must be used for each water heater that is part of the system.
• The water heaters must all be direct-vented.
• The common-venting system shall be in accordance with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or B149.1, Natural Gas and Propane Installation Code
(Current Editions), local codes, and the following manufacturer’s instructions.
• For common-venting pieces and components, the manufacturer recommends
Centrotherm's vent line.
Installaon
Installaon Manual
Intake
wall
Exhaust
Roof
Condensate drain port
Non-Return Valve
Exhaust
wall
Roof
Intake
Non-Return Valve
Condensate drain port
Exhaust
Intake
wall
Roof
Non-Return Valve
Condensate drain port
Allowable models for common-venting
240 Indoor, 340 Indoor, 540 Indoor, 540P Indoor
NOTICE
For details on the installation of a common-vent system, please refer to "Common
Venting Tankless Gas Water Heaters." It is a manual which is available on the water
heater manufacturer's website.
Only the models listed in the table above can be common-vented together. Different
models cannot be common-vented.
Failure to observe these warnings could lead to carbon monoxide poisoning or death.
WARNING
25 Page
To determine the dimension of a system
Determine the vent diameter (D) and the total vent length based on the number of water
height (H). See the table below.
• Total vent length (L)="H"+"W" +
(Number of Elbows x 5)
• Vent diameter="D"
WARNING
• A Non-Return Valve must be installed for each water heater. This prevents
the escape of combuson gas through non-operang appliances.
• For detailed instrucons on the common-venng system, refer to the
instrucons that are packaged with the vent parts or web site.
*Diameters of pipes are in accordance with Centrotherm's specificaons.
**One elbow is equivalent to 5 (1.5 m) linear length, and the maximum number of elbows is 5.
NOTICE
• Regarding the clearances
between the exhaust
terminaon and the
to pp. 26to 28.
• Insert bird screen in
elbow terminals.
Common-venng system
Vent
Diameter*
(D)
Max.
No. of
water
heaters
Max. Vercal and
Horizontal
(Total) Vent Length** (L)
DIP switch sengs
4 in.
(110 mm)
2 25 (7.6 m)
240 Indoor/340 Indoor
OFF
ON
1 2 3 4 5 6 7 8 9 10
No. 6 : ON / No. 7: OFF
540 Indoor
(Upper bank of
DIP switches)
OFF
ON
1 2 3 4 5 6 7 8
No. 3 : ON / No. 4: OFF
5 in.
(125 mm)
2 50 (15.2 m)
3 20 (6.1 m)
6 in.
(160 mm)
2 100 (30.5 m)
3 75 (22.9 m)
4 50 (15.2 m
5 25 (7.6 m)
6 20 (6.1 m)
8 in.
(200 mm)
3 100 (30.5 m)
4 100 (30.5 m)
5 85 (25.9 m)
6 65 (19.8 m)
7 50 (15.2 m)
8 41 (12.5 m)
10 in.
(250 mm)
5 100 (30.5 m)
6 100 (30.5 m)
7 100 (30.5 m)
8 100 . (30.5 m)
"H"
Intake
Exhaust
"D"
Elbow terminal
Elbow terminal
"W"
Non-Return Valve
• Adjust the appro-
priate DIP switches
ledom ot gnidrocca
as shown in the
le table. DO NOT
adjust the other DIP
switches.
(Refer to p. 19 for
the locaon of the
DIP switches.)
• Turn off the power
supply to the water
heater before chang-
ing the DIP switch
sengs.
• Failure to observe
these warnings
could lead to carbon
monoxide poisoning
or death.
WARNING
26 Page
Installaon
Installaon Manual
-Vent terminaon clearances-
Canada Installations
1
US Installations
2
Direct vent and other than
direct vent
Direct vent
Other than
direct vent
A Clearance above grade, veranda, porch, deck, or balcony 1 ft (30 cm) 1 ft (30 cm)
B Clearance to window or door that may be opened 3 ft (91 cm)
1 ft
(30 cm)
4 ft (1.2 m) below or to
side of opening; 1 ft (30
cm) above opening
C Clearance to permanently closed window 0 0 0
D
Vertical clearance to ventilated soffit located above
the vent terminator within a horizontal distance of 2
feet (61cm) from the center line of the termination
3 ft (91 cm) 3 ft (91 cm) 3 ft (91 cm)
E Clearance to unventilated soffit 3 ft (91 cm) 3 ft (91 cm) 3 ft (91 cm)
F Clearance to outside corner 2 ft (61 cm) 2 ft (61 cm) 2 ft (61 cm)
G Clearance to inside corner 2 ft (61 cm) 2 ft (61 cm) 2 ft (61 cm)
H
Clearance to each side of center line extended
above meter/regulator assembly
3 ft (91 cm) * *
I Clearance to service regulator vent outlet
Above a regulator within 3
ft (91 cm) horizontally of the
vertical center line of the
regulator vent outlet to a
maximum vertical distance of
15 ft (4.5 m)
* *
J
Clearance to non-mechanical air supply inlet to
building or the combustion air inlet to any other
appliance.
3 ft (91 cm)
1 ft
(30 cm)
4 ft (1.2 m) below or to
side of opening; 1 ft (30
cm) above opening
K Clearance to mechanical air supply inlet 6 ft (183 cm)
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 (213 cm)**
7 ft
(213 cm)
7 ft (213 cm)
M Clearance under veranda, porch deck, or balcony 1 ft (30 cm)***
1 ft
(30 cm)***
1 ft (30 cm)***
*Clearance in accordance with local installation codes and the requirements of the gas supplier.
**A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
***Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
The vent for condensing water heaters shall not terminate:
1) over public walkways; or
2) near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or
cause property damage; or
3) where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or
other equipment.
Notes:
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
H
D
E
L
B
V
V
V
V
B
F
C
B
B
B
V
V
V
V
V
X
X
A
J
M
Operable
Fixed
closed
Fixed
closed
Operable
B
Inside corner
detail
G
A
K
V
X
= Vent terminal
= Air supply inlet
= Area where the terminal
is not permied
Regulator/Gas meter
vent outlet
I
27 Page
Installaon
Installaon Manual
-Clearances for sidewall terminaons-
Multiple Sidewall Terminations
An exhaust termination must be at least
1 ft (305mm) away from another exhaust
termination. An exhaust termination must
also be at least 2 ft (610 mm) away from
an inside corner. (If the adjacent wall is less
than 2 ft (610 mm) of length, the minimum
required distance away from the inside
corner will be equal to the length of that
adjacent wall.)
Multiple DV Sidewall Terminations
A direct vent (DV) termination must be
at least 1 ft (305 mm) away from other
direct vent terminations.
A direct vent termination must also be at
least 2 ft (610 mm) away from an inside
corner. (If the adjacent wall is less than
2 ft (610 mm) of length, the minimum
required distance away from the inside
corner will be equal to the length of that
adjacent wall.)
Ancipated Snow level
Exhaust
Terminaon
2
(610 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
Inside
corner
Inside
corner
Ancipated Snow level
2
(610 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
Combined
intake and
exhaust
terminaon
For direct vent sidewall
terminations that use two
separate penetrations for
the intake and exhaust,
keep the termination
clearances shown in the
diagrams on the right.
Improper installation can result in carbon monoxide poisoning or death. Follow all local
and national codes in regards to proper termination clearances. In the absence of such
codes, the clearances below can be used as guidelines. Local codes supersede these
guidelines.
WARNING
1 ft (305 mm) min.
0.5 ft
(159 mm) min.
Exhaust
Intake
Exhaust
Intake
<Case2>
1 ft (305 mm)
min.
0.5 ft
(159 mm) min.
0.5 ft
(159 mm)
min.
Exhaust
Intake
Exhaust
Intake
<Case1>
Exhaust
termination
2 ft (610 mm)
min.
Exhaust and/or direct
vent sidewall terminations
should be at least 2 ft (610
mm) away from an opposite
surface/wall. Do not place
the termination directly in
front of an opening into a
building.
28 Page
Installaon Manual
Installaon
-Clearances for rooop terminaons-
Follow all local and national codes in regards to proper termination clearances. In the absence
of such codes, the clearances below must be met. Local codes supersede these clearances.
Failure to observe this warning may result in severe personal injury or death.
WARNING
• Exhaust terminations must be at least 1 ft (305 mm) away from any obstructions.
• Minimum spacing between multiple terminals:
• intake terminals: 1 ft (305 mm) spacing between each
• exhaust terminals: 1 ft (305 mm) spacing between each
• The exhaust termination must be a horizontal distance of at least 2 ft (610 mm) from a
wall or surface unless specified differently by local code.
• Failure to observe this warning may result in severe personal injury or death.
WARNING
3 ft (914 mm) min.
Exhaust gas
Intake air
1 ft
(305 mm) min.
1 ft
(305 mm) min.
Anticipated
snow level
Flat roof termination
Vercal wall
Ancipated snow level
1
(305 mm)
min.
1
(305 mm)
min.
2
(610 mm)
min.
2
(610 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
3 (914 mm) min.
Exhaust gas
Exhaust gas
Intake air
Intake air
Multiple flat roof terminations
Canadian requirements differ from the guidelines in this section. In Canada, follow
the requirements of B149.1 (Natural Gas and Propane Installation Code, current
edition) as well as local and provincial codes. Contact your local code enforcement
agency for direction.
NOTICE
Exhaust gas
2 ft (610 mm) min.
Intake air
1 ft
(305 mm) min.
1 ft
(305
mm)
min.
1 ft
(305 mm)
min.
Anticipated
snow level
Angled roof termination
Exhaust
gas
Exhaust
gas
Intake air
Intake air
1
(305 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
1
(305 mm)
min.
2 (610 mm) min.
Ancipated snow level
1
(305 mm)
min.
3 (914 mm) min.
Multiple angled roof terminations
29 Page
GAS SUPPLY AND GAS PIPE SIZING
-General-
• Do not use this water heater with any gas other than the one listed on the rating
plate.
• Ensure that any and all gas regulators used are operating properly and providing gas
pressures within the specified range shown below. Excess gas inlet pressure may
cause serious accidents.
• Conversion of this unit from natural gas to propane or vice versa will void all
warranty. Contact your local distributor to get the correct unit for your gas type. The
manufacturer is not liable for any property and/or personal damage resulting from
gas conversions.
• Failure to observe these warnings could result in severe personal injury, carbon
monoxide poisoning, or death.
WARNING
• The minimum and maximum inlet gas pressures are:
Gas type Inlet gas pressure
Natural Gas Min. 4.0” W.C. (1.00 kPa) – Max. 10.5” W.C. (2.61 kPa)
Propane Min. 8.0” W.C. (1.99 kPa) – Max. 14.0” W.C. (3.48 kPa)
• Inlet gas pressures that fall outside the range of values listed above may adversely affect the
performance of the water heater. These pressures are measured when the water heater is in full
operation and in stanby.
