INTELLIHOT I250 GENII (01) PDF MANUAL

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

If the information in the instructions is not followed exactly, a fire or explosion could result causing property damage, personal injury, or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

To avoid product damage, personal injury, or even possible death, carefully read, understand, and follow all the instructions in this Operation and Installation Manual before installing this product. Improper installation, adjustment, alteration, or maintenance can cause injury, loss of life, and/or property damage. This water heater should be installed and serviced by a qualified technician. The lack of proper service can result in a dangerous condition.

The following items are shipped with the water heater:

• Operation & Installation Manual

• Wall Mounting Bracket

• Condensate Drain (see Warning)

• Communication Cable

• Pressure Relief Valve (must be installed)

The condensate drain line is shipped from the factory with a loop held together with plastic ties. Do not remove the ties and/or straighten the loop. This loop forms an air block (trap) which prevents carbon monoxide from exiting the water heater through the drain line. Improper installation of the drain line can result in excessive levels of carbon monoxide, which can lead to severe personal injury or death.

• DO NOT use this water heater for any purpose other than water heating.

• Read, understand, and follow the Installation and Operation Manual, including all warnings and precautions, before operating this water heater. If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury, or loss of life.

• Follow all local codes and the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the USA or the Natural Gas and Propane Installation Code in Canada (CSA B149.1).

• This water heater must be installed by a licensed plumber, gas fitter, and/or professional service technician. Installation by unqualified person(s) voids the warranty.

• DO NOT use or store flammable liquids around the water heater, including gasoline, oils, spray paints, etc.

• DO NOT operate this water heater unless it is properly vented to the outside (the exhaust vent piping must be connected from the unit directly to the outside). Improper venting can cause a build-up of carbon monoxide, which can result in brain damage or death. Exhaust gases must be completely expelled out of the building.

• This water heater is factory preset for NATURAL GAS but may be field converted for use with propane. For propane conversion, refer to the Propane (LPG) Conversion section of this manual. Connecting the water heater to any other gas supply can result in property damage, serious injury, or even death.

• This water heater is suitable for use in potable water heating applications. The cold and hot water fittings on the top of the water heater MUST NOT be connected to any heating system.

• The water heater temperature is factory set to 120°F (49°C). Hot water temperatures above 125°F can cause severe burns instantly or death from scalds. If the proposed water heater outlet temperature is to be set above 125°F, installation of a thermostatically controlled (or temperature limiting) mixing valve is recommended for all hot water going to faucets to avoid the risk of scalding. Examples include commercial applications where 140°F (60°C) is often needed or if the space heating temperature required is higher than the domestic hot water. Always check the temperature of the hot water before bathing, showering, washing, etc.

• Protect against snow and debris accumulation around the vent terminations. Regularly inspect the exhaust vent pipe and the air intake pipe to ensure they remain clear from obstructions at all times.

Make sure you know the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the water heater is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the water heater checked by a qualified technician before resuming operation.

• DO NOT use this appliance if any part has been under water.

• DO NOT reverse the cold water and gas connections as this will damage the gas valve.

• DO NOT over-tighten fittings as damage may occur, causing internal leakage.

• The appliance should be located in an area where leakage within the unit or at its connections will not result in damage to the surrounding area. The manufacturer will not be responsible for any damage resulting from leaking if adequate drainage is not provided.

Note: Due to continuous product improvements, the design and technical specifications are subject to change without notice.

For operation at elevations above 2,000 feet, the hot water delivery output should be reduced by 4% for each 1,000 feet above sea level.

¹ Service clearances are suggested to allow for normal service.

² Mounting bracket automatically sets this distance.

¹ Using sizes other than specified can cause damage to the water heater and will void the warranty.

1. Select an interior location for the installation. Each installation is unique; therefore, take the time to find the best location for the water heater.

a. Install the water heater near locations that use hot water, such as bathroom, kitchen, or laundry room faucets.

b. Select a location that minimizes the length of the water pipe.

c. If the distances are long or if the faucet or appliance requires “instant” hot water, we recommend running a recirculation pipe back to the water heater from the farthest fixture.

d. Insulate the hot water supply and recirculation pipes.

e. Select a location away from foot traffic and away from areas where dust, debris, chemical agents, or other combustible materials could accumulate.

f. Allow sufficient space for service and maintenance access to all gas, water, and drain connections. Refer to “3.3 Clearance Requirements”.

g. Make sure the location meets all building code requirements.

2. Minimize the distance that the exhaust gas outlet and air intake inlet must travel to an exterior wall.

a. The exhaust gas outlet must not be located next to a walkway, near soffit vents, crawl space vents, or other areas where condensate (water vapor) could cause damage or create a hazard. Refer to “7.7 Venting Clearance Specifications” for additional information.

b. The air intake inlet vent must be separated from the exhaust gas outlet per guidelines in section “7. Air Intake Inlet and Exhaust Gas Outlet Pipe Connections”.

c. Contaminated or dirty air drawn into the intake pipe can damage the water heater. The warranty does not cover damage caused by airborne contaminants.

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

4. Locate the water heater and all the water pipes in an area where the ambient temperature always remains above freezing.

a. When the water heater is connected to an electrical power supply, it will automatically prevent the water from freezing inside the unit.

b. The unit’s freeze protection system will not prevent the water in the surrounding pipes from freezing.

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

6. Check the water quality.

a. Proper operation of the water heater requires that the water meets EPA quality standards. The table in section “18. Warranty” shows the maximum contaminant levels allowed, based on the EPA National Secondary Drinking Water Regulations (40 CFR Part 143.3).

b. If contaminated water is suspected, discontinue use of the water heater and contact an authorized technician or licensed professional.

c. If the incoming water is known to have a high mineral content or “hardness” (see “18. Warranty”), treatment is recommended upstream from the water heater.

In cold climates, if there is a power failure, the unit’s freeze protection system will not operate and can result in water freezing inside the heat engine. To prevent damage to the water heater, turn OFF the gas supply and inlet water valve. Drain the unit completely as per “14.2 Draining the Water Heater”. Damage caused by freezing water is not covered by the warranty.

1. Select a location for the installation.

a. Install the water heater near locations that use hot water, such as bathroom, kitchen, or laundry room faucets.

b. Select a location that minimizes the length of the water pipe.

c. If the distances are long or if the faucet or appliance requires “instant” hot water, we recommend running a recirculation pipe back to the water heater from the farthest fixture.

d. Insulate the hot and cold water supply and recirculation pipes to prevent freezing or burns due to hot surfaces.

e. Select a location away from foot traffic and away from areas where dust, debris, chemical agents, or other combustible materials could accumulate.

f. Allow sufficient space for service and maintenance access to all gas, water, and drain connections. Refer to “3.3 Clearance Requirements”.

g. Make sure the location meets all building code requirements.

h. Contaminated or dirty air drawn into the intake pipe can damage the water heater. The warranty does not cover damage caused by airborne contaminants.

i. Ensure that the air intake is free (and remains free) from grass clippings, wood chips, landscaping, and other debris. The exhaust gas outlet must be above the minimum code height of the defined snow line for the surrounding area.

j. Install Intellihot outdoor kit IGT-SPR0063. For installation instructions and details, see manual IGT-MNL0019.

2. Locate the unit close to a drain and near gas and water connections. The water heater produces a significant amount of condensate during normal operation and should be located near a suitable drain where damage from a possible leak will be minimal. If installing on a roof, installing the water heater in a location, without a drain, will void the warranty and the manufacturer will not be responsible for any resulting water damages that may occur. For additional information, refer to “8.4 Condensate Drain Line”.

