A.O. Smith ACT-199I-N, ACT-199I-P, ACT-199O-N, ACT-199O-P User Manual

Commercial Condensing Tankless Water Heater

Installation Manual and Owner’s Guide

RD

ANSI Z21.10.3 CSA 4.3

Models

• CT-199 Indoor	• CT-199 Outdoor
	(USA only)

Gas Tankless Water HeaterTM

Suitable for combination potable water heating and space heating. Please refer to local codes for spaceheating compliance.

If the information in these instructions is not followed exactly, a fire or explosion may

WARNING result causing property damage, personal injury or death.

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

-WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electric switch, do not use any phone in your building.

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

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

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

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

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

Keep this manual near the water heater for future reference whenever maintenance, adjustment, or service is required.

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

2 Page

Installation 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.

3 Page

Installation Manual

Specifications

SPECIFICATIONS

	Model
	Natural Gas Input	BTU/h
	(Operating Range)
	Propane Input	BTU/h
	(Operating Range)
	Gas Connection
	Water Connections

	Water Pressure*			psi (MPa)
	Natural gas			" W.C.
	Inlet Pressure			(kPa)
	Propane			" W.C.
	Inlet Pressure			(kPa)
	Weight			lbs. (kg)
	Dimensions			inch
				mm
	Ignition
			Supply	VAC/Hz
	Electric	Consumption	Operation	W/A
			Freeze-	W/A
			Standby
			Protection	W/A

Water heater category**

CT-199 Indoor	CT-199 Outdoor
	Min.: 15,000
	Max.: 199,000
	Min.: 13,000
	Max.: 199,000
	3/4" NPT
	3/4" NPT
	15 - 150 (0.1 - 1)
	Min. 4.0 (1.00)
	Max. 10.5 (2.61)
	Min. 8.0 (1.99)
	Max. 14.0 (3.48)
59 (26.8)	59 (26.9)

H 22.4 x W 17.7 x D 10.7

H 570 x W 450 x D 272

Electric Ignition

120/60

89.0 / 0.74

4.2 / 0.04

175 / 1.5

	Category	N/A
	IV

*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.

4 Page

Installation Manual

Introduction

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 CT-199 Indoor model is only to be installed indoors. The CT-199 Outdoor model is only to be installed outdoors.

•The principle behind tankless water heaters is simple:

Intake port										Exhaust

Exhaust thermistor						Secondary
						6 heat exchanger
	7 Thermistor					Primary
						heat exchanger
			5 Burners
	Bypass valve					4Igniter
Water control valve
							Gas valves
	4					4 Fan motor
7	Computer board					3
	Thermistor						Flow sensor
8	1						Condensate
		7			4		drain port
	7	Thermistor		2	Gas
	Hot water outlet			Cold water inlet

*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.

5 Page

Installation Manual

Safety Guidelines

SAFETY GUIDELINES

SAFETY DEFINITION

Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

DANGER

Indicates an imminently hazardous situation which, if not avoided, could result

in death or serious injury.

WARNING

Indicates an imminently hazardous situation which, if not avoided, could result CAUTION in minor or moderate injury.

NOTICE Indicates information considered important but not hazard related.

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.

•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 WARNING 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.

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Installation Manual

Installation

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 CT-199 Indoor model is to be installed indoors only. This unit is 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 model 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 CT-199 Outdoor model 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 noncombustible surfaces.

7 Page

Installation Manual

Installation

WARNING

NOTICE

•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.

•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 4 grains per gallon (70 ppm) for commercial 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.

8 Page

Installation Manual

Installation

CLEARANCES

Top

Maintain all clearances around the water heater. Failure to do so could create a fire hazard, potentially leading to death, serious

WARNING injury, and/or property damage.