• Inlet gas pressure must not exceed the above maximum values; gas pressure above the specified range
will cause dangerous operating conditions and damage to the unit.
• Until testing of the main gas line supply pressure is completed, ensure the gas line to the water heater
is disconnected to avoid any damage to the water heater.
• If the gas supply pressure to the heater is greater than the specified maximum, a field-supplied
regulator is required. The regulator must lower the gas pressure within the approved range.
• Install the gas regulator according to the manufacturer's instructions.
• The regulator must be sized for the water heater input and provide the specified pressures that are
listed on the rating plate.
• In the absence of minimum install distance, it is recommended that there is at least 3 ft (1 m) of piping
between the regulator outlet and the water heater's inlet gas connection.
-Gas connecons-
1. Install a manual gas shutoff valve between the water heater and the gas supply line.
2. When the gas connections are completed, it is necessary to perform a gas leak test either by applying
soapy water to all gas fittings and observing for bubbles or by using a gas leak detection device.
• The water heater and its individual shutoff valve must be disconnected from the gas supply
piping system during any pressure testing of that system at test pressures in excess of 1/2 psi
(3.5 kPa).
• The water heater must be isolated from the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 psi (3.5 kPa).
3. Always purge the gas line of any debris and/or water before connecting to the gas inlet.
Size the gas pipe appropriately to supply the necessary volume of gas required for
the water heater using ANSI Z223.1/NFPA 54 in the USA or B149.1 in Canada or
local codes. Otherwise, flow capabilities and output temperatures will be limited.
NOTICE
Installaon
Installaon Manual
30 Page
Installaon
Installaon Manual
-Natural gas supply piping-
Maximum delivery Capacity in Cubic Feet of Gas per Hour (based on IPS Pipe carrying Natural Gas with 0.60 Specific
Gravity with a Pressure Drop of 0.5" W.C.).
Based on Energy Content of 1,000 BTU/Cubic ft: The water heater requires 160 Cubic ft/hr for the 240 model, 180
Cubic ft/hr for the 340 model, and 199 Cubic ft/hr for the 540 model.
The following tables are from NFPA 54.
-Propane (LP) supply piping-
Maximum Capacity of Propane (LP) Based on 11" W.C. supply pressure at a 0.5" W.C. pressure drop
Pipe Size
Length
Diameter
10'
(3 .0 m)
20'
(6.1 m)
30'
(9.1 m)
40'
(12.2 m)
50'
(15.2 m)
60'
(18.3 m)
70'
(21.3 m)
80'
(24.4 m)
90'
(27.4 m)
100'
(30.5 m)
125'
(38.1 m)
150'
(45.7 m)
200'
(61.0 m)
1/2"
172 118 95 81 72 65 60 56 52 50 44 40 34
3/4"
360 247 199 170 151 137 126 117 110 104 92 83 71
1"
678 466 374 320 284 257 237 220 207 195 173 157 134
1
1/4"
1,390 957 768 657 583 528 486 452 424 400 355 322 275
1
1/2"
2,090 1,430 1,150 985 873 791 728 677 635 600 532 482 412
2"
4,020 2,760 2,220 1,900 1,680 1,520 1,400 1,300 1,220 1,160 1,020 928 794
Unit: Cubic feet per hour
Water
heater
199,000 BTU/h
Dryer
35,000 BTU/h
Gas meter
Furnace
120,000 BTU/h
Range
65,000 BTU/h
A
B
C
10' (3 m)Length
1/2" Pipe size
15' (4.6 m)Length
1/2" Pipe size
15' (4.6 m)Length
1" Pipe size
10'(3 m)Length
3/4" Pipe size
10' (3 m )Length
1" Pipe size
5' (1.5 m) Length
1-1/4" Pipe size
10' (3 m)Length
3/4" Pipe size
5' (1.5 m)Length
1-1/4" Pipe size
Gas sizing example
(Natural Gas)
Unit: kBTU per hour
Pipe Size
Length
Diameter
10'
(3 .0 m)
20'
(6.1 m)
30'
(9.1 m)
40'
(12.2 m)
50'
(15.2 m)
60'
(18.3 m)
70'
(21.3 m)
80'
(24.4 m)
90'
(27.4 m)
100'
(30.5 m)
125'
(38.1 m)
150'
(45.7 m)
200'
(61.0 m)
1/2"
268 184 148 126 112 101 93 87 82 77 68 62 53
3/4"
567 393 315 267 237 217 196 185 173 162 146 132 112
1"
1,071 732 590 504 448 409 378 346 322 307 275 252 213
1
1/4"
2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 440
1
1/2"
3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 675
2"
6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 1,260
Based on Energy Content of 1,000 BTU/Cubic ft:
Divide each appliance's BTU/h requirement by 1,000 BTU/ft
3
to get the appliance's ft
3
/h requirement.
Take into account the distance the appliance is from the gas meter, look in the above gas chart to properly size the line.
For sections of the gas line supplying gas to more than one appliance (Ex: Point A to Point B), add up the cubic ft per hour
requirements of the appliances that are being supplied by that section, and size to the farthest appliance.
For Example: The section from A to B supplies gas to the furnace, range and dryer. Adding up the BTU/h requirements and
dividing by 1,000 yields a cubic ft per hour requirement of 220 cubic ft of gas per hour. The farthest appliance is the range, which
is 50 ft away from the meter. Looking at the above chart, and under the column of 50 ft, Section A to B needs to be 1" in order
to supply 220 cubic ft.
31 Page
Installaon
Installaon Manual
WATER CONNECTIONS
Do not use this appliance if any part has been under water. Immediately contact
a qualified installer or service agency to replace a flooded water heater. Do not
attempt to repair the unit! It must be replaced!
WARNING
Do not reverse the hot outlet and cold inlet connections to the water heater. This will
prevent the water heater from activating properly.
NOTICE
All pipes, pipe fittings, valves and other components, including soldering materials, must be suitable for
potable water systems.
1. A manual shutoff valve must be installed on the cold
water inlet to the water heater between the main
water supply line and the water heater.
2. In addition, a manual shutoff valve is also recommend-
ed on the hot water outlet of the unit. If the water
heater is installed within, or subjected to, a closed loop
water system, a thermal expansion tank
or code approved device to handle thermal expansion
must be installed.
3. Before installing the water heater, flush the water line to remove all debris, and after installation is
complete, purge the air from the line. Failure to do so may cause damage to the heater.
4. There is a wire mesh filter within the cold inlet to trap debris from entering your heater. This will need
to be cleaned periodically to maintain optimum flow. (Refer to p. 51.)
Cold
inlet
Hot
outlet
Gas inlet
As Close as
Possible
Pressure relief valve
-Pressure relief valve-
The water heater has a high-temperature shutoff switch built in as a standard safety feature (called a
Hi-Limit switch) therefore a “pressure only” relief valve is required.
• This unit does not come with an approved pressure relief valve.
• An approved pressure relief valve must be installed on the hot water outlet.
• The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow local codes.
• The discharge capacity must be at least 160,000 BTU/h for the 240 model, 180,000 BTU/h for the 340
model, and 199,000 BTU/h for the 540 model.
• The pressure relief valve needs to be rated for a maximum of 150 psi (1 MPa).
• The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash
outward and cause damage or personal injury.
• Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in
(152 mm) from the floor. This discharge tube must allow free and complete drainage without any
restrictions.
• If the pressure relief valve discharges periodically, this may be due to thermal expansion in a closed
water supply system. Contact the water supplier or a local plumbing professional on how to correct
this situation. Do not plug the pressure relief valve.
• The pressure relief valve must be manually operated periodically to check for correct operation.
Before operating the valve manually, check that it will discharge in a place for secure disposal.
• No valve must be placed between the relief valve and the water heater.
WARNING
Hot water could be released when the pressure relief valve is opened. This
could result in severe personal injury. Before operating the pressure relief
valve manually, check that it will discharge in a safe place. If water does not
flow freely from the end of the discharge pipe, turn the gas supply and power
OFF and call a qualified person to determine the cause.
Refer to the pressure relief valve manufacturer's instructions for inspection
and maintenance requirements.
32 Page
Installaon
Installaon Manual
CONDENSATE DRAIN
• The water heater does not include a built-in condensate neutralizer cartridge for reducing the pH level
of condensate water. If local codes dictate that condensate must be neutralized prior to drainage, a
condensate neutralizer must be installed. An accessory Neutralizer assembly (100112159/TH-NT01)
is sold separately. (Refer to p. 10.)
• In the absence of applicable local codes and regulations, the manufacturer recommends that
condensate be disposed of into a drain. Connect a drain tube from the condensate drain port (shown
below) located on the bottom of the water heater to a standard drain.
Follow all code requirements
of the local authority for
condensate neutralizers and
whether or not they are required
for the installation.
Condensate drain port
NOTICE
• Discharge condensate (acidic water) in accordance with all local codes and com-
mon safety practices.
• Use corrosion resistant pipe, such as PVC, for the condensate drain line.
Do not use metal pipe.
• The condensate drain does not require a trap.
• Maintain a downward slope on the drain line(s), including installations in which
the drain is not directly below the water heater.
• A field-supplied bypass is required if a neutralizer is installed.
• Do not connect the condensate drain line directly to a condensate pump.
• If the drain line is required to have bends, ensure that there are no kinks that
will restrict the flow of condensation.
NOTICE
The water heater is a high efficiency condensing water heater that produces condensate (acidic water).
The acidic condensate generated in the secondary heat exchanger can be neutralized by the neutralizer
accessory (100112159/TH-NT01).
Although a neutralizer is not required, a condensate drain must be installed as described on the next page.
-Condensate drain connecons-
33 Page
Installaon
Installaon Manual
*Maintain downward slope, including installations in which the drain is not directly below the heater.
**A 2" (50 mm) minimum distance must be maintained between the condensate line and drain to allow
full flow of the condensation.
1/2"
Condensate
drain tube*
Overflow bypass*
(1/2" Condensate
drain tube)
Neutralizer cartridge (Included
with Neutralizer accessory)
1/2" MPT x 3/8" FPT (Included
with Neutralizer accessory)
1/2" Condensate drain tube*
1/2" Condensate drain tube*
1/2" FPT x 1/2" HB (Included
with Neutralizer accessory)
1/2"
Condensate
drain tube*
1/2" MPT
Condensate
connection
Floor drain, standpipe,
or other acceptable drain
2" (50 mm)
MIN. distance**
Floor drain, standpipe,
or other acceptable drain
Installation
with neutralizer
Installation
without neutralizer
2" (50 mm)
MIN. distance**
• The condensate drain is at atmospheric pressure (non-pressurized) and therefore must
be allowed to drain freely with gravity only. Ensure that the condensate drain tube is
not plugged or blocked, and ensure that it slopes downward to allow condensate to
flow freely. All portions of the condensate drain (neutralizer and drain tube) must
be at a lower elevation than the water heater to prevent condensate water from
building up inside the heat exchanger.