3. Locate the water heater and all the water pipes in an area where they can be properly insulated.

a. When the water heater is connected to an electrical power supply, it will automatically prevent the water from freezing inside the unit.

b. The unit’s freeze protection system will not prevent the water in surrounding pipes from freezing.

All water heaters come with an upper mounting bracket with predrilled holes spaced on 16 inch centers to facilitate easy installation on standard wall studs. If the strength of the wall is insufficient or if the framing is nonstandard or uneven, reinforce the area using a sheet of plywood before installing the water heater. Avoid installation on inside walls that can transmit operational noises to occupants while the unit is operating.

To mount the water heater to the wall:

1. Place the upper mounting bracket on the wall and ensure that it is level. Use two appropriately sized wood screws to mount the bracket securely to the studs. Ensure that it is affixed securely and can support the weight of the 90 pound unit.

2. With assistance, hang the unit’s interlocking bracket (1) onto wall bracket (2).

3. Loosen the four mounting screws in the lower bracket, and slide it against the wall to create a 5/8″ air space.

4. Retighten the four mounting screws and install two appropriately sized wood screws in lower bracket (3) to secure the unit to the wall.

5. Make sure the unit is plumb and level, and tighten the four sheet metal screws on bottom bracket (3). When properly installed, there should be a 5/8″ air space between the back of the water heater and the wall.

SAFETY INSTRUCTIONS: Only the brackets included with the water heater should be used to mount the unit. Water heaters weigh approximately 93 lbs. and must be securely attached to the wall.

CAUTION: According to the National Institute for Occupational Safety and Health, the recommended maximum safe lifting weight is 51 lbs., with all lifting conditions perfect; minimal forward reach, steady load close to the body, straight back, load between knees and shoulders, and good grips. To avoid personal injury, always use these proper lifting techniques and use two people to move the water heater, which weighs 90 lbs.

1. Determine fuel source; natural gas or propane.

2. Measure gas pressure.

3. Install a gas pressure regulator and vent pipe if gas pressure is above maximum recommendations.

4. Measure the length of the supply pipe.

5. Select the proper gas piping material.

6. Select the proper gas piping diameter.

7. Install a drip leg on the gas pipe.

8. Install a manual shut-off valve.

9. Test all gas pipe connections for leaks.

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

i200/250 series water heaters are designed to operate at gas pressures as low as 2.5” W.C. (at maximum firing rate). Gas inlet pressures to the unit should not exceed 14″ W.C. under any condition (when unit is firing or not firing).

1. If the gas inlet pressure is higher than recommended, install a gas pressure regulator to lower gas pressure to an acceptable level.

2. The gas pressure regulator must have the same or higher minimum to maximum modulation range as the i200/i250 model it is regulating. For example, an i200/1250 gas pressure regulator should have a modulation range of 30,000 BTU/h to 199,950/250,000 BTU/h.

3. When multiple units are connected, use a dedicated gas pressure regulator for each unit.

4. Regulators should be mounted with a minimum of 12″ of straight length pipe on either side.

Make sure the gas supply regulator is properly vented by following all local codes and the gas regulator manufacturer’s recommendations.

1. The vent pipe must be at least the same size as the regulator vent.

2. When multiple units are connected, each regulator must have a separate vent pipe.

3. Vent pipes must not be connected together or connected with any other appliance requiring external venting.

4. When selecting the size, the pipe diameter must be increased by one size for every 20 feet of pipe.

a. Each 90° elbow is equivalent to approximately: 4.5 feet for nominal pipe sizes of up to 1-1/2”; 10.5 feet for nominal pipe sizes of up to 4″.

b. Each 45° elbow is equivalent to approximately: 2 feet for nominal pipe sizes of up to 1-1/2”; 5 feet for nominal pipe sizes of up to 4″.

Length of Gas Supply Pipe:

1. Make sure the length of the supply pipe does not exceed the maximum recommended length as per “6.9 Gas Pipe Sizing Tables”.

a. Measure the straight length of the gas supply pipe from the gas meter to the water heater or other appliances requiring gas. Include the additional length for any elbows into the calculation. The diameter of the pipe must be in relation to the length.

b. The total straight length of gas pipe, as well as the additional length for any elbows, must be considered when sizing the gas pipe. Total equivalent length should be calculated from the meter or source location to the last connected water heater.

c. Gas pipe size should be selected on the total equivalent length. The gas volume for cubic feet per hour (CFH) flow will be the input divided by the calorific value of the fuel to be supplied.

d. Use “6.9 Gas Pipe Sizing Tables” or refer to the gas pipe manufacturers sizing information to determine the correct diameter for the supply pipe.

e. The diameter of the gas pipe will vary according to the specific installation requirements.

Gas Piping Material:

1. All gas pipe and components must comply with NFPA local codes and utility requirements minimum. Only gas approved fittings, valves, or pipe should be used.

2. Standard industry practice for gas pipe is Schedule 40 iron pipe and fittings. All high and low gas pressure piping systems must comply with local utility and building codes.

3. Assembled pipe should be clean of all scale, debris, metal particles, or foreign material.

4. The piping must be supported from the floor, ceiling, or walls and not by the water heater itself.

Note: The water heater should be the first appliance to be connected to the gas supply pipe.

1. Determine the gas requirement of the water heater(s) and other appliances requiring gas.

2. Size the pipe diameter according to the COMBINED total maximum BTUH volume for all the appliances as if they were all operating at the same time. Use “6.9 Gas Pipe Sizing Tables”.

3. Select the proper header pipe according to the number of units being connected together, as shown in the chart.

4. The maximum pressure drop from the source to the final water heater must not exceed 0.3″ W.C.

5. The maximum gas flow rate required is the sum of the maximum inputs of each unit divided by the heat of combustion of the fuel supplied at the location, (approximately 1,030 BTU per cubic foot for natural gas or 2,520 BTU per cubic foot for propane).

Note: The fuel supplier or utility should be consulted to confirm that sufficient volume and normal pressure is provided to the building at the discharge side of the gas meter or supply pipe.

1. Install a shut-off valve. Local codes may require multiple units to have a shut-off valve on the main gas supply pipe and one on each unit.

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

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

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

c. The gas pipe must not be supported by the water heater or the drip leg.

3. If an excess flow valve (EFV) is installed in the gas pipe, check the manufacturer’s minimum and maximum flow capacity rating. An improperly sized EFV will not allow the full flow of gas to the water heater and will cause the unit to malfunction.

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

5. Test all gas pipe connections.

a. All the gas pipe connections should be tested as prescribed in NFPA 54.

b. In multiple unit applications, each unit should be isolated before testing any piping system that may exceed the allowable pressure of 14.0″ W.C.

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

Note: BTU/h capacities are based on specific gravity of 0.6, pressure drop of 0.5″ W.C.

Note: For 1/2″ pipe BTU/h capacities are based on specific gravity of 0.6, pressure drop of 4.6″ W.C. For all other pipe sizes, capacities are based on specific gravity of 0.6, pressure drop of 3.0″ W.C.

Note: The pipe BTU/h capacities are based on specific gravity of 1.5, pressure drop of 0.5″ W.C.

1. Select the desired type of venting system: Two Pipe Vent System (Direct) or Single Pipe Vent System (Power).

2. Select the desired termination of the air intake inlet and exhaust gas outlet pipe; outside wall or roof.

3. Determine the straight pipe distance and the number of elbows required to route the air intake inlet and exhaust gas outlet pipes to their termination point.