Side

Back

Side

Front

Bottom

	Model	Top	Bottom	Front	Back	Sides
	CT-199 Indoor	12 in.	12 in.	4 in.*	0.5 in.	3 in.
		(305 mm)	(305 mm)	(102 mm)	(13 mm)	(76 mm)
	CT-199 Outdoor	36 in.	12 in.	24 in.	0.5 in.	3 in.
		(914 mm)	(305 mm)	(610 mm)	(13 mm)	(76 mm)

*24 inches recommended for maintenance.

INCLUDED ACCESSORIES

Check that these items below are included with the water heater.

Installation manual		Temperature remote controller kit*		Bird screen	Communication cable
and owner’s guide			Outdoor model only	Indoor models only
			100112572
			(TM-RE40)
	Qty: 1		Qty: 1	Qty: 2	Qty: 1
*Refer to p. 10 and 35.
			OPTIONAL ITEMS
#	Model		CT-199 Indoor	CT-199 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

9 Page

Installation Manual

Installation

1. Temperature remote controller:

100112572 (TM-RE40)

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.

3. Neutralizer kit: 100112159 (TH-NT01)

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.

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.)

4. Sidewall vent terminator (Hood) and Wall thimble:

			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
	Terminator Hood	Wall Thimble	Termination + Thimble 4 - 7 in (102 - 178 mm)	100112424
			Termination + Thimble 5 - 10 in (123 - 254 mm)	100112425

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.

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.

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.

6. Non-return valve: 100113130

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.)

7. PVC Adapter: 100113129

This adapter transitions from the Non-return valve outlet to 4" schedule 40 PVC pipe.

10 Page

Installation Manual

Installation

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.

Prohibited

Prohibited

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).

Ensure that you meet the minimum clearances shown below for a direct vent termination:

3 ft

(914 mm)

						USA:1ft(30cm)min.
						Canada:3ft(91cm)min.
USA:1ft(30cm)min.						USA:1ft(30cm)min.
Canada:3ft(91cm)min.						Canada:3ft(91cm)min.

USA: 12 in. (30 cm) above grade and above anticipated snow level Canada: 12 in. (30 cm) above grade

Anticipated snow level

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.

2 ft

(610 mm)

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.

Inside

Corner

11 Page

Installation Manual

Installation

HIGH-ALTITUDE INSTALLATIONS

			•	Adjust the appropriate DIP switches according to model and elevation as
				shown below. DO NOT adjust the other DIP switches.
	WARNING		•	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.

Indoor model

Altitude	0 to 2,000 ft	2,000 to	3,000 to	5,000 to	7,500 to
DIP switches	(0 to 610 m)	3,000 ft	5,000 ft	7,500 ft	10,100 ft
	(DEFAULT)	(611 to 914 m)	(915 to 1,524 m)	(1,525to2,286m	(2,287to3,078m)
	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6
CT-199	OFF	OFF	OFF	OFF	OFF
(Lower bank of	No. 2 : OFF	No. 2 : OFF	No. 2 : OFF	No. 2 : OFF	No. 2 : ON
DIP switches)	No. 3 : OFF	No. 3 : ON	No. 3 : OFF	No. 3 : ON	No. 3 : ON
	No. 4 : OFF	No. 4 : OFF	No. 4 : ON	No. 4 : ON	No. 4 : ON

Outdoor model

Altitude	0 to 2,000 ft	2,000 to	4,000 to
DIP switches	(0 to 610 m)	4,000 ft	6,000 ft
	(DEFAULT)	(611 to 1,219 m)	(1,220to1,829m)
	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6	ON 1 2 3 4 5 6
CT-199	OFF	OFF	OFF
(Lower bank of	No. 2 : OFF	No. 2 : OFF	No. 2 : ON
DIP switches)	No. 3 : OFF	No. 3 : OFF	No. 3 : OFF
	No. 4 : OFF	No. 4 : ON	No. 4 : ON

NOTE: The dark squares indicate the correct DIP switch positions.

Lower bank of DIP switches

Installation altitude

The maximum certified or allowable installed altitude is 10,100 ft (3,078 m) for indoor model and 6,000 ft (1,829 m) for outdoor model.