• Condensate cannot be effectively neutralized if the neutralizer elements inside the
Neutralizer accessory have been completely consumed. If this happens, condensate
will remain acidic and can possibly cause damage to items such as pipes, concrete,
etc., if drained improperly.
• The actual life of the neutralizer may vary, depending on the application and usage.
Replace the cartridge when the condensate pH goes below 6.0.
• Please ensure that the cartridge is properly replaced before the neutralizer elements
have been completely consumed.
• All preventative measures and safety practices must be adhered to when draining condensate.
The manufacturer will not be responsible for any damage caused by condensate.
• A drain pan, or other means of protection against water damage, is recommended to
be installed under the water heater in case of leaks.
NOTICE
2" (50 mm)
MIN. distance**
1/2" MPT
Condensate connection
34 Page
Outdoor models
Boom view of water heater
View of electrical
connecons of water heater
Indoor models
Connect
Power supply
120VAC, 60Hz
Ground
Green screw
Installaon
Installaon Manual
ELECTRICAL CONNECTIONS
• Follow the electrical code requirements of the local authority having jurisdiction.
In the absence of such requirements, follow the current edition of the National
Electrical Code ANSI/NFPA 70 in the U.S. or the current edition of CSA C22.1
Canadian Electrical Code Part 1 in Canada.
• When servicing or replacing parts within the water heater, label all wires prior to
disconnection to facilitate an easy and error-free reconnection. Wiring errors can
cause improper and dangerous operation. Verify proper operation after servicing.
• Failure to observe these warnings could result in personal injury or death.
WARNING
All Indoor models come with a power plug instead of a junction box. The following procedure is for
outdoor model only.
1. The water heater must be electrically grounded. Do not attach the ground wire to either the gas or
the water piping.
2. The water heater requires a 120 VAC, 60 Hz electrical power supply that is properly grounded.
• A proper disconnect (i.e. on/off switch, power plug, etc.) controlling the main power to the water
heater must be provided for service reasons. (Must comply with local codes.)
• Connect the power supply to the water heater exactly as shown in the wiring diagram.
3. A green screw is provided in the junction box to ground the connection.
4. The water heater can be hardwired or wired to a plug-in.
5. The use of a surge protector is recommended in order to protect the unit from power surges.
35 Page
TEMPERATURE REMOTE CONTROLLER
-Included accessories-Outdoor models only
<MountingandWiringtheRemoteController>
1.
Take off the Back plate from the remote controller with a flat head screwdriver. (Fig. A and B)
2.
Attach the Back plate on the wall with the two provided screws. (Fig. B)
3.
If you use another cable, crimp the Fork terminals to the wires. (Fig. C)
Installaon
Installaon Manual
Fig. B
Back plate
3-1/4 inches
Attach the screws
Cut out the partition with pliers.
(removed during later steps.)
Main body
Fig. A
Main body
Twist
Press and twist flat head
screwdriver against the cutout.
Remote controller cable
1-3/8 Inch
(35 mm)
Fig. C
1-5/8 Inch
(41 mm)
Fork
Terminals
100209924 (TM-RE42)
It is also an optional accessory as a second remote for the indoor models. Refer to pp. 9 and 10.
*The optional remote controller (sold separately) has no remote controller cable.
Verify that the items listed below are included with the remote controller.
Temperature
remote controller
Screws Fork terminals Manual
Remote controller
cable*
Qty: 1
Qty: 2
Qty: 4
Qty: 1
Qty: 1
-Installaon-
• This remote controller is NOT waterproof.
• The water heater can only have one remote controller.
• Do not install in high temperature environments, high humidity conditions outdoors, in
direct sunlight, or within the reach of children.
• Make sure the remote controller does not come into contact with water or oil.
• Failure to observe these warnings could result in personal injury or electrical shock.
WARNING
• Do not place the remote controller cable close to other wires from other products.
• Cables used for the remote controller connection must be:
• Minimum 20 gauge wire (No polarity)
• Maximum 400 ft (122 m) long
NOTICE
• The remote control is an optional accessory that can be installed in a hall, closet, etc., to allow for
temperature adjustment without having to go to the heater.
• When installed, the remote will take priority over the built-in controller of indoor models.
36 Page
4.
Tighten the two Fork terminals beneath the two Remote controller terminal screws on the back
of the main body. (Fig. D-1)
5.
Cut out the inlet for the remote controller cable from the bottom of the main body. (Fig. D-2)
6.
Place the Main body back on the Back plate, with the Remote controller cable running out of
the bottom inlet.
<Howtoconnecttheremotecontrollertothewaterheater>
1.
Disconnect power supply from the water heater.
2.
Take off the water heater’s front cover.
3.
Locate the two terminals for the remote controller in the water heater. (Refer to the Fig. E-1 and
E-2.)
4.
Take off the back plate from the remote controller, and then attach the two fork terminals to
the connector base on the back side of the remote controller with two screws. Make sure the
terminals are firmly fixed. (See the above instructions for installation of the remote controller.)
5.
Pull the remote controller cable through the hole at the bottom of the water heater’s casing.
6.
Secure both controller cable terminals to the terminals on the computer board as shown below.
(Secure them underneath the screw terminals. No polarity.)
* Do NOT jump or short-circuit the cables, or computer will be damaged.
7.
Replace the front cover securely.
Remote controller
terminals
Fig. D-1
Two fork terminals
Remote controller cable
Inlet for the remote
controller cable
Cut out
Fig. D-2
Installaon
Installaon Manual
240 and 340 models
100209924
(TM-RE42)
Connect other end to these terminals
Fig. E-1
100209924
(TM-RE42)
Connect other end to these terminals
540 model
Fig. E-2
37 Page
EASY-LINK SYSTEM
(540 model only)
The 540 model water heaters can combine with the following approved heaters with communication cables to
work as a multiple-unit manifold system.
• The built-in Easy-Link System allows up to 4 units to manifold together.
• A communication cable (gray color) comes with each 540 model.
You can manifold from 2 to 4 units without the need for a multi-unit controller. A 4-unit system has full automatic
modulation between 13,000 BTU/h (Propane) or 15,000 BTU/h (Natural gas) to 796,000 BTU/h.
-Easy-Link connecon procedures-
1. Make sure the power to the heaters are off.
2. Verify the DIP switch set temperatures of all units within the system. Every single water heater
must be set to the same set temperature. If a remote controller is used, it should be installed to the
“PARENT” unit. The controller will set the temperature for the entire system. NOTICE: Only a remote
approved for use with the "PARENT" model may be installed.
3. Select one unit to be the “PARENT” unit. The “PARENT” unit should be one of the end units.
4. “PARENT” unit:
Locate the two banks of DIP switches at the bottom left of the computer board of the unit that you
select to be the “PARENT” unit. Change DIP switch No. 1 on the lower bank of DIP switches to the
ON position. Refer to the following page. Do not change any DIP switches on any of the “CHILD” units.
Installaon
Installaon Manual
Approved heaters that can be combined with 540 model
in an Easy-Link System
710 model /710 ASME
520 model
540 model
540P model (Only when 540P is a PARENT unit in the system. )
Hot Out
Gas In
Cold In
Due to the dierence in the connector type
for the Easy-Link System between the 710
and 540, cut out the connectors for the
Easy-Link System and then splice the wires
directly together when connecng the 710
and 540 in the Easy-Link System.
Easy-Link connectors
Wire
cutters
• The Easy-Link System is limited to up to 4 units. If you connect more than 4 units, only
the first 4 units will work as a part of the Easy-Link System. The other additional units
will not work.
• The 540 model cannot be combined together with other models not listed on the
table above.
• A 540P model only can be connected to 540 models where the 540P is the PARENT
unit in the system.
• When a 540 model is connected to other models listed above in an Easy-Link System,
contact the manufacturer.
• When a 710 and 540 are connected together in an Easy-Link System, change DIP
switch No.6 on the lower bank of DIP switches on the 540 model computer board to
the "ON" position. (See the following page for detail.)
• A remote controller is not required for an Easy-Link System. However, it does provide
for more temperature options and ease of maintenance.
• If a remote controller is used, the temperature on all the units in the system will auto-
matically be set to the same temperature that is set on the remote.
• When a remote is used in an Easy-Link System, it must be connected to the parent unit.
• Only one remote can be connected.
NOTICE
38 Page
5. Between the “PARENT” and the “CHILD-1” units:
Connect the “PARENT” connector of the “PARENT” unit to the “1” connector of the “CHILD-1” unit
using the supplied linking cable.
6. Between the “CHILD-1” and the “CHILD-2” units:
Connect the “2” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit.
7. Between the “CHILD-2” and the “CHILD-3” units:
Connect the “2” connector of the “CHILD-2” unit to the “1” connector of the “CHILD-3” unit.
8. Verify that all cables are connected like the diagram below (B).
9. Turn on power to the “PARENT” unit. Turn on “CHILD-1”. When the (remote and/or temperature)
controller displays a number, turn on “CHILD-2”.
When the (remote and/or built-in temperature) controller displays a number, turn on “CHILD-3”.
Make sure the (remote and/or built-in temperature) controllers display the unit #. The numbering
system automatically allocates the unit # to each water heater in the Easy-Link System, in accordance
with the table at right.
(Refer to p.53.)
(B) Basic diagram of connections between the Easy-Link System units
Installaon
Installaon Manual
Type of unit Unit # of easy-link Type of unit Unit # of easy-link
Parent 1 Child 2, 3, or 4
(A) 540 model computer board
PARENT unit
540
CHILD unit
540
CHILD unit
540
CHILD unit
540
PARENT
Communicaon cable
Connectors
Lower bank of
DIP switches
OFF
ON
1
1
1
12
2
2
2
PARENT
PARENT
PARENT
1
2
3
4
5
6
Connectors Connectors Connectors
1
2
3
4
5
6
OFF
ON
OFF
ON
1
2
3
4
5
6
OFF
ON
1
2
3
4
5
6
Lower bank of
DIP switches
Lower bank of
DIP switches
Lower bank of
DIP switches
Built-in/
remote
controller
• The dark squares indicate the correct position of the DIP switch.
• When the 540P, 710, or 520 is a PARENT unit in an Easy-Link System, refer to the
respective manual for DIP switch settings.