4. Determine the diameter of pipe required to properly bring in intake air and vent exhaust gas.

5. Verify the location of the air intake inlet and exhaust gas outlet terminations are within state and local codes.

6. Select an approved material for the air intake inlet pipe.

7. Select an approved material for the exhaust gas outlet pipe.

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

WARNING: BREATHING HAZARD CARBON MONOXIDE GAS

• Do not operate flood damaged water heaters.

• Install venting system according to the required codes and material manufacturers specifications.

• Do not obstruct fresh air intakes or exhaust outlets. Adequately support all vent system piping.

• Do not place vapor emitting products near water heater or air intake.

• Place working carbon monoxide detectors outside each sleeping area.

• Do not operate the water heater before properly installing the exhaust outlet.

• Visually inspect the vent system and eliminate any possible area where condensation could create a blockage of intake or exhaust air.

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

1. Select one of the two venting configurations: two pipes (direct vent) configuration or with one pipe (power vent) configuration.

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

3. Select the desired material for the air intake inlet and exhaust gas outlet pipes.

CAUTION: This water heater has a factory preset control to limit the exhaust gas temperature to 149°F (65°C) when PVC is selected in the “Flue Type” programming section. As a result, the water heater can be vented with Schedule 40 PVC. If the incoming (or recirculation return) water temperature does not exceed 150°F (66°C), the exhaust gas temperature will not exceed 149°F (65°C).

WARNING: When the unit is set for CPVC (polypropylene pipe), flue temperatures can reach 190°F (88°C). PVC pipe will melt at temperatures above 149°F (65°C) and could, therefore, result in a fire. Make sure the setting and the type of material (“7.8 Exhaust Gas Outlet Pipe Materials”) being used for the flue are compatible. For this application use Schedule 80 CPVC or Approved Polypropylene in the USA or Type BH Special Gas Vent Class IIB (CPCV) or Class IC (Polypropylene) that conforms to ULC-S636 in Canada. Also refer to “7.8 Exhaust Gas Outlet Pipe Materials”.

On multiple unit installations, the air intake inlet and exhaust gas outlet pipe from each water heater must be connected into the properly-sized common piping. Use the table in “7.6 Intake Air Inlet and Exhaust Gas Outlet Pipe Diameter and Length” to determine the diameter of the common connecting piping between each individual water heater.

4. Determine the length and corresponding diameter for the air inlet pipe and route the pipe to the desired termination location.

a. For termination of the pipe to the outside, continue installing the required pipe to a suitable outside location. Glue all connections, making sure the joints are sealed airtight.

b. Install suitable pipe support hangers every four to five feet, or as local building codes require.

5. Determine the length and corresponding diameter for the exhaust gas outlet pipe and route it to a suitable outside location.

a. Glue all connections, making sure the joints are sealed airtight.

b. Install all horizontal exhaust gas outlet pipe with a minimum two degree (1/4″ per foot) slope back toward the water heater. This allows any condensate that accumulates in the exhaust gas outlet pipe to properly drain back into the unit.

c. Install suitable pipe support hangers every four to five feet, or as local building codes require.

SAFETY INSTRUCTIONS: Do not connect any other appliance vents to the water heater inlet or outlet pipes.

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

1. Terminate the air intake inlet pipe with a 90° elbow (angled down). Use a flange and PVC screen (not supplied).

2. Terminate the exhaust gas outlet pipe on the exterior wall at least 12″ above ground and at least 18″ away from the air intake inlet pipe, or as required by local building codes. In areas of high snow fall, protect the vent terminations from blockage. Use a flange and PVC guard to seal the opening against weather infiltration. (A separation of 18″ – 36″ is recommended, otherwise use 72″ or greater).

For multiple units, the separation distance requirements are:

• 0 – 17.9″: Not allowed
• 18″ – 36″: Allowed
• 36.1″ – 71.9″: Not allowed
• 72″ or greater: Allowed

3. To avoid moisture and frost build-up to openings on adjacent homes, use 45° elbows, 90° elbows, or tees for the vent termination to direct the exhaust gas fumes away from the building.

Venting the unit through the roof is also an option. With this installation method, the terminations must extend at least 12″ over maximum potential snow levels, or as required by local building codes. In areas of high snow fall, protect the vent terminations from blockage.

Terminate the air intake inlet pipe with two 90° elbows (angled down). A suitable roof flashing and vent cap (not supplied) should be installed.

The exhaust termination must be 12″ USA or 18″ Canada over maximum snow level or as required by local code, and 12″ Minimum from the air intake.

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

If desired, an optional concentric venting system, which uses one 5″ opening through an exterior wall or roof, can be used, as opposed to cutting two 3” openings.

To avoid moisture and frost build-up to openings on adjacent homes, use a 45° elbow, a 90° elbow, or a tee for the vent termination to direct the exhaust gas fumes away from the building.

Follow all installation instructions included with the concentric vent kit when installing this type of vent system.

For side wall termination, the exhaust should be 1″ from the wall and 12″ above the highest anticipated snow level or grade.

For roof termination, the exhaust should be 12″ USA or 18″ Canada over maximum snow level or as required by local code.

In order to conform to some national codes, when two or more water heaters are installed they must be individually vented. When two or more units are vented near each other, each vent termination must be installed, as shown, to avoid recirculation of flue gases. A minimum distance of 18 inches must be maintained between each vent termination.

Follow all installation instructions included with the concentric vent kit when installing this type of vent system.

Intake air should have 1″ maximum (TYP) clearance from the wall. Exhaust should be a minimum of 12″ to maximum expected snow level.

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

To avoid moisture and frost build-up to openings on adjacent homes, use a 45° elbow, a 90° elbow, or a tee for the vent termination to direct the exhaust gas fumes away from the building.

When using the single exhaust gas outlet pipe or power vent method, the following table outlines the required opening sizes for the intake air coming into the room and the required CFM requirements per water heater.

*Where two openings are used, one must be within 12″ of the floor and the other opening must be within 12″ of the ceiling.

**Where one opening is used, it must be located within 12″ of the ceiling.

SAFETY INSTRUCTIONS: Do not operate the unit in an area that will draw in outside air contaminated with high levels of dust, sawdust, aerosols, such as paint, or other airborne contaminants. If necessary, purchase and install appropriate air filters and follow a regular cleaning program to ensure an adequate supply of clean, outside intake air.

Note: Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.

Note: Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.

Note: Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.

Note: Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.

1 pipe – Only exhaust out pipe is connected and the combustion air intake is from within the room. For example, one i200 with a 3″ diameter, the maximum exhaust pipe length for 1 pipe is 200 feet.

2 pipes – Both the Combustion air intake and the exhaust pipe are connected. In this case, the table specifies the maximum length per pipe. For example, one i200 with 3″ diameter, 100 feet maximum is allowed for combustion air intake pipe and exhaust out pipe. The 100 feet maximum is per pipe.

Note:

1. Reduce the maximum equivalent length above by 5 feet per 90° elbow used and by 2 feet per 45° elbow used. Do not exceed the above set limits.

2. If multiple units are common vented, then the units must be cascaded. Please refer to the combustion section for how to do combustion with common vented units.

*Per local/gas supplier codes. Use clearances in accordance with local building codes and local gas supplier.

** For single vent pipe (power vent) allow four feet (1.2 m) below or to the side of opening and one foot above opening.

¹ In accordance with Z223.1

² In accordance with CSA B149.1

Note: The vent for this appliance shall not terminate:

• Over public walkways; or

• 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

• Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

SAFETY INSTRUCTIONS (Canadian installations): For Canadian installations, plastic exhaust gas outlet piping must comply with CAN/CGA B149.1 and be certified to the Standard For Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products.