12 Page

					Installation Manual
					Installation
					VENTING INSTRUCTIONS
					Indoor models
					-General-
			•		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
	WARNING
					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.

13 Page

Installation Manual

Installation

-Combustion air supply-

WARNING

NOTICE

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.

•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.

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 combustion and ventilation. Consult a qualified person if you’re unsure of the proper way to supply air to your water heater.

Check for Chemicals:

Air for combustion and ventilation must be clean and free of corrosive chemicals. If corrosive chemicals, such as sulfur, flourine, 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. Examplesoflocationsthat require outside air due to chemicals include:

•Beauty salons

•Photo processing labs

•Indoor pools

•Laundry, hobby, or craft 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?

Ventilation with outside air is recommended for all installations. 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 tightly sealed and often 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 ventilation. If you are unsure if your installation location has enough ventilation, contact your local gas utility company or code officials for a safety inspection or direct vent the water heater

The following instructions will help determine if it may be possible to install the water heater without outside ventilation.

Calculate total BTU/h rating of all appliances.

To calculate the combustion air and ventilation required, add up the total BTU/h ratings of all gas burning 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.

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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 rating, the amount of ventilation required may be greater.

Example:
	Gas Burning Appliance	BTU/h Rating
	Gas Water Heater	199,000
	Furnace	75,000
	Dryer	20,000
	Total	294,000

Your appliances:

Gas Burning Appliance	BTU/h Rating
Gas Water Heater

Total

Calculate the air volume of the room

Air requirements depend on the size of the room.

Room Volume (ft3) = Floor Area (ft2) X Ceiling Height (ft)

If there are large objects in the room (e.g., refrigerator, furnace, car), subtract their volume from the volume of the room to get a better estimate of the air available.

Air Volume = Room Volume - Object Volume

NOTE: Adjoining rooms with permanently opened doorways can be counted as part of the calculation.

Calculate required air volume

A water heater installed in an unconfined attic, garage, or space requires that the space be at least 50 ft3

(1.42 m3) per 1,000 BTU/h of the total input for all gas burning appliances in the same area.

Required Air Volume (ft3) =Total Appliance Energy Rating (btu/h) X 50 ft3 / 1000 (btu/h) Example:

(294,000 / 1000) x 50 = 14,700 ft3

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 sufficient air. Go to “Install with outside ventilation” if you want to provide combustion air with outside ventilation.

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 ventilation. However, be sure to consider the effects of exhaust fans. Exhaust fans can affect the amount of combustion 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 fire properly. Back-drafting may also result, which is when negative air pressure pulls air backwards through chimneys or appliance vents. These events can cause unsatisfactory water heater performance. The best solution is to direct vent the water heater or install an adequate number of make-up air vents. (See “Install with outside ventilation”.) For more information, consult a qualified technician or your local gas utility.

Install with outside ventilation

Ventilationwithoutsideairisrecommended,and,formostinstallations,isneeded. Theremaybeexisting ventilationthatisadequate,oryoumayneedtoaddmoreventilation.

Supplying outside air to the water heater typically requires two openings. One opening must be within 12 in

(305mm)fromthefloorandthesecondopeningmustbewithin12in(305mm)fromtheceiling. Althougha 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. Twoopeningsmustbeusedwhenventilatingwithairfromanotherroom.

The outside air can be taken from a crawl space or attic open to the outdoors and adequately ventilated. You may use vertical or horizontal ducts.

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Determine type of ventilation

There are several types of ventilation that can be used. The various options are listed below. See also the illustrations on the next page.

1.Direct to outdoors

2.Vertical ducts

3.Horizontal ducts

4.Single opening (not recommended; must be at least 100 in2 (6.5 cm2) . Not appropriate for confined spaces smaller than 50 ft3 (1.42 m3)per 1,000 BTU/h or when getting 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 rating of all appliances in the space (use your calculation 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 ventilation.