• Either a built-in controller or a remote controller is required for the Easy-Link
System for ease of usage and maintenance.
NOTICE
WARNING
• To change the DIP switch settings for the Easy-Link System, locate the lower
bank of DIP switches at the bottom left of the computer board of 540.
• DO NOT adjust any other DIP switches .
• Turn off the power supply to the water heater before changing the DIP switch
settings.
• Failure to observe this warning could result in carbon monoxide poisoning or death.
PARENT
Lower bank of DIP switches
Upper bank
of
DIP switches
Easy-Link /
Mul-Unit
connectors
are next to
the computer
board.
540 DIP switch settings for Easy-Link System
Lower bank of DIP switches
PARENT CHILD
Connection
with 710
1
2
3
4
5
6
OFF
ON
No. 1 ON
1
2
3
4
5
6
OFF
ON
No. 1 OFF
1
2
3
4
5
6
OFF
ON
No. 6 ON
39 Page
MULTI-UNIT SYSTEM
Multiple 540 models can be combined for a Multi-Unit System, along with the multi-unit controller (Part
100112691 (TM-MC02)). The multi-unit controller can control from 2 units to 20 units for commercial or
residential applications. For a 20-unit system, the computer can modulate between the usages of 13,000
BTU/h (Propane) or 15,000 BTU/h (Natural gas) to 3.98 Million BTU/h.
An individual cut-off switch is recommended for each unit in a Multi-Unit System for the purpose
of
maintenance.
Multi-Unit System connection diagram
Multi-unit controller with the remote controller wiring:
• DIP switch settings: Default position (It does not need adjustment.)
• This is the connection diagram for a 540 model and a multi-unit controller in the Multi-Unit System.
The example above shows three water heaters.
• The multi-unit controller automatically allocates the unit # (1-20) to each water heater in the Multi-
Unit System.
• In a Multi-Unit System, connect the “[1]” connector and the “[2]” connector with the communication
cable (refer to p. 9) or 18 gauge wire cables. The total cable length can be up to 250 ft (76.2 m) long.
• In a Multi-Unit System, 540 models can only be connected with other 540 models or 710 models.
• The multi-unit controller allocates random numbering. See the controller instructions to learn how
to renumber the system units sequentially.
OFF
ON
1
1
1
2
2
2
PARENT
PARENT
PARENT
1
2
3
4
5
6
Connectors Connectors Connectors
OFF
ON
OFF
ON
Lower bank of
DIP switches
Lower bank of
DIP switches
Lower bank of
DIP switches
1
2
3
4
5
6
1
2
3
4
5
6
Communicaon cable
Remote controller cable
Unit 1
Unit 2 Unit 3
Remote controller
supplied with controller
Terminals for
water heaters
100112691
(TM-MC02)
Remote controller
terminals
Cold IN
Hot Out
540
100112691
(TM-MC02)
Installaon
Installaon Manual
• For detailed instructions on the multi-unit controller, refer to the instructions
that are packaged with the multi-unit controller.
• If 710 and 540 models are to be connected together in a Multi-Unit System, refer to
the installation manual of the multi-unit controller for more details.
NOTICE
40 Page
APPLICATIONS
-Space-heang applicaons-
-Recirculaon-
*The recirculation pump is to be controlled by:
-Dual-set aquastat (recommended w/timer)
*The recirculation pump is to provide no less than 2 GPM (7.5 L/min) and no more than 4 GPM (15 L/min) through
each activated unit in the system.
Applicaons
Installaon Manual
Air vent
Hot water outlet to xtures
Recirculaon
pump
Air
separator
S
Check valve
Check valve
Y-Strainer
Cold water inlet
Expansion tank
Gas supply
Ball valves
Unions
Hot water outlet
Cold water inlet
Gas inlet
Pressure
relief valve
This is a concept drawing only.
• This water heater is suitable for combination water (potable) heating and
space heating and not suitable for space heating applications only.
• In order to purge air in water pipes within a closed-loop system, an air vent
and air separator should be installed in the system. Required circulation
flow rates are labeled next to each application diagram. These flow rate
requirements must be followed.
• Toxic chemicals used in boiler treatments such as alcohol, glycerol and glycol
groups must not be introduced into the system.
• The water heater can be used to supply potable water and space heating and
shall not be connected to any heating system or component(s) previously
used with non-potable water where any chemicals were added to the water
heating appliances.
• When the system requires water for space heating at temperatures higher
than required for other uses, a means such as a mixing valve shall be installed
to temper the water for those other uses in order to reduce scald hazard
potential.
• Water temperature over 125 °F (52 °C) can cause severe burns instantly or
death from scalding.
• Failure to observe these warnings could result in severe personal injury or
death.
WARNING
41 Page
• Priority Control Devices such as a flow switch, an Aquastat or other
electronic controller can be used to prioritize the domestic water system over
the heating system.
• Follow all local codes, or in the absence of local codes, follow the current
edition of the National Standard Code, ANSI Z21.10.3 • CSA 4.3.
• This illustration is a concept design only. The reference to the 1/8
th
hole
in check is only for the State of Massachusetts. There are a wide variety
of variations to the application of controls and equipment presented.
Designers must add all necessary safety and auxiliary equipment to conform
to code requirements and design practice. For more details, contact the
manufacturer.
NOTICE
120 VAC
switch or
outlet
Hot water outlet
Unions
T-handle gas shuto valve
Check valve
Electronically controlled
pump mer. Acvates
every 6 hours for 60
seconds. Wire to
product approved pump
HeangCoil
(used with air-handler)
Cold water supply
3-inch gas exhaust
vent (Discharge must
comply with local and
state codes.) Cannot
be common vented
with other appliances
An approved temperature and pressure
relief valve. Tie to locaon approved by
local codes and must meet BTU rang of
water heater model used
Check valve will have
1/8-inch hole drilling
in clapper oponal
Atmospheric
vacuum
breaker
Shuto
valve
Pressure
gauge
Apply correct thermal
expansion tank-size
per applicaon
Shuto valves
Shuto valves
Check valves
Cold water inlet
Gas inlet
Water
lter
Drain
plug
Thermostac mixing valve
Hot water
supply and
return to
heang coil
System installed with reverse
acng aquastat to shut o fan.
Suggested but not required by
248 CMR
50’-0” maximum distance from
water heater to fan coil.
(Developed length) Not including
coil in heang unit
NSF-61 product
approved pump
Automac tempering device
must be installed below
the top of the water heater
as per manufacturer’s
recommendaons
Piping loop
between water
heater and fan
coil shall be in
compliance with
248 CMR
Tempered water to
plumbing xtures. Must
meet temperature
requirements of 248 CMR
All water piping should be insulated
in accordance with 780 CMR
(Massachuses energy code)
-Dual-purpose hot water heang-
(Domestic and Space Heating):
Diagrammatic layout of radiant heating and domestic water heater.
The recirculation pump is to provide no less than 2 GPM (7.5 L/min) and no more than 4 GPM (15 L/min)
through each activated unit in the system
Installaon
Installaon Manual
Ball
Valve
Isolation
Valve
42 Page
INITIAL OPERATION
Inial operaon
Installaon Manual
IF YOU SMELL GAS:
• Do not try to start the water heater.
• Do not touch any electric switches; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
• Failure to observe these warnings could lead to fire or an explosion, resulting in
severe injury or death.
WARNING
Operation
1.
Once the above checks have been completed, please clean filter
of any debris. Refer to p. 51 for instructions.
2.
Fully open the manual water control valve on the water supply
line.
3.
Open a hot water tap to verify that water is flowing to that tap,
then close the hot water tap.
4.
Fully open the manual gas control valve installed.
5.
Turn on the 120 VAC, 60 Hz power supply to the water heater.
6.
Now you are ready to enjoy hours of endless hot water.
• Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time.
• Open the main gas supply valve to the unit using only your hand to avoid any spark. Never use
tools. If the knob will not turn by hand, do not try to force it; call a qualified service technician.
Forced repair may result in a fire or explosion due to gas leaks.
• Be sure to check for the presence of leaking gas toward the bottom of the unit because some
gases are heavier than air and may settle towards the floor.
• Check the GAS PRESSURE. Refer to pp. 29 and 51.
• Do not try to light the burner manually. It is equipped with an electronic ignition device which
automatically lights the burner.
• Check for PROPER VENTING and COMBUSTION AIR to the water heater.
• Purge the GAS and WATER LINES to remove any air pockets.
• Do not use this appliance if any part has been under water. Immediately contact a qualified
installer or service agency to replace a flooded water heater. Do not attempt to repair the unit!
It must be replaced!
FOR YOUR SAFETY, READ BEFORE OPERATING
43 Page
Owner's Guide
Operang Safety
Owner's Guide
CONGRATULATIONS
Congratulations and thank you for choosing our tankless water heater.
Before use, we recommend that you read through this owner's guide
carefully. Keep this manual for future reference.
If you need an additional manual, contact the manufacturer or your
local distributor. When you call, please tell us the product name and
the serial number of your unit written on the rating plate of the water
heater.
44 Page
Operang Safety
Owner's Guide
OPERATING SAFETY
WARNING:
Ifyoudonotfollowtheseinstructionsexactly,areorexplosionmayresult
causingpropertydamage,personalinjuryorlossoflife.
A.Thisappliancedoesnothaveapilot.Itisequippedwithanignitiondevicewhichautomatically
lightstheburner.Donottrytolighttheburnerbyhand.
B.BEFOREOPERATINGsmellallaroundtheapplianceareaforgas.Besuretosmellnextto
theoorbecausesomegasisheavierthanairandwillsettleontheoor.
WHATTODOIFYOUSMELLGAS
• Donottrytolightanyappliance.
• Donottouchanyelectricswitch;donotuseanyphoneinyourbuilding.
• Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegassupplier’s
instructions.
• Ifyoucannotreachyourgassupplier,calltheredepartment.
C.Useonlyyourhandtoturnthegasshutoffvalve.Neverusetools.Ifthevalvewillnotturnby
hand,don’ttrytorepairit,callaqualiedservicetechnician.Forceorattemptedrepairmayresult
inareorexplosion.
D.Donotusethisapplianceifanyparthasbeenunderwater.Immediatelycontactaqualied
installerorserviceagencytoreplaceaoodedwaterheater.Donotattempttorepairtheunit!It
mustbereplaced!
1. STOP!Readthesafetyinformationaboveonthislabel.
2. Turnoffallelectricpowertotheappliance.
3. Donotattempttolighttheburnerbyhand.
4. Turnthegasshutoffvalvelocatedontheoutsideoftheunittotheclosedposition.
5. Waitve(5)minutestoclearoutanygas.Ifyouthensmellgas,STOP!Follow“B”inthe
safetyinformationaboveonthislabel.Ifyoudon’tsmellgas,gotothenextstep.