All units come factory installed with 3 inch polypropylene (PP) venting. The maximum allowable venting distances are the same regardless of vent material selected.

*Note: Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel (PPSU – polyphenylsulfone) in nonmetallic venting systems is prohibited. Covering nonmetallic vent pipe and fittings with thermal insulation is prohibited.

**Note: The components (pipe, fittings, primers, and glues) must be from a single manufacturer; do not interchange. Follow the pipe manufacturer’s certified instructions.

SAFETY INSTRUCTIONS: Do not use cellular foam core pipe to vent exhaust gases.

This water heater has a built-in exhaust gas outlet temperature control that limits the exhaust gas temperature to a maximum of 149°F (65°C) for PVC pipe. In commercial applications, which require higher water temperatures, exhaust gas temperature can reach 190°F (88°C) and require materials, such as polypropylene (PP), stainless steel (SS), or CPVC.

If the temperature approaches the upper limit, the burner will turn off automatically to protect the vent pipe. Once the exhaust gas temperature has dropped to a normal operating level, the unit will automatically restart.

If the inlet/return water temperature will exceed 150°F (66°C), do not use PVC pipe. Follow the display prompts to set the maximum water temperature for the exhaust gas outlet pipe material being used (e.g., “Are you sure you would like to change exhaust material? In this setting exhaust temp can reach 190 °F. Ensure suitable vent materials are used.” YES/NO).

The air intake inlet pipe can be made of any approved plastic or metal vent material. ABS, PVC, polypropylene, galvanized steel, and/or flexible corrugated ducting are all examples. When using a corrugated material, ensure there is no inadvertent crimping or blockage to the air intake inlet pipe.

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

• Do not use 90 degree t-fitting for exhaust gas outlet.

• Do not use 90 degree transition into a reducer or a straight pipe.

• Do not direct exhaust gas from opposite directions. Use a 45 degree transition, as shown (with a minimum 3X diameter straight section before the transition).

• Horizontal transitions should be equipped with a condensate drain (ensure 1/4″ rise per foot run).

• Do not transition into a reducer. Transitions should always be directed into a straight run of pipe.

• Do not use reducers in a straight run of pipe.

Note: If the flow rate changes faster than ten GPM every one second, an error message will appear and a water hammer arrester must be installed to prevent damage to the water heater.

1. Install the hot water pipe and the pressure relief valve as per “8.2 Hot Water Connection”.

NOTICE: When tightening any fittings to the connections on the water heater, care should be exercised not to overtighten these joints and damage the unit.

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

3. Install a condensate drain line with the back flow preventer loop as per “8.4 Condensate Drain Line”.

4. After installation has been completed, fill and test the water heater for proper flow and inspect for leaks as per “14.3 Filling the Water Heater”.

5. Run the hot water for a few minutes and then clean the inlet water strainer located on the cold water inlet fitting as per “14.1 Cleaning the Inlet Water Strainer”. This strainer must be cleaned periodically to maintain proper water flow.

Install and connect the hot water pipes. Keep the hot water pipes as short as possible to deliver hot water to the fixtures quickly. If an optional hot water storage tank is required, connect the hot water pipes to this tank also.

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

1. Connect a 3/4″ NPT coupler to the water heater’s hot water connection.

2. Install a 3/4″ union connection.

3. Install the supplied 3/4″ 150 psi maximum pressure relief valve, as required by your local code.

WARNING: To prevent serious personal injury, do not install any shut-off device between the water heater and the pressure relief valve. This valve is designed to release abnormally high pressure within the water heater in the event of a system problem.

NOTICE: The pressure relief valve must be rated at 150 psi, the maximum btu/h output of the unit (199,950 or 250,000), and comply with all local building codes and standards. Do not install any restrictions or other valves prior to the pressure relief valve.

4. Following local building codes, install a 3/4″ manual shut-off valve with 3/4″ NPT fittings.

5. Install and route a discharge pipe from pressure relief valve to within six inches of the floor and directed away from walkways or other appliances.

a. Route the relief valve to within six inches of the floor to prevent injury in the event of a discharge.

b. The diameter of the pipe from the relief valve must be equal to the outlet size of the relief valve.

c. Do not use reducers in the outlet pipe.

d. Do not install any valves, restrictions, elbows, or other blockages in the outlet pipe.

e. For multiple unit installations, the outlet piping must not be connected together. Each pipe must be separately routed to a suitable drain.

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

7. To conserve energy, insulate all hot water pipes and recirculation pipes.

SAFETY INSTRUCTIONS: Do not insulate the pressure relief valve.

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

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

Install and connect the cold water pipes.

Note 1: If the incoming water is known to have a high mineral content or “hardness”, treatment is recommended upstream from the water heater.

When the water heater is installed in a closed loop recirculation system, and if the cold water supply pipe has a back flow preventer, then an expansion tank should be installed to allow for water expansion.

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

1. Connect a 3/4″ NPT coupler to the water heater’s cold water connection.

2. Install a 3/4″ union connection.

3. Following local building codes, install a 3/4″ manual shut-off valve with 3/4″ NPT fittings.

4. Connect the unit to the existing cold water pipes. If the existing plumbing is 1/2″ pipe, adapters may be used to transition from the 3/4″ pipe.

5. Connect the unit to the building’s cold water pipes. If multiple water heaters are being installed, the diameter of the main cold water pipe needs to be sized by an engineering professional.

Note: Isolation valve kits can be used if incoming water treatment is anticipated (such as a water softener) due to hardness levels or heavy usage of the unit.

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

7. Leak test the water pipes. Repair any leaks immediately.

Due to its efficient design, the water heater produces condensate (water) as a normal by-product of heating the water. This condensate is acidic, with a pH level between 3 and 4. Local building codes may require an in-line neutralizer, to be installed (not included) to treat this water. The maximum condensate flow rate is 1.8 GPH.

1. Attach and tighten the flex hose with the loop to the barb fitting located on the bottom of the unit.

WARNING: The drain line is shipped from the factory with a loop held together with plastic ties. Do not remove the ties and/or straighten the loop. This loop forms an air block (trap) which prevents carbon monoxide from exiting the water heater through the drain line. Improper installation of the drain line can result in carbon monoxide build, which can lead to severe personal injury or death.

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

Note: Ensure that the flex tube is not pinched or kinked. The tube should freely drain. The tube termination should not be immersed in water.

3. Route the drain line to nearby floor drain, neutralizer, or condensate pump.

a. If a floor drain is used to remove the discharge, route the drain hose over or into the drain.

b. Long drain lines should contain a union to facilitate servicing the unit or cleaning the drain line.

4. If a floor drain is not closely available, a condensate pump can be used to pump the condensate to a remote drain.

a. Route the hose from the condensate pump to a nearby floor drain or drain pipe.

b. The condensate pump must be supported by the floor or other means; it cannot be supported by the connecting pipes.

General Information:

The CO2 level must be adjusted by a qualified technician using a combustion analyzer. The CO2 adjustment is performed with the cover removed and the unit in operation. Gas valve adjustments should be made only by qualified service personnel. Use the values on “3.5 Exhaust Gas Standards” for proper CO2 level.

Adjustment Procedure:

1. Remove the front cover from the water heater.

2. Loosen the screw (1) on the gas pressure test port and connect a manometer to measure the gas pressure.

3. Insert the combustion analyzer probe into the exhaust gas test port (2) on the top of the unit.

4. Turn the unit ON. From the “Main Menu”, select “Test Modes”.

5. Select “High Fire” (maximum BTU) and verify that the CO2 reading on the combustion analyzer is correct per “3.5 Exhaust Gas Standards”.