Calculate minimum size of vent openings and ducts

The vent cross-sectional 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 opening may need to be larger to meet the minimum free area requirements.

Use the following formula to calculate the required cross-sectional area:

Cross-sectionalarea=minimumfreearearequired÷percentfreeareaofcovering(indecimals–e.g.,60%=0.6)

For example, an installation area that requires openings with 100 in2 (645 cm2) of free area would need 134 in2 (865 cm2) openings if using metal louvers rated at 75% free area (100 in2 ÷ 0.75 = 134 in2).

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 flow:

•Each vent opening must be no smaller than 100 in2 (645 cm2).

•Ducts must have the same cross-sectional 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 automatically during operation.

•Keep louvers and grills clean and free of debris or other obstructions.

Check that air source is clean and free of chemicals

Air for combustion and ventilation must be clean and free of corrosive or flammable chemicals. A failure due to corrosive chemicals in the air is not covered by the warranty. Combustion air must be free of acid-forming chemicals such as sulfur, fluorine, and chlorine. Be sure that air at the vent inlets is free of such chemicals.

Table 1

Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply – Air from outdoor or indoor spaces.

Based on the total BTU/h input rating for all gas burning appliances within a confined space.

Opening Source	Minimum Free Area
Direct to outdoors*	1 in2	(6.5 cm2) per 4,000 BTU/hr (see Figure 1, 2)
Vertical ducts	1 in2	(6.5 cm2) per 4,000 BTU/hr (see Figure 3)
Horizontal ducts	1 in2	(6.5 cm2) per 2,000 BTU/hr (see Figure 4)
Single Opening	1 in2	(6.5 cm2) per 3,000 BTU/hr (see Figure 5)
Two permanent openings	1 in2 (6.5 cm2) per 1,000 Btu/hr (see Figure 6)
to another room**	Opening: 100 in2 (645 cm2) MIn
	Minimum dimension of air openings:
	no less than 3 in (76 mm)

*These openings connect directly with the outdoors through a ventilated attic, a ventilated crawl space, or through an outside wall.

**United States: For direction on combining spaces in different stories within the structure, refer to the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54. In Canada, contact your local code enforcement agency for

direction.

See graphics on next page.

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Combustionairsupplyoptions

		Gable vent
		to outdoors
		Install above
		insulation
	Confined	Outlet air to		12” (305 mm)
		attic1in2 (6.5cm2)		maximum
	Space	per 4,000 btu/h
			Two permanent
	Alternate		Openings	Confined
		Inlet air from	1 in2 (6.5 cm2)
	Air Inlet			Space
		the crawl space	per 4,000 btu/h	12” (305 mm)
				maximum

1 in2 (6.5cm2)		Open		foundation vent
per 4,000 btu/h
Figure 1 - Direct to outdoors openings						Figure 2 - Direct to outdoors openings
							Two permanent openings

	Gable vent
	to outdoors
	Install above
	insulation
Confined	Outlet air to
Space	attic 1 in2(6.5cm2)
	per 4,000 btu/h
	Inlet air duct
	1 in2 (6.5cm2)
	per 4,000 btu/h
	12”(305mm)
	maximum

Figure 3 - Vertical duct openings

Alternative

Opening

Location

Confined

Space 1 in2 (6.5 cm2) per 3,000 btu/h

	1 in2 (6.5 cm2)
	per 2,000 btu/h
Confined	Outlet
Space	Outdoor
	Air Ducts

Inlet

1 in2 (6.5 cm2) per 2,000 btu/h

Figure 4 - Horizontal duct openings

12” (305 mm)
maximum
Confined
Space	Two permanent	1 in2 per
	Openings	1,000 btu/h
12” (305 mm)
maximum

Figure 5 - SIngle opening

Figure 6 - Two permanent openings

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-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.