6. Turnthegasshutoffvalvelocatedontheoutsideoftheunittotheopenposition.
7. Turnonallelectricalpowertotheappliance.
8. Iftheappliancewillnotoperate,followtheinstructionsin“ToTurnOffGastoAppliance,”and
callyourservicetechnicianorgassupplier.
1. Turnoffallelectricpowertotheapplianceifserviceistobeperformed.
2. Turnthegasshutoffvalvelocatedontheoutsideoftheunittotheclosedposition.
FORYOURSAFETYREADBEFOREOPERATING
OPERATINGINSTRUCTIONS
TOTURNOFFGASTOAPPLIANCE
45 Page
Operang Safety
Owner's Guide
ApressurereliefvalvelistedascomplyingwiththestandardforReliefValveandAutomaticGasShutoff
DevicesforHotWaterSupplySystem,ANSIZ21.22
・
CSA4.4,shallbeinstalledatthetimeofinstallation
ofthewaterheaterinthelocationspeciedbythemanufacturer.Localcodesshallgoverntheinstallationof
reliefdevicesforsafetyoperationofthewaterheater.Thereliefvalvemustnotberemovedorplugged.
Novalveshallbeplacedbetweenthe reliefvalveandthewaterheater.The relieffromthedischargeof
thepressurereliefvalveshallbedisposedofinasuitableplacewhereitwillcausenodamage.Also,there
shallbenootherreducingcouplingorotherrestrictionsinstalledonthedischargelinetorestrictow.
SeeInstallationManualheading“PRESSURE RELIEFVALVES”forinstallationandmaintenanceofrelief
valvedischargelineandothersafetyprecautions.
Vaporsfromammableliquidswillexplodeandcatchrecausingdeathorsevereburns.
Donotuseorstoreammableproductssuchasgasoline,solventsoradhesivesinthesameroomor
areanearthewaterheater.
Keepammableproducts:
1. Farawayfromheater.
2. Inapprovedcontainers.
3. Tightlyclosedandoutofreachofchildren.
4. Waterheaterhasamainburner,whichmay
comeonatanytimeandwilligniteammable
vapors.
Vapors:
1. Cannotbeseen.
2. Areheavierthanair.
3. Goalongwayontheoor.
4. Canbecarriedfromotherroomstothemain
burnerbyaircurrents.
Donotinstallwaterheaterwhereammableproductswillbestoredor
usedunlessthemainburnerisatleast18”abovetheoor.This
willreduce,butnoteliminatetheriskofvaporsbeingignitedbythe
mainburner.
Readandfollowwaterheaterwarningsandinstructions.Iftheowner’s
manualismissing,contacttheretailerormanufacturer.
FlammableVapors
FLAMMABLES
1. Watertemperatureover125°F(52°C)cancausesevereburnsinstantlyordeathfrom
scalds.
2. Children,disabledandelderlyareathighestriskofbeingscalded.
3. Feelwaterbeforebathingorshowering.
4. Temperaturelimitingvalvesareavailable.Seemanual.
5. Theoutlettemperatureofthewater heater issetat120°F(50°C).Ifyou require watertemperatures
belowthissetting,followtheinstructionmanual.
6. Usethisheateratyourownrisk.Testthewaterbeforebathingorshowering.Donotleavechildrenor
aninrmpersonunsupervised.Seeyourlocalwatersupplycompany[plumbinghardwareretailer]for
temperaturelimitingvalvesthatareavailable.
BRÛLURE
BURN
CHAUDECHAUDE
HOTHOT
CHAUDE
HOT
DANGER
DANGER
46 Page
Normal Operaon
Owner's Guide
NORMAL OPERATION
BUILT-IN CONTROLLER AND REMOTE CONTROLLER
The illustraon below shows an example of the controllers. The exact display may dier from examples.
"COLD" Button
"HOT" Button
Press the "HOT" button or the "COLD"
button to set the hot water temperature.
STAND BY LED (Orange)
The indicator is ON to show that
power is ON.
IN USE LED (Green)
The indicator lights during combustion.
"INFO" Button
Each time the button is pressed,
the operation mode is selected
in the sequence of the following.
Inlet water
temperature
Outlet water
temperature
Water
flow
When the STAND BY LED is ON, the
hot water temperature will be
displayed.
Display for Temperature
"ON/OFF" Button
Press this button to
start or stop operation.
Built-in controller
Remote controller
• When the remote controller is installed it will take priority over the built-in controller.
• The controller has an energy saving mode. Five minutes after the water heater stops
operating, the backlight of the controller turns off.
• The backlight of the remote will turn back on once the water heater begins firing again.
NOTICE
GENERAL
1. Open a cold water
fixture.
2. Mix hot water with the cold water
to get the correct temperature water.
3. When finished, close the
water fixtures.
• Flow rate to activate the water heater: 0.5 gallon per minute at the default set
temperature (1.9 L/min).
• Flow rate to keep the water heater running: 0.4 gallon per minute (1.5 L/min).
NOTICE
Temperatures above 125 °F (52 °C) can cause severe burns or death from scalding.
Children, disabled and the elderly are at high risk of being injured.
WARNING
°F 120 125 130 135 140 145 150 155
°C 49 52 54 57 60 63 66 68
Time to produce
serious burn
more
than 5
min.
1½ to 2
min.
about
30 sec.
about
10 sec.
less than
5 sec.
less than
3 sec.
about
1½ sec.
about
1 sec.
47 Page
Normal Operaon
Owner's Guide
Operation
Screen on the controller
Built-in controller Remote controller
1.
Turn on the 120 VAC power supply to the unit (the water
heater or the multi-unit controller).
2.
Press the "ON/OFF" button on the controller in order to
turn the controller on.
3.
When ON, the STAND BY LED is lit.
4.
It shows the set temperature on its display as shown in
the picture on the right. (EX.: 120 °F)
5.
Press the "HOT" button or the "COLD" button to set the
temperature setting of the unit.
Increasing temperature from 120 °F (50 °C) to 125 °F (52 °C) :
1. The water heater must be in Stand By to increase the
temperature.
2. Press the "HOT" button to set 120 °F (50 °C).
3. Press and hold the "INFO" button and the "HOT"
button for at least 3 seconds. The remote will emit a
beep and change to 125 °F (52 °C).
4. Press the "HOT" button to set up to 140 °F (60 °C).
Increasing temperature above 140 °F (60 °C)
-540 model only-:
1. The water heater must be in Stand By to increase the
temperature.
2. Press the "HOT" button to set 140 °F (60 °C).
3. Press and hold the "INFO" button and the "HOT"
button for at least 3 seconds. The remote will emit a
beep and change to 145 °F (63 °C).
4. Press the "HOT" button to set up to 160 °F (70 °C).
(EX.: 120 °F)
OUTLET WATER TEMPERATURE SETTING
-Set temperature
TEMPERATURE TABLE OF CONTROLLER
°F 100 105 110 115 120* 125 130 135 140
°C 38 40 43 45 50* 52 55 57 60
a) For 240 and 340 models
°F 100 105 110 115 120* 125 130 135 140 145 150 155 160
°C 38 40 43 45 50* 52 55 57 60 63 65 68 70
b) For 540 model with 100209924(TM-RE42-Standard model)
*Factory setting (Default): 120 °F
48 Page
Normal Operaon
Owner's Guide
ADDITIONAL FEATURES
-Informaon mode-
You can get some information about the water heater condition by pressing the "INFO" button. For more
information, follow the procedures below:
INFO
Button
Operation
Screen on the controller
Built-in controller Remote controller
1st. press
Inlet water temperature will be
displayed on the controller by pressing
the "INFO" button.
Inlet water temperature
(EX.: 60 °F)
2nd. press
Outlet water temperature will be
displayed on the controller by pressing
the "INFO" button.
Outlet water temperature
(EX.: 120 °F)
3rd. press
And then, water flow will be displayed
on the controller by pressing the
"INFO" button.
4th. press
Press the "INFO" button to finish
information mode.
Water flow
(EX.: 3.5 GPM)
-Unit conversion mode-
Units of measure can be changed from Imperial to Metric and vice versa. For example, temperature can
be changed from °F to °C. Flow rate will also change from gallons per minute to liters per minute when
this setting is changed. Follow this procedure to change this setting:
Operation
Screen on the controller
Built-in controller Remote controller
1.
Press the "ON/OFF" button on the controller in
order to turn the controller on.
2.
When ON, the orange LED is lit.
3.
The previous set temperature will be displayed on
the screen.
4.
Press the "INFO" buttons for at least 3 seconds.
5.
The set temperature should now be displayed in the
alternate unit of measurement.
(EX.: 100 °F)
(EX.: 38 °C)
When the water heater is connected with the remote controller, the built-
in controller will not operate temperature settings. It will only work for the
information mode (Indoor models only).
NOTICE
49 Page
TEMPERATURE SETTINGS ON THE PCB
(WITHOUT REMOTE CONTROLLER)
WARNING
• Adjust the appropriate DIP switches according to model and temperature as
shown below. DO NOT adjust the other DIP switches.
• Turn off the power supply to the water heater before changing the DIP switch
settings.
• Failure to observe these warnings could lead to carbon monoxide poisoning,
severe personal injury, or death.
There are 2 preset temperatures , 120 °F (50 °C) and 140 °F (60 °C), that you can select by changing the
DIP switch settings on the computer board without the remote controller. See below.
When the remote controller is in normal operation, the set temperature of the remote controller is given
priority over the set temperature of the DIP switch settings.
Normal Operaon
Owner's Guide
• The temperature has been preset at the factory to 120 °F (50 °C).
Computer board
120 °F (50 °C)
DEFAULT
140 °F (60 °C)
No. 9 : OFF
No. 9 : ON
240 and 340 models
OFF
ON
1 2 3 4 5 6
7 8 9
10
OFF
ON
1 2 3 4 5 6 7 8 9 10
Bank of
DIP switches
NOTE: The dark squares indicate the correct DIP switch positions.
(Lower bank of DIP switches)
120 °F (50 °C)
DEFAULT
140 °F (60 °C)
OFF
ON
1 2 3 4 5 6
No. 5 : OFF
OFF
ON
1 2 3 4 5 62 3 4 5 6
No. 5 : ON
540 model
Computer board
Upper bank of
DIP switches
Lower bank of
DIP switches
FLOW
Appliance/Use
Flow rate
GPM (US) L/min
Lavatory Faucet 1.0 3.8
Bath Tub 4.0 – 10.0 15.2 - 37.8
Shower 2.0 7.5
Kitchen Sink 1.5 5.6
Dishwasher 1.5 5.6
Washing machine 4.0 15.2
Household Flow Rates
Taken from UPC 2006
• The flow rate through the water heater is limited
to a maximum of 6.6 GPM (25 L/min) for the 240
model, 8.0 GPM (30 L/min) for the 340 model, and
10.0 GPM (38 L/min) for the 540 model.
• The temperature setting, along with the supply
temperature of the water will determine the flow
rate output of the unit.
• Please refer to the temperature vs. gallons per
minute charts on p. 64 to determine the likely flow
rates based on your local ground water temperature
and your desired outlet water temperature.
• Refer to the table to the right for typical
household plumbing fixture flow rates to determine
what the water heater can do in a household
application.
50 Page
Normal Operaon
Owner's Guide
MAINTENANCE AND SERVICE
• Turn off the electrical power supply and close the manual gas shutoff valve
and the manual water control valve before servicing.
• Failure to do so could result in severe personal injury, or death.
WARNING
• Clean the cold-water inlet filter. (Refer to the Unit Draining and Filter Cleaning Section in this page.)
• Be sure that all openings for combustion and ventilation air are not blocked.
• The venting system should be checked annually for any leaks, corrosion, blockages or damage.
• The burner should be checked annually for dust, lint, grease or dirt.
• Keep the area around the water heater clear. Remove any combustible materials, gasoline or any
flammable vapors and liquids.
• If the relief valve discharges periodically, it may be due to thermal expansion in a closed water supply
system. Contact the water supplier or local plumbing inspector on how to correct this situation.
• Visually check the burner flames (see below) through the burner window in the burner assembly
located at the middle of the water heater.
Sasfactory
Blue ame
Unsasfactory
Flame
blowing up
Unsasfactory
Red or Yellow
ame
The manufacturer recommends having the unit checked once a year or as necessary by a licensed
technician. If repairs are needed, any repairs should be done by a licensed technician.
FREEZE PROTECTION SYSTEM
• This water heater comes equipped with heating blocks to protect it from damage associated with
freezing. When the freeze protection thermostat senses air temperature below 36.5 °F (2.5 °C), the
blocks will heat up to prevent freezing of the unit.
• To operate these freeze protection systems, there has to be electrical power to the unit. Damage
to the heat exchanger caused by freezing temperatures due to power loss is not covered under the
warranty. In cases where power losses can occur, consider the use of a backup power supply.
• In any areas subject to freezing temperatures, the manufacturer highly recommends an indoor installa-
tion with an indoor model.
• The manufacturer also highly recommends the use of a backflow preventer (sold separately) to mini-
mize the amount of cold air entering through the exhaust venting when the water heater is off.
• It is the installer’s responsibility to be aware of freezing issues and take all preventative measures. The
manufacturer will not be responsible for any damage to the heat exchanger as a result of freezing.
• If you will not be using your heater for a long period of time:
1. Completely drain the water out of the unit. Refer to p. 51.
2. Disconnect power to your heater.
This will keep your unit from freezing and being damaged.
Only pipes within the water heater are protected by the freeze protection system.
Any water pipes (hot or cold) located outside the unit will not be protected.
Properly protect and insulate these pipes from freezing.
NOTICE
51 Page
Normal Operaon
Owner's Guide
UNIT DRAINING AND FILTER CLEANING
Inlet water
valve
Gas
valve
Drain plug
(Small)
Drain plug
with Filter (Large)
Pressure
port
-Measuring inlet gas pressure-
The water heater cannot perform properly without sufficient inlet gas pressure. Below are instructions
on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL.
1. Shut off the manual gas valve on the gas supply line.
2. Remove the screw from the pressure port which is located on the gas inlet of the water
heater shown in the diagram on the right.
3. Connect the manometer to the pressure port and zero the manometer.
4. Re-open the manual gas valve. Verify that there are no gas leaks.
5. With all gas burning equipment off, take a reading of the static gas pressure and make a note
of it.
6. Measure gas supply pressure at maximum heater operation: Open hot water faucets to cre-
ate maximum flow. Press the MAX button on the computer board. (Refer to the diagrams
below.) Take a reading of the supply dynamic gas pressure with all gas burning equipment
running at maximum rate.
7. The static and dynamic pressures should be within the ranges specified on the heater's rating
plate and the table on p. 29.
8. The difference of static to dynamic pressure should not exceed 1.5" W.C. Pressure drops
that exceed 1.5" W.C. can indicate restricted gas flow, undersized gas lines, and/or undersized supply regulators.
(NOTICE: In Canada, the pressure drops cannot exceed those specified in CSA B149.1.)
9. Measure gas supply pressure at minimum heater operation: Reduce water flow so the heater is running at mini-
mal operation. Press the MIN button on the computer board. (Refer to the diagrams below.) Take a supply gas
pressure reading and verify that it is within the specified inlet gas pressure range.
1. Turn off all electric power to the water heater if service is to be performed.
2. Turn the manual gas valve located on the outside of the unit to the off position.
3. Failure to follow these steps could lead to fire or explosion, resulting in personal injury
or death.
WARNING
240 and 340 Computer board
MAX button
MIN button
540 Computer board
MAX button
MIN button
1. Close the manual gas shutoff valve.
2. Turn off power to the unit and wait a couple of seconds. Turn on
again.
3. Wait 30 seconds, and then turn off power to the unit.
4. Close the inlet water valve.
• If the heater is part of an Easy-Link or Multi-Unit System, close
the inlet and outlet water valves to isolate the heater. Then pro-
ceed to step 6.
5. Open all hot water taps in the house. When the residual water
flow has ceased, close all hot water taps.
6. Have a bucket or pan to catch the water from the unit’s drain
plugs. If Isolation valves are installed, open the drains to drain the
water. If isolation valves are not installed, unscrew the two drain
plugs (large and small) to drain all the water out of the unit. Do
not lose the o-rings that will be on the two drain plugs.
7. Wait a few minutes to ensure all water has completely drained
from the unit.
8. Clean the filter: Check the water filter located within the cold
inlet. With a tiny brush, clean the water filter of any debris which
may have accumulated and reinsert the filter back into the cold
water inlet.
9. Securely screw the drain plugs back into place.
Hand- tighten only.
52 Page
TROUBLESHOOTING
GENERAL
PROBLEM SOLUTIONS
TEMPERATURE and AMOUNT OF HOT WATER
It takes a long time to
get hot water at the
fixtures.
• The time it takes to deliver hot water from the water heater to your fixtures
depends on the length of piping between the two. The longer the distance
or the bigger the pipes, the longer it will take to get hot water.
• If you would like to receive hot water to your fixtures more quickly you
may want to consider a hot water recirculation system. (p. 40)
The water is not hot
enough.
• Compare the flow and temperature. See the charts on p. 64.
• Check cross plumbing between the cold water lines and hot water lines.
• Is the gas supply valve open fully? (p. 42)
• Is the gas line sized properly? (p. 30)
• Is the gas supply pressure sufficient? (pp. 29 and 51)
• Is the set temperature set too low? (p. 47 and 49)
The water is too hot. • Is the set temperature set too high? (p. 47 and 49)
The hot water is not
available when a
fixture is opened.
• Make sure the unit has 120 VAC, 60 Hz power supply.
• If you are using the remote controller and/or temperature controller, is
the power button turned on?
• Is the gas supply valve open fully? (p. 42)
• Is the water supply valve open fully? (p. 42)
• Is the filter on the cold water inlet clean? (p. 51)
• Is the hot water fixture sufficiently open to draw at least 0.5 GPM
(1.9 L/min) through the water heater? (p. 46)
• Is the unit frozen? (p. 50)
• Is there enough gas in the tank / cylinder? (For Propane models)
The hot water turns
cold and stays cold.
• Is the flow rate enough to keep the water heater running? (p. 46)
• If there is a recirculation system installed, does the recirculation line have
enough check valves? (p. 40)
• Is the gas supply valve open fully? (p. 42)
• Is the filter on the cold water inlet clean? (p. 51)
• Are the fixtures clean of debris and obstructions?
• Check if the flow rate is too low. (p. 46)
Fluctuation in hot
water temperature.
• Is the filter on the cold water inlet clean? (p. 51)
• Is the gas line sized properly? (p. 30)
• Is the supply gas pressure sufficient? (pp. 29 and 51)
• Check for cross connection between the cold water lines and hot water
lines.
WATER HEATER
Unit does not ignite
when water goes
through the unit.
• Is the flow rate over 0.5 GPM (1.9 L/min)? (p. 46)
• Check for the filter on the cold water inlet. (p. 51)
• Check for reverse connection and cross connection.
• If you use the remote controller and/or temperature controller, is the
power button turned on?
• Check if the inlet temperature is too high. If it is too close to the set
temperature, the water heater will not activate.
The fan motor is
still spinning after
operation has stopped.
• This is normal. After operation has stopped, the fan motor keeps running
from 15 to 70 seconds in order to re-ignite quickly, as well as purge all the
exhaust gas out of the flue.
Unit sounds abnor-
mal while in opera-
tion
• Contact the manufacturer at 1-877-737-2840 (USA)
1-888-479-8324 (Canada).
Troubleshoong
Owner's Guide
53 Page
PROBLEM SOLUTIONS
BUILT-INCONTROLLERAND
REMOTE CONTROLLER
Controller does not
display anything when
the power button is
turned on.
• Make sure the unit is supplied with power.
• Make sure the connection to the unit is correct. (pp. 35 and 36)
NOTICE:
When the unit has not operated for five minutes or more, the display
of the controllers turns off to conserve energy.
When the
controller turned
ON, STAND BY LED
is lit.
Built-in controller
Although the controller of the parent unit will display the set
temperature at the Easy-Link System, the controller of the child unit
will not display the set temperature.
An ERROR code is
displayed.
• Please see pp. 53 to 56.
EASY-LINK SYSTEM
540 model only
How are the unit
numbers assigned?
• For an Easy-Link System, the Parent unit is always labeled #1 and all
other subsequent Child units are numbered randomly.
• To check which numbers are assigned to which Child units, push the
increase button on the computer board of any Child unit as shown
below. The unit number will be displayed on the temperature con-
troller of the Child unit and/or the remote controller of the Child
unit, if installed. (Refer to pp. 37 and 38.)
Increase buon to check
unit number
Troubleshoong
Owner's Guide
ERROR CODES
-General-
• The units have self-diagnostic functions for safety and convenience when troubleshooting.
• If there is a problem with the installation or the unit, the error code will be displayed on the built-in
controller and remote controller.
• Consult the table on the following pages for the description of each error code.
Error code indicator on
the temperature controller
Error code indicator on the remote
controller
Error code on the computer board
Indicated by 1/2-second flashes on the Green LED.
240 and 340 models
Green LED
540 model
Green LED
54 Page
-Single unit Installaon-
Example: If your unit has a “321” error code (which signifies an inlet thermistor failure)
• Indicator on the built-in controller or remote controller : “321” will be displayed
on the screen.
• Green LED on the computer board: The green LED on the computer board will indicate this code with
two flashes every 1/2 second. The pattern will repeat with a three second delay between patterns.
Error code
Error code Green LED
on on on on
on on
off off off off off
321
Troubleshoong
Owner's Guide
Error Code
on the temperature
controller
Green LED
The number
of flashes
Flash paern
031 701 711
One
311 321 331 341
391 441
Two
111 121
Three
611 651 661
Four
101 941 991
Five
510 551 721
Six
on on
off
off
0.5 sec. on, 0.5 sec. off 3 sec. off
Error Indication
-Easy-Link System-
(540 model only)
Error codes will be displayed differently with units installed in an Easy-Link System. The built-in/remote
controller installed in a PARENT unit will show both the error code and which unit has the error code.
Below is an example of how an error code of "321" is displayed in an Easy-Link System.
Example: If Unit #2 has the “321” error code (inlet thermistor failure)
Indoor model installation
Indicator on the built-in and/or remote controller of Parent unit*: “321” and "2" will alternately flash
on the display.
Unit #1
PARENT
Unit #2
CHILD
Unit #4
CHILD
Unit #3
CHILD
Unit #2: "321" will flash
intermittently on the
display. The green LED
on the computer board
will flash twice, just like
in the single unit exam-
ple.
Unit #3 and #4: These
units will not display
anything, as the error
code does not pertain
to them.
*If the remote controller is installed in the Parent unit, the remote controller has priority over the built-in
controllers.
55 Page
-Fault Analysis of Error Codes-
If the error code is displayed on the computer board of the water heater or remote controller and/or
temperature controller, please check the following. After checking, consult with the manufacturer.
Troubleshoong
Owner's Guide
Controller
Green
LED
Malfunction
description
Diagnosis
031
One
Flash
Incorrect DIP switch
setting
• Check the DIP switch settings on the PCB (Part #701).
101
Five
Flashes
Warning for the “991”
error code
• Check the gas type of the water heater.
• Check if there is any blockage in the intake air and/or exhaust.
• If the water heater is installed as a direct-vent system, check
whether there is enough distance between the intake air
terminal and the exhaust terminal.
• Check the altitude/elevation of area of where the water heater
is installed.
• Check if there is grease and/or dirt in the burner (Part #101) and the
fan motor (Part #103), especially if the water heater has been installed
in a contaminated area.
111
Three
Flashes
Ignition failure • Check if the Hi-limit switch (Part #412) is properly functioning.
• Check for connection/breakage of wires (Part #413, 708, 709, 711)
burn marks on the computer board (Part #701), and/or soot on the
flame rod (Part #108).
• Check if there is a buzzing spark ignition sound coming from the
burner (Part #101) when water heater prepares for combustion.
• Listen for the double “clunk” sound coming from gas valve
assembly (Part #102) when water heater goes into combustion.
• Check if there is leaking from heat exchanger (Part #401).
121
Three
Flashes
Loss of flame • Check if the Hi-limit switch (Part #412) is functioning properly.
• Check for connection/breakage of wires (Part #413, 708, 709,
711) burn marks on the computer board (Part #701), and/or soot
on the flame rod (Part #108).
• Check if there is leaking from heat exchanger (Part #401).
311
Two
Flashes
Outlet thermistor
failure (240 /340 models
only)
Heat exchanger
thermistor failure
(540 model only)
• Check for connection/breakage of wires and/or debris on therm-
istor (Part #407, 408, 411, 715).
321
Two
Flashes
Inlet thermistor fail-
ure
Error code Green LED
on on on on
on on
off off off off off
321
Unit #1
PARENT
Unit #2
CHILD
Unit #3
CHILD
Unit #4
CHILD
Green LED on the computer board
Outdoor model installation
Indicator on the remote controller of Parent unit (If it is installed): “321” and "2" will alternately flash
on the display.
No. 2 Unit: The green
LED on the computer
board will indicate this
code with two flashes
every 1/2 second.
No. 3&4 Unit: No sign.
56 Page
Troubleshoong
Owner's Guide
Controller
Green
LED
Malfunction
description
Diagnosis
331
Two
Flashes
Outlet thermistor fail-
ure (540 model only)
• Check for connection/breakage of wires and/or debris on therm-
istor (Part #407, 408, 411, 715).
341
Two
Flashes
Exhaust thermistor
failure (Indoor models
only)
391
Two
Flashes
Air-fuel ratio rod fail-
ure
• Check for connection/breakage of wires (Part #709) and/or soot
on the AFR rod (Part #108).
441
Two
Flashes
Flow sensor failure
(Easy-Link System only)
• Check for connection/breakage of wires and/or debris on the
flow sensor impeller (Part #402).
510
Six
Flashes
Abnormal main gas
solenoid valve
• Check for connection/breakage of wires (Part #708) and/or burn
marks on the computer board (Part #701).
551
Six
Flashes
Abnormal gas
solenoid valve
• Check for connection/breakage of wires (Part #708) and/or burn
marks on the computer board (Part #701).
611
Four
Flashes
Fan motor fault • Check for connection/breakage of wires, dust buildup in the fan motor
(Part #103) and/or burn marks on the computer board (Part #701).
• Check for frozen/corrosion of connectors (Part #103).
651
Four
Flashes
Flow adjustment
valve fault (Easy-Link
System only)
• Inspect the flow adjustment valve (Part #402), for connection/
breakage of wires, locked motor drive due to scale buildup, and/
or water leakage.
661
Four
Flashes
Bypass valve fault
(540 model only)
• Inspect the bypass valve (Part #403), for connection/breakage of
wires, locked motor drive due to scale buildup, and/or water leakage.
701
One
Flash
Computer board fault • Check for connection/breakage of wires (Part #714).
711
One
Flash
Gas solenoid valve
drive circuit failure
• Refer to the 111 and 121 error codes.
721
Six
Flashes
False flame detection • For indoor models, check if condensate drain is installed on the
vent collar of the water heater.
• Check if there is leaking from heat exchanger (Part #401).
741
N/A
Miscommunication
between water heater
and remote controller
• Check the model type of the remote controller.
• Inspect the connections between the water heater and remote
controller.
• Check the power supply of the water heater.
751
N/A
Miscommunication
between water heater
and temperature
controller (Indoor
models only)
• Inspect the connections between the water heater and tempera-
ture controller.
• Check the power supply of the water heater.
761
N/A
Miscommunication in
Easy-Link System
• Check if the connections between the parent unit and the child
units are correct. Refer to p. 37 to 38.
941
Five
Flashes
Abnormal exhaust
temperature (Indoor
models only)
• Check if the set temperature is higher than 140°F (60°C) and the
system is Recirculation.
991
Five
Flashes
Imperfect
combustion
• Check the gas type of the water heater.
• Inspect the environment around the water heater. Determine
how long the unit has been installed.
• Check the altitude/elevation of the area of where the water
heater is installed.
• Check if there is any blockage in the intake air and/or exhaust.
• If the water heater is installed as a direct-vent system, check
whether there is enough distance between the intake air termi-
nal and the exhaust terminal.
• Check if there is grease and/or dirt in the burner (Part #101) and
the fan motor (Part #103), especially if the water heater has been
installed in a contaminated area.
57 Page
COMPONENTS DIAGRAM
Indoor models
Outdoor models
Case assembly
Temperature
remote controller
724
723
722
056
052
052
003
007
002
050
006
704
005
052
702
704
008
052
050
052
717
702
713
004
002
001
001
004
Temperature controller
Indoor models
Components Diagram
Owner's Guide
58 Page
540 model
240 and 340 models
Computer board assembly
Surge box assembly
121
713
703
706
063
709
053
703
711
701
713
103
709
402
707
708
714
721
407
408
701
714
403
715
721
707
722
715
402
402
103
713
708
711
709
716
716
722
402
061
Components Diagram
Owner's Guide
59 Page
Components Diagram
Owner's Guide
Burner assembly
101
104
115
106
107
108
110
109
111
711
112
062
053
053
709
053
401
103
105
065
054
113
114
102
708
119
151
118
055
051
150
057
055
063
117
053
116
062
121
714
719
707
711
117
540 model
Manifold
assembly
Burner assembly
60 Page
Components Diagram
Owner's Guide
Water Way assembly
402
460
456
461
458
404
417
407
454
405
457
406
410
455
408
458
454
462
C
D
052
059
052
409
417
Water outlet section
Water inlet section
403
456
460
458
462
B
A
Bypass section
(540 model)
D
A
E
459
454
411
412
058
F
413
452
450
414
451
414
418
416
009
C
453
468
468
052
455
463
455
469
052
463
462
467
064
462
462
473
466
466
415
451
465
418
414
464
471
064
D
472
153
152
053
718
470
415
401
B
E
F
473
451
458
458
458
458
458
540 model
240 and 340 models
61 Page
PARTS LIST
Item # Description
Part #
240, 340 and
540 models
T-H3J, T-H3S and
T-H3 models
001 Case assembly for Indoor models
for Outdoor models
N/A
N/A
EK159
EK164
002 Front cover for 240 and 340 Indoor
for 240 and 340 Outdoor
for 540 Indoor
for 540 Outdoor
100074663
100074664
100074665
100074666
EK187
EK188
EK158
EK174
003
004
005
006
007
Intake air port assembly
Bracket
Junction box
Power supply cord assembly
Back guard panel
100074667
N/A
100074668
100074669
N/A
EK170
EK162
EK190
EK171
EK161
008
009
Chamber fixing plate
Condensate drain port
N/A
100074203
EK160
EKH23
050
051
052
053
Truss screw M4×12 (W/Washer) SUS410
Truss screw M4×10 (W/Washer)
Truss screw M4×10 (Coated) SUS3
Truss screw M4x10 SUS
100074210
100074509
100074211
100074245
EW000
EW001
EW002
EW003
054
055
056
057
Hex head screw M4×12 (W/Washer) SUS3
Hex head screw M4x8 FEZN
Pan screw M4x20
Tap tight screw M4x12 FEZN
100074510
100074248
N/A
100074385
EW004
EW005
EW018
EKK31
058
059
060
061
Pan head screw M3x6 SUS3
Truss head screw M4x6 SUS3
Tap tight screw M4x12
Screw M3x6 Plus bind FEZN
100074272
100074512
100076269
N/A
EW00A
EW009
EKK37
EK191
062
063
064
065
Pan screw M4x8 MFZN
Wire clamp 60
Screw M4x10
Screw M3x6 SUS3
100074526
100074233
N/A
100074514
EW00D
EM167
EK230
EW00B
101
102
Burner assembly
Manifold with gas valve assembly LP
Manifold with gas valve assembly NA
100074670
100074671
100074672
EK192
EK181
EK182
103 Fan motor for Indoor models
Fan motor for Outdoor models
100074606
100074228
EK109
EKK25
104
105
106
107
Burner gasket
Fan damper for Indoor models
Burner window
Rod holder gasket
100074216
100074466
100074218
100074219
EKK2X
EM381
EKK2V
EKK2W
108
109
110
111
Flame rod
Igniter rod
Rod holder
Rod cap
100074673
100074222
100074221
100074223
EK193
EKK0F
EKK32
EKN61
112
113
114
115
Burner damper LP
Burner damper NA
Manifold gasket A
Manifold gasket B
Burner holder gasket
100074674
100074675
100074229
100074230
100074217
EK183
EK169
EKK2Y
EKK2K
EKK0G
Parts List
Owner's Guide
62 Page
Parts List
Owner's Guide
Item # Description
Part #
240, 340 and
540 models
T-H3J, T-H3S and
T-H3 models
116
117
118
Pressure port
Combustion chamber tube
Gas inlet
100074227
100074528
100074616
EKK2D
EX019
EK117
119
121
Gas inlet ring
Surge box plate
100074526
N/A
EX00D
EK163
150
151
152
153
O-ring P18 NBR (Black)
O-ring P20 NBR (Black)
Silicon ring for Outdoor models
Exhaust port for Outdoor models
100074533
100074242
100074678
100074679
EZP18
EK042
EK157
EK177
401 Primary heat exchanger assembly for 240 and 340 models
Primary heat exchanger assembly for 540 model
100074698
100074699
EK252
EK250
402
403
404
405
406
Flow adjustment valve / Flow sensor
Bypass valve for 540 model
Water inlet
Inlet drain plug
Inlet water filter
100074624
100074625
100074377
100074381
100074382
EK129
EKD58
EKK1U
EKK2B
EKK2C
407 Inlet thermistor for 240 and 340 models
Inlet thermistor for 540 model
100074398
100074626
EKK4J
EK137
408 Outlet thermistor for 240 and 340 models
Outlet thermistor for 540 model
100074680
100074374
EK207
EKK1A
409
410
411
Water outlet
Outlet drain plug
Heat exchanger thermistor for 540 model
100074681
100074383
100074281
EK208
EKK2E
EKK2T
412 Hi-Limit switch for 240 and 340 models
Hi-Limit switch for 540 model
100074412
100074280
EM212
EKN34
413
414
Overheat-cut-off fuse
Pipe heater
100074334
100074682
EK333
EK209
415 Inlet heater for Indoor models
Inlet heater for Outdoor models
100074683
100074684
EK210
EK211
416
417
Drain tube
Inlet heater
100074685
100074629
EK231
EK105
418 Secondary heat exchanger for Indoor models
Secondary heat exchanger for Outdoor models
100074700
100074701
EK251
EK256
450
451
452
453
Pipe heater fixing plate
Heater fixing plate 16
Fuse fixing plate 18
Fuse fixing plate 14
100074703
100074310
100074251
100074331
EKK27
EK031
EKK26
EK029
454
455
456
457
O-ring P4 FKM
O-ring P6 FKM
O-ring P14 FKM
O-ring P15 FKM
100076303
100076305
100076306
100076307
EZF04
EZF06
EZF14
EZF15
458
459
460
461
O-ring P16 FKM
Fastener “4-11”
Fastener “14-22”
Fastener “16A”
100076308
100074282
100074290
100074410
EZF16
EKH30
EKK24
EM192
63 Page
Parts List
Owner's Guide
Item # Description
Part #
240, 340 and
540 models
T-H3J, T-H3S and
T-H3 models
462
463
464
465
Fastener “16-25A”
Fastener “6-15”
Flat heater
Drain tube
100074389
100074297
100074686
100074687
EKK39
EX12K
EK217
EK218
466 Cold pipe for 240 and 340 models
for 540 model
100074688
100074689
EK219
EK220
467
468
469
470
Stainless heat exchanger out pipe
Header connection
Drain port
Thermistor fixing plate
100074690
100074691
100074692
100074291
EK222
EK226
EK228
EX13H
471
472
473
Exhaust thermistor gasket
Hi-limit switch for exhaust
Gasket
100074296
100074289
100074693
EX13L
EKH6G
EK229
701 Computer board for 240 model
for 340 model
for 540 model
100074694
100074695
100074696
EK186
EK175
EK176
702
703
704
Rubber grommet
Surge box
120 VAC wire for Indoor models
for Outdoor models
100076470
100076100
100074601
100074697
EX00B
EK280
EK146
EK143
706
707
708
120 VAC Power ON-OFF switch
Remote controller wire for 240 and 340 models
for 540 model
Gas valve wire
100074326
100074649
100074650
100074651
EKK4V
EK189
EK165
EK168
709
711
Flame rod wire
Igniter assembly
100074652
100074640
EK166
EK153
713 Switch wire with thermostat for Indoor models
for Outdoor models
100074655
100074656
EK184
EK185
714
715
716
717
Proportional gas valve wire
24V cables for 540 model
Computer board cover
Cable clamp for Indoor models
100074657
100074658
100074375
N/A
EK167
EK179
EKK1M
EX13C
718
719
721
722
723
Exhaust thermistor for Indoor models
Remote fixing plate for 540 model
Exhaust Hi-limit switch wire
Temperature controller for Indoor models
Fixing plate
100074316
100074644
100074659
100074660
100074661
EKH6E
EK152
EK180
EK173
EK178
724 Temperature remote controller 100209924 TM-RE42
64 Page
OUTPUT TEMPERATURE CHART
Chart is based on properly sized gas line
Output Temperature Chart
Owner's Guide
When the set temperature is 130 °F (55 °C) or higher, maximum flow rate
is limited to 8.0 GPM (30.3 l/m).
240 model
340 model
540 model
68A161-7
2000534710 (REV. C)
100
(38)
105
(40)
110
(43)
115
(45)
120
(50)
125
(52)
130
(55)
135
(57)
140
(60)
40°F (4°C)
5.1 4.7 4.3 4.1 3.8 3.6 3.4 3.2 3.0
50°F（10°C)
6.1 5.5 5.1 4.7 4.3 4.1 3.8 3.6 3.4
60°F（16°C)
6.6 6.6 6.1 5.5 5.1 4.7 4.3 4.1 3.8
70°F（21°C)
6.6 6.6 6.6 6.6 6.1 5.5 5.1 4.7 4.3
0.0
2.0
4.0
6.0
8.0
40°F (4°C) 50°F（10°C) 60°F（16°C) 70°F（21°C)
30
15
0
Output Hot Water GPM
Set temp.°F(°C)
Incoming temp.
(L/M)
(19.2)
(23.0)
(25.0)
(25.0)
(17.7)
(20.9)
(25.0)
(25.0)
(16.4)
(19.2)
(23.0)
(25.0)
(15.3)
(17.7)
(20.9)
(25.0)
(14.4)
(16.4)
(19.2)
(23.0)
(13.5)
(15.3)
(17.7)
(20.9)
(12.8)
(14.4)
(16.4)
(19.2)
(12.1)
(13.5)
(15.3)
(17.7)
(11.5)
(12.8)
(14.4)
(16.4)
100
(38)
105
(40)
110
(43)
115
(45)
120
(50)
125
(52)
130
(55)
135
(57)
140
(60)
40°F（4°C)
5.7 5.3 4.9 4.6 4.3 4.0 3.8 3.6 3.4
50°F（10°C)
6.8 6.2 5.7 5.3 4.9 4.6 4.3 4.0 3.8
60°F（16°C）
8.0 7.6 6.8 6.2 5.7 5.3 4.9 4.6 4.3
70°（21°C)
8.0 8.0 8.0 7.6 6.8 6.2 5.7 5.3 4.9
0.0
2.0
4.0
6.0
8.0
10.0
40°F（4°C) 50°F（10°C) 60°F（16°C） 70°（21°C)
Output Hot Water GPM
Set temp.°F(°C)
Incoming temp.
30
15
0
(L/M)
(21.6)
(30.3)
(30.3)
(25.9)
(19.9)
(30.3)
(28.8)
(23.5)
(18.5)
(30.3)
(25.9)
(21.6)
(17.3)
(28.8)
(23.5)
(19.9)
(16.2)
(25.9)
(21.6)
(18.5)
(15.2)
(23.5)
(19.9)
(17.3)
(14.4)
(21.6)
(18.5)
(16.2)
(13.6)
(19.9)
(17.3)
(15.2)
(12.9)
(18.5)
(16.2)
(14.4)
100
(38)
105
(40)
110
(43)
115
(45)
120
(50)
125
(52)
130
(55)
135
(57)
140
(60)
150
(65)
160
(70)
40°F（4°C)
6.3 5.8 5.4 5.0 4.7 4.4 4.2 4.0 3.8 3.4 3.2
50°F（10°C）
7.6 6.9 6.3 5.8 5.4 5.0 4.7 4.4 4.2 3.8 3.4
60°F（16°C)
9.5 8.4 7.6 6.9 6.3 5.8 5.4 5.0 4.7 4.2 3.8
70°F（21°C)
10.0 10.0 9.5 8.4 7.6 6.9 6.3 5.8 5.4 4.7 4.2
0.0
2.0
4.0
6.0
8.0
10.0
12.0
40°F（4°C) 50°F（10°C） 60°F（16°C) 70°F（21°C)
45
30
15
0
(L/M)
Output Hot Water GPM
Set temp.°F(°C)
Incoming temp.
(23.9)
(28.6)
(35.8)
(37.9)
(22.0)
(26.0)
(31.8)
(37.9)
(20.4)
(23.9)
(28.6)
(35.8)
(19.1)
(22.0)
(26.0)
(31.8)
(17.9)
(20.4)
(23.9)
(28.6)
(16.8)
(19.1)
(22.0)
(26.0)
(15.9)
(17.9)
(20.4)
(23.9)
(15.1)
(16.8)
(19.1)
(22.0)
(14.3)
(15.9)
(17.9)
(22.4)
(13.0)
(14.3)
(15.9)
(17.9)
(11.9)
(13.0)
(14.3)
(15.9)
Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water temperature
Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water temperature
Output Temperature vs. GPM (Max. 10.0 GPM) with Various Inlet Water temperature