6. Select “Low Fire” (minimum BTU) and verify that the CO2 reading on the combustion analyzer is correct per “3.5 Exhaust Gas Standards”.

7. If the CO2 readings are incorrect, remove the cap (3) from the gas valve offset adjustment port. Use a small flat-blade screwdriver to turn the offset adjustment screw. Turn the screw counter-clockwise to increase CO2 and clockwise to decrease CO2. Make adjustments in small 1/8 turn increments. Wait at least 60 seconds after each adjustment for the combustion analyzer reading to stabilize.

8. If the CO2 is correct at low fire but incorrect at high fire, adjust the throttle screw (4) on the gas valve. Turn the screw counter-clockwise to increase CO2 and clockwise to decrease CO2. Make adjustments in small 1/8 turn increments. Wait at least 60 seconds after each adjustment for the combustion analyzer reading to stabilize.

9. If adjustments are made, recheck CO2 readings at both high and low fire rates and make further adjustments, if necessary. Verify that the gas pressure readings are within the recommended values.

10. Turn the unit OFF. Remove the combustion analyzer probe and manometer.

11. Tighten the screw on the gas pressure test port and replace the cap on the gas valve offset adjustment port.

12. Replace the front cover.

General Information:

The water heater is factory set for natural gas but can be converted to propane (LPG) using the LP Conversion Kit (P/N: IGT-ACC0020). The conversion must be performed by a qualified service technician. Failure to use the correct conversion kit or failure to properly convert the unit can cause dangerous operating conditions, property damage, serious injury, or death. After conversion, verify proper operation by following the steps in “10. Adjusting CO2 Level”.

Conversion Procedure:

1. Turn OFF the electrical power to the water heater.

2. Turn OFF the gas supply at the manual gas shut-off valve.

3. Remove the front cover from the water heater.

4. Remove the six screws securing the burner cover plate (1) and remove the plate.

5. Remove the two screws (2) securing the burner (3) and remove the burner from the heat exchanger.

6. Remove the six screws (4) securing the orifice plate (5) and remove the plate from the gas valve.

7. Replace the orifice plate (5) with the LP orifice plate from the conversion kit. Make sure the gasket is properly seated.

8. Reinstall the burner (3) and secure it with the two screws (2).

9. Reinstall the burner cover plate (1) and secure it with the six screws.

10. On the control panel, navigate to “Settings” > “More” > “Gas Type”. Select “LP”.

11. Replace the front cover.

12. Turn ON the gas supply and electrical power.

13. Check all connections for leaks using a gas leak detector or soap solution.

14. Adjust the CO2 levels by following the steps in “10. Adjusting CO2 Level”.

15. Place the LP conversion label from the kit next to the rating plate on the side of the unit.

1. Ensure the unit is connected to a power source.

2. The display will show “Intellihot” then the “Main Menu”.

3. To turn the unit ON, press “Unit ON/OFF” so it displays “Unit ON”.

4. To turn the unit OFF, press “Unit ON/OFF” so it displays “Unit OFF”.

1. From the “Main Menu”, select “Settings”.

2. Select “Time”.

3. Use the “+” or “-” buttons to adjust the hours and minutes. Select “AM” or “PM”.

4. Select “Save” to save the settings.

1. From the “Main Menu”, select “Settings”.

2. Select “Temperature”.

3. Use the “+” or “-” buttons to adjust the temperature to the desired setting (factory default is 120°F).

4. Select “Save” to save the settings.

WARNING: Water temperatures above 125°F can cause severe burns instantly or death from scalds. Before changing the temperature setting, read the warning on page 6 of the manual.

1. From the “Main Menu”, select “Settings”.

2. Select “More”.

3. Select “Security”.

4. Select “Set Passcode”.

5. Enter a four-digit passcode using the number pad and select “Enter”.

6. Re-enter the passcode to confirm and select “Enter”.

7. Select “Save” to save the settings.

Once set, the passcode will be required to access the “Settings” menu.

1. From the passcode entry screen, select “Forgot Passcode”.

2. A temporary passcode will be displayed. Use this passcode to access the “Settings” menu.

3. It is recommended to set a new passcode immediately.

The Life Screen provides a quick overview of the water heater’s status. To access it, select “Life” from the “Main Menu”. It displays:

• Unit Status (e.g., Standby, Heating)

• Current Set Temperature

• Inlet Water Temperature

• Outlet Water Temperature

• Water Flow Rate (GPM)

From the “Main Menu”, select “Unit Info”. This screen displays:

• Model Number

• Serial Number

• Software Version

• Burner Cycles

• Hours of Operation

1. From the “Main Menu”, select “Settings”.

2. Select “More”.

3. Select “Error History”.

This screen will display a list of past error codes, with the most recent errors at the top. This information can be helpful for troubleshooting.

General Information:

Up to ten i200/i250 units can be connected (cascaded) together. The units communicate with each other to optimize performance and efficiency. No master unit is required.

Installation Procedure:

1. Install each water heater according to the single unit installation instructions.

2. Connect the supplied communication cables between the units. Each unit has two communication ports (Com 1 and Com 2). Connect a cable from Com 2 of the first unit to Com 1 of the second unit, Com 2 of the second unit to Com 1 of the third unit, and so on. The Com 1 port of the first unit and the Com 2 port of the last unit will remain open.

3. Turn ON the power to all units.

4. On the control panel of one unit, navigate to “Settings” > “More” > “Cascade Setup”.

5. The screen will display the number of detected units. Verify this matches the number of installed units.

6. If the number is incorrect, check the communication cable connections and try again.

7. Once the correct number of units is displayed, select “Save”. The settings will be automatically applied to all connected units.

Note: When units are cascaded, temperature and other settings can be adjusted from any unit, and the changes will apply to all units in the system.

The inlet water strainer should be cleaned periodically to maintain proper water flow. The frequency of cleaning depends on water quality.

1. Turn OFF the electrical power to the water heater.

2. Turn OFF the cold water supply at the shut-off valve.

3. Open a hot water faucet to relieve pressure in the system.

4. Place a bucket under the cold water inlet to catch any water.

5. Unscrew the plug (1) on the cold water inlet fitting. The strainer (2) is attached to the plug.

6. Remove the strainer from the plug and clean it with water and a soft brush. Do not use harsh chemicals or abrasive materials.

7. Inspect the O-ring (3) on the plug for damage and replace if necessary.

8. Reinstall the strainer onto the plug.

9. Screw the plug back into the inlet fitting and tighten securely.

10. Turn ON the cold water supply and check for leaks.

11. Close the hot water faucet and turn ON the electrical power.

Draining the water heater may be necessary for service, extended periods of non-use in freezing conditions (if power is off), or relocation.

1. Turn OFF the electrical power to the water heater.

2. Turn OFF the gas supply at the manual gas shut-off valve.

3. Turn OFF the cold water supply at the shut-off valve.

4. Open a hot water faucet to allow air into the system and facilitate draining.

5. Connect a hose to the drain valve (if equipped, typically part of service valve kit) or carefully disconnect the lowest point of the water piping. If using the condensate drain port for complete draining, be aware it is acidic water initially.

6. Allow the unit to drain completely. This may take several minutes.

7. Once drained, disconnect the hose (if used) and close the drain valve or reconnect piping.

8. Close the hot water faucet.

NOTICE: If the unit is being drained to prevent freezing due to a power outage, ensure all water is removed. Damage caused by freezing is not covered by warranty.