	Item	Material	United States	Canada
		Schedule 40 PVC	ANSI/ASTM D1785
	Exhaust pipe and	PVC-DWV	ANSI/ASTM D2665
		Schedule 40 CPVC	ANSI/ASTM F441
	Fittings
		Schedule 40 ABS-DWV	ANSI/ASTM D2661	ULC S636 Certified
		Polypropylene	UL-1738	Materials Only
		PVC	ANSI/ASTM D2564
	Pipe Cement/Primer	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.

•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.

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.

	Max. Vertical or Horizontal (Total) Vent Length
		3" (76 mm) venting		4" (102 mm)
No. of Elbows				venting
	0 to 3,000 ft	3,001 to 6,000 ft	6,001 to 10,100 ft	0 to 10,100 ft
	(0 to 914 m)	(915 to 1,829 m)	(1,830 to 3,078 m)	(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 p. 20 and p. 21.

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-DIP switch settings for vent length-

Typical installations using PVC, CPVC, ABS, or polypropylene vent

•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.
	WARNING
		•	Failure to observe these warnings could lead to carbon monoxide poisoning

or death.

<Two-pipe, direct-vent installation>

Horizontal Installation	Vertical Installation
	Wall
Hanger	Roof
Hanger	Roof flashing

Fire stop

Connect between exhaust vent collar and piping.

See the instructions below.

For details of the optional items, refer to the Installation manual for each optional item.

Upper bank of

DIP switches

Lower bank of

DIP switches

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
	Vent	5 to 20 ft	21 to 40 ft	41 to 70 ft	5 to 50 ft	51 to 100 ft
	length	(1.5 to 6.1 m)			(1.5 to 15.2 m)
	Model		(6.2 to 12.2 m)	(12.3to21.3 m)		(15.3 to 30.5 m)
		(DEFAULT)			(DEFAULT)
	CT-199	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8
		OFF			OFF
	(Upper bank		OFF	OFF		OFF
	of	No. 3 : O N	No. 3 : OFF	No. 3 : O N	No. 3 : O N	No. 3 : OFF
	DIP switches)
		No. 4 : OFF	No. 4 : OFF	No. 4 : O N	No. 4 : OFF	No. 4 : OFF

*PVC concentric termination (100112163) installation is applied to the DIP switch settings of 3" (76 mm) venting. (Refer to p. 10.)

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<How to install intake and exhaust venting (two-pipe, direct-vent) with the indoor model>

3" (76 mm) vent connection

4" (102 mm) vent connection

	3"(76 mm)	3" (76 mm)
	straight pipe	straight pipe
	3" (76 mm) coupling	3" (76 mm) coupling
		(included)
	(included)
		Exhaust vent collar
	Intake vent collar	(Female)
	(Female)

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.

	4" (102 mm)	4" (102 mm)
	straight pipe	straight pipe
		3"x 4"
	3"x 4"	(76 x 102 mm)
		increaser
	(76 x 102 mm)
	increaser	Exhaust vent collar
	Intake vent collar	(Female)
	(Female)

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.

<Single-pipe with room-air intake installation>

Horizontal Installation	Wall
Hanger

Elbow

Connect between exhaust vent collar and piping.

See the instructions below.

Vertical Installation

Roof

Roof flashing

Elbow

Fire stop

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 : Single vent pipe installations

	Vent diameter	3" (76 mm) venting*		4" (102 mm) venting
	Vent	5 to 45 ft		5 to 50 ft
	length		46 to 70 ft		51 to 100 ft
		(1.5 to 13.7 m)		(1.5 to 15.2 m)
	Model		(13.8 to 21.3 m)		(15.3 to 30.5 m)
		(DEFAULT)		(DEFAULT)
	CT-199	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8	ON 1 2 3 4 5 6 7 8
		OFF		OFF
	(Upper bank		OFF		OFF
	of	No. 3 : O N	No. 3 : OFF	No. 3 : O N	No. 3 : OFF
	DIP switches)
		No. 4 : OFF	No. 4 : OFF	No. 4 : OFF	No. 4 : OFF
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