Filling the water heater is necessary after installation, draining, or servicing.

1. Ensure all gas, water, and vent connections are secure.

2. Ensure the drain valve (if applicable) is closed.

3. Turn ON the cold water supply at the shut-off valve.

4. Open the nearest hot water faucet to allow air to escape from the system.

5. Allow water to flow until all air is purged from the system and water flows steadily from the hot water faucet.

6. Close the hot water faucet.

7. Check all water connections for leaks and repair if necessary.

8. Once the unit is filled and leak-free, electrical power and gas supply can be turned ON.

NOTICE: Do not operate (fire) the water heater until the heat engine is completely filled with water. Operating the unit without water can cause severe damage.

For installations in the State of Massachusetts, the following requirements must be met:

1. Installation must be performed by a licensed plumber or gas fitter.

2. A CO detector must be installed in the same room as the appliance if the unit is installed in a bedroom or bathroom.

3. The vent system must comply with all Massachusetts codes.

4. The unit must be installed in accordance with 248 CMR: Board of State Examiners of Plumbers and Gas Fitters.

Refer to section 17.1 of the manual for specific notice details that must be adhered to before installation in Massachusetts.

Possible Cause & Solution:

• No power to unit:

– Check circuit breaker or fuse. Reset or replace if necessary.

– Ensure power cord is securely plugged into a working outlet.

• Faulty power cord or internal wiring:

– Inspect power cord for damage. Replace if damaged (qualified technician only).

– Check internal wiring connections (qualified technician only).

• Defective control panel or main control board:

– Contact qualified service technician.

Possible Cause & Solution:

• Gas supply is OFF:

– Ensure manual gas shut-off valve is open.

– Check gas meter or propane tank valve.

• Insufficient gas pressure:

– Verify gas pressure meets requirements (see section 6.3). Contact gas supplier if low.

• Air in gas line:

– Purge air from gas line (qualified technician only).

• Incorrect gas type setting (if converted to LP):

– Verify gas type setting on control panel is correct for the fuel being used.

• Faulty igniter or flame sensor:

– Clean flame sensor (qualified technician only).

– Test igniter and flame sensor for proper operation. Replace if faulty (qualified technician only).

• Blocked vent or air intake:

– Inspect vent terminations and pipes for obstructions. Clear any blockages.

• Water flow rate too low for activation (below 0.6 GPM):

– Ensure sufficient water flow through the unit. Clean faucet aerators and showerheads.

• Inlet water strainer clogged:

– Clean inlet water strainer (see section 14.1).

• Error code displayed:

– Refer to error code list in manual or contact technician.

Possible Cause & Solution:

• Water flow rate exceeds unit capacity for the set temperature rise:

– Reduce water flow rate at fixtures.

– Consider if a higher capacity unit or multiple units are needed for demand.

• Inlet water temperature is very low:

– Unit performance is affected by inlet water temperature. This may be normal in colder climates.

• Incorrect CO2 adjustment:

– Have CO2 levels checked and adjusted by a qualified technician (see section 10).

• Clogged inlet water strainer:

– Clean inlet water strainer (see section 14.1).

• Faulty gas valve or modulating control:

– Contact qualified service technician.

• Scale buildup in heat exchanger (hard water areas):

– Descale heat exchanger (qualified technician only). Consider installing a water softener.

• Recirculation system issues (if applicable):

– Check recirculation pump operation and settings.

– Ensure proper piping for recirculation system.

Possible Cause & Solution:

• Temperature setting on control panel is too high:

– Adjust temperature setting to a lower, safe level (see section 12.4). Read scalding warnings.

• Faulty temperature sensor or control board:

– Contact qualified service technician.

• Minimum flow rate issue causing overheating before shutdown:

– Ensure flow rates are above minimum activation, inspect for partially closed valves.

Possible Cause & Solution:

• Refer to the Error History screen (see section 12.8.1) and the troubleshooting guide in the manual for specific error code meanings and solutions.

• Common error codes relate to ignition failure, flame loss, sensor faults, overheating, or communication issues in cascaded systems.

• Try resetting the unit by turning the power OFF and then ON.

• If the error persists, note the error code and contact a qualified service technician.

Possible Cause & Solution:

• Normal combustion and fan noise:

– Some operational noise is normal.

• Vibration due to improper mounting:

– Ensure unit is securely mounted to the wall (see section 5.1).

• Air in water lines (popping/rumbling):

– Purge air from water lines by fully opening hot water faucets.

• Scale buildup in heat exchanger (kettling noise):

– Descale heat exchanger (qualified technician only).

• Loose components or fan issue:

– Inspect for loose panels or internal components (qualified technician only).

– Check fan for obstructions or damage (qualified technician only).

Possible Cause & Solution:

• Condensate drain line is blocked or kinked:

– Inspect drain line for obstructions or kinks. Clear or straighten as needed.

– Ensure drain line has proper downward slope.

• Condensate trap (loop) is not properly formed or is blocked:

– Ensure the factory-supplied loop in the drain line is intact. Clean if necessary.

• Condensate pump failure (if used):

– Check power to condensate pump and its operation. Replace if faulty.

• Drain port on unit is clogged:

– Disconnect drain line and carefully check unit’s drain port for blockage (qualified technician only).

Please follow the mixing valve manufacturer guidelines.

For single unit installations, ensure the electrical outlet being used is wired with at least 12 gauge wire and grounded. A GFI ground fault receptacle is recommended. Only one water heater should be plugged into an outlet with 12 gauge wire. It should also be connected to at least a 15 Amp circuit breaker. The electrical power required for the water heater is 120V AC at 60 Hz.

The plug provided with the unit is polarity sensitive. Ensure that the “line” and “neutral” are at the correct locations in the wall socket using a 3-wire receptacle tester or other similar testing device. If the polarity is reversed, it will cause the unit to malfunction and turn off every 15 seconds.

If multiple units are being installed, the gauge of wire must be increased to meet the additional electrical load. Consult the electrical codes for the correct wire size.

Yes, if desired, the water heater can be wired into the electrical system by removing the power cord and replacing it with electrical cable. If this method is used, a separate ON/OFF switch must be installed to remove power from the unit.

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

This procedure is required:

1) only during installation in a high-altitude location over 8,000 feet, or

2) when converting the unit from natural gas to propane.

This procedure should be performed only by a qualified service technician.

The CO2 and CO standards are as follows:

Note: The values listed are for nominal conditions. Variables such as gas pressure, heating value of the gas, humidity, and temperature of combustion air can impact CO and CO2 values.

Before any adjustments are made, the service technician must confirm the static gas pressure meets these minimum requirements:

Natural Gas – 8″ W.C.

Propane – 11″ W.C.

If units are cascaded and common vented, then combustion must be performed only one unit at any given time. Please valve off the hot water outlet of other units and power off them before performing combustion analysis on the active unit.

1. Remove the front cover panel.

2. Locate the gas valve on the heat engine.

3. Remove the condensate tube and use that port to insert a calibrated flue CO2 gas analyzer to check gas levels.

Follow the display screens. (Navigate through Main Menu -> Flow/Temp -> Settings -> Combustion).

Do NOT change the blower speed settings. This adjustment MUST be performed by factory personnel ONLY. Changing this setting WILL VOID the warranty!

Create a hot water flow of at least 5.0 GPM, as shown on the display screen. If flow rate is inadequate, a pop-up message will notify to increase the flow.

1. At a flow rate of at least 6.0 GPM, the heat engine will start.

2. Allow three minutes of operation at High Fire.

3. Record “initial output” in the High Fire Recorded Values table.

4. If the CO2 values are within the appropriate range (Natural Gas High Fire: 9.1% to 9.3%, < 200 ppm CO; Propane High Fire: 10.1% to 10.5%, < 200 ppm CO), proceed to Low Fire adjustment. Otherwise, continue with High Fire adjustment:

a. Use a flat blade screwdriver to turn the High Fire screw clockwise to decrease and counterclockwise to increase the CO2 value.

b. Adjust in 1/4 turn increments.

c. Wait three minutes to stabilize flue gas readings and recheck values.

d. Adjust until values fall with specified range.

5. Once the desired values are achieved, record the new High Fire CO2 “adjusted values” in the table.

1. Press LOW FIRE on the display screen.

2. Record “initial output” in the Low Fire Recorded Values table.

3. Adjust the Low Fire screw while the burner operates at low fire using a 2mm hex wrench. Turn clockwise to increase CO2 and counterclockwise to decrease CO2. The appropriate CO2 range for Natural Gas Low Fire is 9.1% to 9.3% with < 60 ppm CO, and for Propane Low Fire is 10.1% to 10.5% with < 60 ppm CO.

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

1. When the heat engine has been properly adjusted, turn off water flow.

2. Remove flue gas analyzer probe and reinstall condensate hose.

3. Press the backspace icon to return to the main screen.

4. Check for gas leaks using a leak detector.

5. Install the front cover. If converting to propane, proceed to the “Natural Gas to Propane Conversion” section.

Before converting the unit for propane, verify the current gas inlet pressure meets the recommended pressure. The recommended propane static gas pressure is 11″ W.C. (minimum 2.5″ W.C. non-corrugated, black iron; maximum 14″ W.C.). Record the verified pressure. Also, note that this conversion process requires CO2 levels to be adjusted as per Section 10.

1. Turn the water heater OFF using the display screen.

2. Place the circuit breaker for the water heater at the main electrical panel in the OFF position. Verify there is no power to the unit(s).

3. Remove the front cover panel and locate the main circuit board.

4. Locate DIP Switch 1.

5. Move the DIP switch into the Propane position.

6. Reset the circuit breaker to the ON position. Turn the water heater ON using the display screen.

Follow the display screens (Main Menu -> Settings -> Adv. Settings) to make sure the unit display shows “UNIT SET FOR PROPANE”. After verification, refer to Section 10 in this PDF for instructions to adjust CO2 levels for propane.

1. When the power cord is plugged in, the Main Menu screen will automatically appear.

2. To turn the water heater OFF, press and hold the Power button in the upper left of the screen.

3. To turn the unit ON, press the Power button.

Turning the unit OFF using the power button does not disconnect it from the power source. Whenever working around electrical components within the water heater, turn OFF the power at its source (e.g., circuit breaker). Touching live electrical components can cause serious injury or death.

A sleep mode screen (typically a hexagon shape) will appear after a period of inactivity on the control panel.

1. From the Main Menu, select SETTINGS.

2. Select TIME/DATE.

3. Press the Up/Down arrows on the screen to make adjustments to the hour, minute, am/pm, month, day, and year.

4. Press the Back button to return to the main screen.

Note: The outlet water temperature is factory preset to 120°F; however, these commercial water heaters are capable of heating water to 190°F. Hot water temperature over 125°F (52°C) can cause severe burns. Check water temperature before use.

1. Ensure all water faucets are closed and the unit is not operating.

2. On the Main Menu screen, firmly press the temperature adjust slider and slide it to the right to increase the temperature or to the left to decrease. Hold the icon until the current set point on the display reaches the desired temperature.

3. For finer temperature adjustments, use the (+) and (-) icons that may appear on the temperature adjustment screen.

4. Follow any prompts shown on the screen.

1. From the Main Menu, select SETTINGS.

2. Select SECURITY.

3. Press ON next to PASSCODE.

4. Follow the prompts to choose and enter a 4-digit passcode using the on-screen keypad.

If a passcode is set, it must be entered prior to accessing the main screen.

If the unit passcode is lost or forgotten, press the “?” icon on the passcode entry screen. This will open the technical support screen. Call the provided technical support number to obtain the passcode. Have your Model Number, Serial Number, date installed, location, application, and any error code ready.

1. From the Main Menu, select LIFE.

2. The screen will display a visual indication of the remaining life of various components like Water Valve, Blower, Electrode, Gas Valve, and O-Rings.

Service recommended: Order the appropriate replacement part as soon as possible. To reset the life indicator for that part after replacement, press and hold the appropriate bar on the Life Screen and follow the prompts.

Service Required: Take IMMEDIATE action when this screen appears because the part life is critical. To reset the life indicator after replacement, press and hold the appropriate bar and follow the prompts.

Some service alert reset codes are:

Note: Parts can be ordered by contacting technical support.

1. From the Main Menu, select UNIT INFO.

2. The screen will display “ABOUT YOUR WATER HEATER” showing the Model, Software version, and Serial Number. It also provides a “CONTACT US” button which leads to technical support information.

Please have the following information ready: Model Number, Serial Number, date installed, location, application, and error code (if any).

1. From the Main Menu, select MORE.

2. Select ERROR HISTORY.

3. The error history screen provides an overview of past errors on the unit, including date and time.

The benefits of connecting multiple units are:

• When demand for hot water is low, fewer units will operate.

• If one unit has an error code, the others will continue to operate.

• Changing the settings (temperature, time, etc.) on one unit changes settings on all the units.

• It allows shut down of one unit for maintenance while the others continue to operate.

The water heaters communicate through a cable connection between each water heater.

Cascading support is as follows:

For connecting multiple units:

1. Perform physical connections for gas, power, venting, water, and condensate drains as per installation instructions.

2. Do Not connect communication cables at this time.

3. Power up all the units.

4. On each unit, assign a unique number from one through ten. To do this, navigate from the Main Menu to SETTINGS, then CASCADING. On the “Multi-Unit Setup” screen, select a unique number for that unit using the +/- buttons. Set STAGING to ON.

5. If necessary, press the Power button to turn OFF each water heater in the system and disconnect power from all the units before proceeding with communication cable connections.

WARNING: Before making any adjustments or connections inside the water heater cabinet, make sure the power is disconnected. Unplug the water and/or turn the circuit breaker OFF.

After assigning unique numbers and powering down:

1. Remove the front cover and locate the main circuit board on all units.

2. Set DIP switch 3 on the electronic board on all units as follows:

a. On the first water heater in the cascade, position DIP Switch 3 to the ON position.

b. On any water heater unit between the first and last unit, position all DIP Switch 3 switches in the OFF position.

c. On the last water heater in the cascade, position DIP Switch 3 to the ON position.

3. Using the supplied cables, connect one end of a cable into either of the two jack receptacles on the circuit board of one unit and the other end to the jack in the next unit, daisy-chaining them together.

a. Pass the communication cable through the grommet located in the bottom of the cabinet.

b. Secure the cable using a zip tie if needed.

c. Replace the front cover.

4. Reconnect the power and turn the water heaters ON. The water heaters should now be ready to communicate with each other and operate as a single system.

Note: Whenever a change is made to any one water heater (e.g., temperature setting), all the other units in the system will be automatically updated to the new settings.

The inlet water strainer should be inspected and cleaned every three months initially to establish a cleaning schedule.

1. Turn OFF electrical power to the water heater.

2. Position a container under the strainer on the water inlet pipe. The container must be large enough to hold the water in the pipe.

3. Close the water inlet and outlet valves. Remove the strainer’s plug and allow water to drain from the pipe. (Note: If a water shut-off valve was not installed, shut OFF the main water supply valve.)

4. Remove the strainer screen, clean it, and reinstall it in the housing.

5. Replace the strainer’s plug.

CAUTION: Hot water can cause burns. Ensure the water heater is OFF, power is disconnected, and the unit has cooled completely.

1. Press the Power button to turn OFF the water heater. Disconnect the electrical power.

2. Close the water supply inlet and outlet valves (handle perpendicular to the pipe).

3. Remove the front cover panel. Place a container or other method to retain/divert water under the heat engine inlet. (Note: The heater contains about one-half gallon of water.)

4. Remove the clip holding the pipe into the heat engine. Flex the pipe enough to allow the water to drain from the heat engine.

Note: Do not allow water to pool in the cabinet; remove spilled water with a dry cloth.

5. When all water has drained, replace the pipe and the clip.

1. Open the hot water outlet valve. Slowly open the cold water inlet valve.

2. Open a hot water faucet. Once a steady stream of water flows and all trapped air is purged from the system, close the hot water faucet.

3. Plug the unit into an electrical power supply.

4. Open a hot water faucet. The water heater should operate normally.

The water heater’s operational flow is as follows:

1. The unit is in a ‘Wait’ state.

2. It checks ‘Is Flow On?’.

3. If Yes, it proceeds to ‘Energize Ignition Module’.

4. It then checks for ‘Successful Ignition?’.

5. If Yes, it proceeds to ‘Set Modulation’.

6. It then performs a ‘Safety Check Passed?’.

7. If Yes, it re-checks ‘Is Flow On?’. If flow is still on, the process relating to modulation and safety checks continues. If flow is off, it returns to the ‘Wait’ state.

8. If at any point ‘Is Flow On?’ (initial), ‘Successful Ignition?’, or ‘Safety Check Passed?’ results in a ‘No’ or failure, an ‘Error Handler’ process is initiated.

The wire color codes are:

Possible Causes:

– Blower noisy / impeller jammed.

– Disconnected signal wire.

– Wiring faulty.

Remedy:

– Inspect blower / impeller. Clean and remove any obstructions.

– Check PWN signal. Check for loose wires / pins, and repair.

– If the problem persists, turn control panel OFF, shut OFF gas valve, disconnect power from unit, and contact an authorized service technician.

Possible Causes:

– Water over-heat switch tripped.

– Faulty DSI, faulty igniter wire, faulty ignition connection, faulty PCB, bad igniter.

– Low gas pressure.

– Wiring faulty.

Remedy:

– Check the pump, cross-over solenoid, and for electrical noise (DSI).

– Replace part (if identified as faulty).

– Adjust gas pressure at regulator, check / increase size of gas pipe, check for gas pipe blockage.

– If the problem persists, turn control panel OFF, shut OFF gas valve, disconnect power from unit, and contact an authorized service technician.

Possible Causes:

– Unplugged connectors.

– Faulty sensor wiring.

– Faulty sensor.

– Heat engine water outlet temperature sensor.

– Flue temperature sensor.

– Inlet water temperature sensor.

– Faulty controller.

Remedy:

– Check connectors and ensure they are securely connected.

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

– Measure resistance of sensor at connector (18 Kohm at 50°F, 10 Kohm at 77°F, 3 Kohm at 140°F).

– Replace controller (if faulty).

Possible Causes:

– Faulty sensor wiring or faulty sensor.

– Inlet water temperature sensor.

– Heat engine water outlet temperature sensor.

– Faulty controller.

Remedy:

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

– Measure resistance of sensor at connector (18 Kohm at 50°F, 10 Kohm at 77°F, 3 Kohm at 140°F).

– Replace controller (if faulty).

Possible Causes:

– Flow rate changes excessive.

– Faulty sensor wiring.

– Faulty sensor.

– Faulty controller.

Remedy:

– Ensure the water flow rate does not change faster than 1 GPM every five seconds.

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

– Measure resistance of sensor at connector (18 Kohm at 50°F, 10 Kohm at 77°F, 3 Kohm at 140°F).

– Replace controller (if faulty).

Possible Causes:

– Incorrect vent set up.

– High inlet temperature.

– Faulty sensor wiring.

– Faulty sensor.

– Faulty controller.

Remedy:

– If vent pipe material is CPVC or polypropylene, ensure that CPVC is selected in the vent material screen.

– Ensure inlet temperature is lower than 150°F if vent pipe material is PVC or lower than 190°F if vent pipe material is CPVC or polypropylene.

– Check for nicked or broken sensor wiring and connectors. Also check for corroded or wet connectors.

– Measure resistance of sensor at connector (18 Kohm at 50°F, 10 Kohm at 77°F, 3 Kohm at 140°F).

– Replace controller (if faulty).

Possible Causes:

– Exhaust blocked (bird, etc).

– Backed up condensate.

– Wiring loose (switch open).

Remedy:

– Check exhaust termination. Check exhaust connection at water heater. Install screens to prevent blockage.

– Check slope of drain. Check for double loops, air locks, or debris in loop.

– Check wiring.

Possible Causes:

– Unplugged connectors.

– Faulty sensor wiring.

– Faulty sensor.

– Flue temperature sensor.

– Inlet water temperature sensor.

– Faulty controller.

Remedy:

– Check connectors and ensure they are securely connected.

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

– Measure resistance of sensor at connector (18 Kohm at 50°F, 10 Kohm at 77°F, 3 Kohm at 140°F).

– Replace controller (if faulty).

Possible Causes:

– Loss of communication between units.

Remedy:

– Check for broken or nicked communication cable or loose connector.

– Ensure that the communication cable is not bundled or tied to any high voltage lines.

– Ensure dip switch (SW3) is ON in first and last units and OFF in all other units.

– Ensure each unit numbering is unique.

Possible Causes:

– Faulty sensor wiring.

– Water valve is damaged or inlet strainer is clogged.

Remedy:

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

– Replace water valve and/or clean strainer.

Possible Causes:

– Incorrect settings.

– Incompatible settings.

– Incorrect software version.

– Faulty wiring.

Remedy:

– Review and correct settings.

– Update software version.

– Check for nicked or broken sensor wiring or connectors. Also check for corroded or wet connectors.

Possible Cause:

– A system alert is present (main menu screen).

– Malfunction of monitored part or system.

Remedy:

– Refer to the remedy for the indicated part or system related to that specific alert.

Possible Cause:

– A fault or error is present (main menu screen).

– Malfunction of monitored part or system.

Remedy:

– Refer to the remedy for the indicated part or system related to that specific fault.

Possible Cause:

– An alert, fault, or error is present (active screen).

– Malfunction of monitored part or system.

Remedy:

– Refer to the remedy for the indicated part or system related to that specific issue.

Indication/Cause & Remedy:

– Shows status of water heater / Sleep mode: Touch display screen to awake.

– Sleep mode passcode protected: Touch display screen to awake and enter passcode.

– Indicates a service problem exists within the monitored parts (e.g., SERVICE ALERT icon): Refer to the remedy for indicated part or system.

– Indicates an alert exists within the monitored systems (e.g., SYSTEM ALERT icon): Refer to the remedy for indicated part or system.

– Indicates a fault exists within the monitored parts or system (e.g., FAULT icon): Refer to the remedy for indicated part or system.

Potable water should comply with EPA secondary maximum contaminant levels (40 CFR part 143.3) as shown below:

The maximum allowable hardness (in grains per gallon, gpg) depends on the unit setpoint temperature and incoming water pressure: