Installation and Operation instructions
INDOOR MODEL
TL-Pro 175C/199C
Warning: If the information in this manual is not followed exactly,
a fire or explosion may 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 trained and certified installer, service agency or the gas supplier.
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified
installer, service agency or the gas supplier.
Upon completion of the installation, these instructions should
be handed to the user of the appliance for future reference.
What to do if you smell gas
• Turn off the gas shut-off valve. Open windows and doors.
• Do not try to light any appliance.
• Do not touch any electrical switch, telephone, and do not use
outlets.
• Extinguish all open flames. Do not smoke! Do not use lighters!
• Warn all occupants of the building. Do not ring doorbells!
• If you can hear gas leaking, leave the building immediately.
Prevent others from entering the building and notify the
police and fire department from outside the building.
• From outside the building, call the gas utility company and a
trained and certified installer.
TL-Pro 175/199 C - Natural Gas
TL-Pro 175/199 C- Propane (LP Gas)
6 720 821 954 (2017/06) US
Temperature Modulated with Electronic Ignition Suitable for heating potable water and space heating
(Intended for variable flow applications)
Table of contents
Table of contents
1
Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3
1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2
FCC rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Appliance details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2
Specifications (Technical data) . . . . . . . . . . . . . . . . . . . . 8
3.3
Unpacking the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4
General rules to follow for safe operation . . . . . . . . . . 10
3.5
Dimensions and minimum installation clearances . . . 11
8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2
Burner does not ignite when hot water is turned ON . . 48
8.3
Water is too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4
Water is not hot enough . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5
Low water flow/pressure . . . . . . . . . . . . . . . . . . . . . . . . 48
8.6
Hot water temperature fluctuates at tap . . . . . . . . . . . . 49
8.7
Noisy burner/heater during operation . . . . . . . . . . . . . . 49
9
Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.1
Error code diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Specialized tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4
Combustion air requirements . . . . . . . . . . . . . . . . . . . .
4.5
Proper location for installing your heater . . . . . . . . . .
4.6
Heater placement and clearances . . . . . . . . . . . . . . . .
4.7
Hanging appliance on the wall . . . . . . . . . . . . . . . . . . .
4.8
Mounting installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9
Gas piping & connections . . . . . . . . . . . . . . . . . . . . . .
4.10 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Filling the condensate trap . . . . . . . . . . . . . . . . . . . . . .
4.13 Domestic hot water recirculation . . . . . . . . . . . . . . . . .
4.14 Space heating applications . . . . . . . . . . . . . . . . . . . . . .
4.15 Measuring gas pressure . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
27
28
28
28
29
30
33
33
34
35
35
37
5
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1
Electrical power supply . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2
Position of the fuses in control unit . . . . . . . . . . . . . . . 38
6
Operation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1
Description LCD Display . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2
For your safety read before operating
your water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4
Temperature selection . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.6
Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.7
Program button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.8
Locked condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7
Maintenance and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2
Winterizing for seasonal use . . . . . . . . . . . . . . . . . . . . .
7.3
Mineral scale build-up . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4
Condensing heat exchanger unit . . . . . . . . . . . . . . . . .
7.5
Adjusting CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6
Program values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7
Control board diagnostics . . . . . . . . . . . . . . . . . . . . . .
2
11 Sensor resistance charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12 Functional scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13 Interior components diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 56
13.1 Interior components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14 Protecting the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15 LIMITED TANKLESS HEATER WARRANTY . . . . . . . . . . . . . . . . 58
16 Installer Checklist to be completed by installer upon
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
42
42
42
42
43
44
46
46
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Key to symbols and safety instructions
1
Key to symbols and safety instructions
1.1
Key to symbols
Warnings
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk are not taken.
The following keywords are defined and can be used in this document:
• NOTICE indicates that damage to property may occur.
• CAUTION indicates that personal injury may occur.
• WARNING indicates that severe personal injury may occur.
• DANGER indicates that severe personal injury or death may occur.
Important information
This symbol indicates important information where
there is no risk to people or property.
Additional symbols
Symbol
▶

•
–
Explanation
Step in an action sequence
Cross-reference to another part of the document
List entry
List entry (second level)
Table 1
1.2
Safety instructions
Read all instructions before installing. Perform the
steps in the indicated sequence. Have the water
heater inspected by a trained service technician at
least once every year. Failure to comply with these
instructions can result in severe, possibly fatal,
personal injury as well as damage to property and
equipment.
Installation and servicing
▶ Risk of fire when soldering and brazing!
Take appropriate protective measures when
soldering and brazing around combustible and
flammable material.
▶ Ensure that only a licensed contractor installs or
services the water heater.
▶ On hot components use only material with
adequate temperature stability.
Installation and commissioning
▶ In the Commonwealth of Massachusetts, the water
heater must be installed by a licensed plumber.
▶ Do not install this device in rooms with a high
moisture level (e.g. bathrooms, saunas).
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Function
▶ To ensure that the water heater functions properly,
follow these installation and maintenance
instructions.
▶ Never close the blow-off line of the T&P safety
valve. For safety reasons, water may escape during
heating.
If you smell gas
▶ Turn off the gas shut-off valve.
▶ Open windows and doors.
▶ Do not try to light the appliance.
▶ Do not touch any electrical switch, telephone, and
do not use outlets.
▶ Extinguish all open flames. Do not smoke! Do not
use lighters!
▶ Warn all occupants of the building. Do not ring
doorbells!
▶ If you can hear gas leaking, leave the building
immediately.
▶ Prevent others from entering the building and notify
the police and fire department from outside the
building.
▶ From outside the building, call the gas utility
company and a trained and certified installer.
If you smell flue gas
▶ Switch off the appliance.
▶ Open windows and doors.
▶ Inform a trained and certified installer.
Insufficient ventilation may cause toxic flue gas to
escape. Risk of poisoning.
▶ Never close off or reduce the size of the air intake
and outlet openings.
▶ The appliance must not be operated until any
obstructions have been removed.
▶ Inform the system operator in writing of the
problem and the associated dangers.
Danger from escaping flue gases
▶ Ensure all vent pipes and chimneys are not
damaged or blocked.
▶ Connect only one appliance to each vent system or
chimney liner.
▶ The venting system piping must not feed into
another air extraction duct.
▶ Do not route the flue system piping through or
inside another air extraction duct.
3
Key to symbols and safety instructions
Danger of explosion of flammable gases
▶ Work on gas components may only be carried out
by a trained and certified installer.
▶ Installation, gas and flue connection, initial
commissioning, electrical connections and annual
maintenance must only be carried out by a trained
and certified installer.
Combustion air
▶ Keep the combustion air free of corrosive
substances (halogenated hydrocarbons that
contain chlorine or fluorine compounds).
Never shut off safety valves!
▶ Water may escape from the safety valve at any time
when the water is being heated.
Inspection/maintenance
▶ Servicing and repairs may only be carried out by a
trained and certified installer.
▶ Immediately correct all faults to prevent system
damage.
▶ Use only PurePro spare parts! Damage caused by
the use of parts not supplied by PurePro may void
the warranty.
Instruct the customer
▶ Explain to the customer how the appliance works
and how to operate it.
▶ Inform the customer that he/she must not carry out
any alterations or repairs.
Danger from electric shock
▶ Ensure that only an authorized contractor performs
electrical work.
▶ Before performing electrical work, disconnect the
power and secure the unit against unintentional
reconnection.
▶ Ensure the system has been disconnected from the
power supply.
Risk of scalding at the hot water draw-off point
▶ When the water heater is in operation,
temperatures in excess of 122 °F (50 °C) can
occur. To limit the temperature at the tap, install a
thermostatic DHW mixing valve.
▶ Water heated for washing the laundry, dishes and
for other cleaning purposes can cause scalding and
permanent injuries.
▶ Children, elderly, and handicapped persons are
more likely to be permanently injured by hot water.
Never leave such individuals in the tub or shower
unattended under any circumstances. Children
must not be allowed to operate hot water faucets
themselves or to fill a bathtub.
4
▶ If the building has occupants in the above groups
who operate hot water faucets, or state laws / local
ordinances stipulate specific water temperatures,
take the following precautions:
– Use the lowest possible temperature setting.
– To prevent scalding, install a tempering device,
such as an automatic mixing valve, at hot water
tap or water heater. Select and install the
automatic mixing valve in accordance with the
valve manufacturer's recommendations and
instructions.
▶ Water exiting from drain valves can be extremely
hot. To avoid injuries:
– Check that all connections are tight.
– Direct exiting water away from people.
▶ Measures must be taken to protect against
excessive temperature and pressure! Installation of
a T&P safety valve is required.
To protect against corrosion and ensure compliance
with the rules for electrical safety, observe the
following points:
▶ Use metal fittings for potable water heating systems
with plastic piping.
▶ Use only original accessories from the
manufacturer.
▶ When installation of the water heater is complete,
inspect the ground conductor (including metal
fittings).
Maintenance
Customers are advised to:
▶ Sign a maintenance and inspection contract with an
authorized contractor. Inspect and maintain the
water heater as necessary on a yearly basis. Service
as needed.
▶ Use only genuine spare parts.
Flooding
▶ After a flood, do not use the appliance if any part
has been submerged. Damage to appliances that
have been submerged can be quite severe and pose
numerous safety risks.
▶ Every appliance that has been submerged must be
replaced.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Key to symbols and safety instructions
For your safety
▶ Do not store or use gasoline or other flammable,
combustible or corrosive vapors and liquids in the
vicinity of this or any other appliance.
DANGER: Fatal accidents!
Carbon monoxide poisoning.
▶ Carefully plan where you install the
heater. Correct combustion air supply
and flue pipe installation are very
important. If a gas appliance is not
installed correctly, fatal accidents can
result such as carbon monoxide
poisoning or fire.
DANGER:
Carbon monoxide poisoning.
▶ Exhaust gas must be vented to outside
using approved vent material. See table
5, page 13 (In Canada use only
ULCS636 approved material). Vent
and combustion air connector piping
must be sealed gas-tight to prevent flue
gas spillage, carbon monoxide
emissions and risk of fire, resulting in
severe personal injury or death.
Approved vent terminations must be
used when penetrating to the outside.
WARNING: Damage to the appliance from over
pressure.
▶ The heater must be disconnected from
the gas supply piping system during any
pressure testing of that system at test
pressures equal to or more than 0.5
psi.
NOTICE:
▶ The appliance should be located in an
area where leakage of the heater or
connections will not result in damage to
the area adjacent to the appliance or to
lower floors of the structure. When
such locations cannot be avoided, it is
recommended that a suitable drain
pan, adequately drained, be installed
under the appliance. The pan must not
restrict combustion air flow.
WARNING:
▶ The maximum inlet gas pressure must
not exceed the value specified by the
manufacturer and the minimum value
listed is for the purpose of input
adjustment.
NOTICE:
DANGER: Electric shock!
▶ Field wiring connections and electrical
grounding must comply with local
codes, or in the absence of local codes,
with the latest edition of the National
Electric Code, ANSI/NFPA 70, or in
Canada, all electrical wiring must
comply with the local codes and the
Canadian Electrical Code, CSA C22.1
Part 1.
DANGER: Electric shock!
Shock hazard: line voltage is present.
▶ Before servicing the water heater,
unplug power supply cord from outlet.
Failure to do so could result in severe
personal injury or death.
▶ If a water heater is installed in a closed
water supply system, such as one
having a backflow preventer in the cold
water supply line, means shall be
provided to control thermal expansion.
Contact the water supplier or local
plumbing inspector on how to control
this situation.
WARNING: Fire danger!
▶ Keep appliance area clear and free from
combustible materials, gasoline and
other flammable vapors and liquids.
NOTICE:
▶ Do not obstruct the flow of combustion
and ventilation air.
NOTICE: Appliance malfunction!
▶ If power is lost while appliance is
operating. Turn off both water and
power for 15 seconds to reset device.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
5
FCC rules
WARNING: Risk of scalding and property damage.
▶ Precautions must be taken prior to
manually operating the relief valve to
avoid contact with hot water
discharged from the relief valve and to
prevent water damage.
NOTICE: Appliance damage!
▶ Label all wires prior to disconnection
when servicing controls. Wiring errors
can result in improper and dangerous
operation. Verify proper operation after
servicing.
WARNING: System damage!
▶ If a relief valve discharges periodically,
this may be due to thermal expansion in
a closed water supply system. Contact
the water supplier or local plumbing
inspector on how to correct this
situation. Do not plug the relief valve.
WARNING: Property damage!
▶ If the water heater is used in a space
heating application, all piping and
components connected to the water
heater must be suitable for use with
potable water.
WARNING: Personal Injury from toxic chemicals.
▶ Toxic chemicals, such as those used for
boiler treatment, shall not be
introduced into the potable water used
for space heating.
WARNING: Personal Injury from toxic chemicals.
▶ A water heater which will be used to
supply potable water shall not be
connected to any heating system or
component(s) previously used with a
nonpotable water heating appliance.
2
Fig. 1
The chart below shows the relationship between water temperature and
time until there is a risk of scalding. It can be used as the basis for
determining the safest water temperature for your application.
Temperature
120 °F (48 °C)
125 °F (51 °C)
130 °F (54 °C)
135 °F (57 °C)
140 °F (60 °C)
145 °F (62 °C)
150 °F (65 °C)
155 °F (68 °C)
Time to severe scalding1)
longer than 5 minutes
1.5 to 2 minutes
approx. 30 seconds
approx. 10 seconds
less than 5 seconds
less than 3 seconds
approx. 1.5 seconds
approx. 1 second
Table 2 Approximate time-temperature relationship until there is a risk
of scalding
1) Source: Moritz, A.R. and Henriques, F.C., Jr. (1947). Studies of thermal injury.
II. The relative importance of time and surface temperature in the causation of
cutaneous burns, Am J of Pathol, 23, 695-720.
FCC rules
FCC: This device complies with Part 15 of the FCC rules. Operation is
subject to the following two conditions: (1) This device may not cause
harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.
6
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Appliance details
3
Appliance details
3.1
Features
Parts
• Key Pad interface control.
• High power pre-mix compact burner with low NOx emissions.
• Modulating Gas Valve with constant gas:air ratio control.
• Modulating water valve for improved comfort and temperature
control.
High quality materials for long working life
• Copper heat exchanger.
• High efficiency Ceramat Burner.
• Compact space saver: mounts on a wall with a supplied bracket.
Features
• Easily removable one-piece cover.
• On/Off and Temperature control switches.
• Reset button.
• Program button (Selectable temperature default).
• Failure codes for easy diagnostics and repair.
• Real-time diagnostics for troubleshooting/informational purposes.
• Built in freeze prevention.
Note: The freeze prevention kit is designed to provide protection for the
water heater down to approximately 5°F for short term conditions only.
It will not protect the appliance in areas where the temperature is
routinely expected to be below freezing.
- The freeze prevention kit will not protect plumbing outside the
appliance from freezing. Precautions should be taken.
PurePro is constantly improving its products, therefore
specifications are subject to change without prior
notice.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
7
Appliance details
3.2
Specifications (Technical data)
Approved in US/Canada
Technical characteristics
Units
TL-Pro 175 C
TL-Pro 199 C
GPM (l/min)
GPM (l/min)
GPM (l/min)
GPM (l/min)
BTU/hr (kW)
BTU/hr (kW)
UEF
BTU/hr (kW)
7.3 (27.6)
6.0 (22.6)
4.4 (16.5)
3.6 (13.8)
160,500 (47)
175,000 (51.2)
0.91
19,900 (5.8)
8.3 (31.4)
6.8 (25.7)
5.0 (18.8)
4.2 (15.7)
184,500 (54)
199,000 (58.3)
0.92
19,900 (5.8)
Selection range
Default temperature
Stability
Gas Requirement
°F ( °C)
°F ( °C)
°F ( °C)
100 - 140 (38 - 60)
122 (50)
 2 ( 1)
100 - 140 (38 - 60)
122 (50)
 2 ( 1)
Gas connection
Peak load inlet gas pressure1)
inches
¾"
¾"
Propane
Natural Gas
Water
water column
water column
8” - 13”
3.5” - 10.5”
8” - 13”
3.5” - 10.5”
Hot water connection
Cold water connection
Minimum water flow2)
Minimum recommended water pressure
Minimum well pressure
Water valve material
Connections:
Combustion
inches
inches
GPM (l/min)
PSI (bar)
PSI
Capacity
Maximum flow rate at a 45 °F (25 °C) rise
Maximum flow rate at a 55 °F (30.6 °C) rise
Maximum flow rate at a 75 °F (41.7 °C) rise
Maximum flow rate at a 90 °F (50 °C) rise
Maximum output
Maximum input
Uniform energy factor
Minimum Input
Temperature Control
CO level
CO2 level (set from factory)
Dimensions
Depth
Width
Height
Weight
Gas types
Natural Gas
LP Gas
Voltage
Nominal
Frequency
Amperage
Idle
Operation
Noise
Water protection3)
¾"
¾"
¾"
¾"
0.5 (1.9)
0.5 (1.9)
30 (2.07)
30 (2.07)
40
40
Polymer (PPS) (Polypropylene Sulfide) Polymer (PPS) (Polypropylene Sulfide)
Bottom of heater
Bottom of heater
ppm
%
 290 (measured)
see table 47
 290 (measured)
see table 47
inches (mm)
inches (mm)
inches (mm)
pounds (kg)
11 ¼ (286)
17 7/8 (452)
30½ (775)
74 (33.5)
11 ¼ (286)
17 7/8 (452)
30½ (775)
74 (33.5)
V AC
Hz
120
60
120
60
mA
A
db (A)
IP
40
 2.5
45 - 65
X4D
40
 2.5
45 - 65
X4D
Table 3
1) To measure Gas Pressure, see Measuring Gas Pressure, chapter 4.15, page 37.
2) Activation varies with inlet water temperatures from 0.5 - 1.6 gallon/minute (1.9 - 6.1 l/m).
3) Protection against water drops.
If appliance is installed at elevations above 2000ft, refer
to chapter 4.3.8 Fan speed adjustment.
8
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Appliance details
Safety devices
• Flame failure device (ionization flame rod sensor)
• Overheat prevention (temperature limiter)
• Inlet temperature sensor
• Outlet temperature sensor
• Back flow temperature sensor
• Exhaust gas temperature sensor
3.3
3.3.2 Remove front cover
▶ Loosen the two Phillips head screws located on bottom rear of cover.
Unpacking the heater
Before installing the unit, be certain you have the correct heater for
your type of Gas - Propane or Natural Gas. Identification labels are
found on the shipping box, and on the rating plate which is located on the
right side panel of the cover.
Fig. 3
Loosen the two screws
▶ Lift front cover panel upward and remove.
Fig. 2
[A]
[B]
Rating plate
Serial number
Type of gas
3.3.1 The box includes
• Tankless water heater
• Bracket for wall hanging the heater
• Exhaust vent adaptor (with 4 screws and gasket provided)
• Combustion air inlet adaptor (with 3 screws and gasket provided)
• Installation manual
• Energy Guide label
The TL-Pro 175/199 C is not approved or designed for:
• Boats or any mobile installation. (Modular homes are acceptable
for installation).
• Use above 8000 ft A.S.L. altitude (see page 23).
• Outdoor installation without installation of Outdoor kit.
Applications where inlet water temperature is higher than 140°F
(60°C). A 3-way valve or mixing valve must be installed before the
appliance if inlet water temperature exceeds this limit.
Fig. 4
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Remove the front cover
9
Appliance details
3.3.3 Remove combustion cover (service only)
▶ Open the four clips and remove the combustion cover.
Fig. 5
Remove the combustion cover
3.4
General rules to follow for safe operation
• 8. Should overheating occur or the gas supply fail to shut off, turn off
the gas supply at the manual gas shut off valve, on the gas line. Note:
manual gas shutoff valve is not supplied with the heater but must be
field installed.
• 9. Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and any gas
control which has been underwater.
• 10. Failure to install heater correctly may lead to unsafe operation
and void the warranty.
• 1. You must follow these instructions when you install your heater. In
the United States: The installation must conform with local codes or,
in the absence of local codes, the National Fuel Gas Code ANSI
Z223.1/NFPA 54.
In Canada: The Installation must conform with CSA B149.(1,2)
INSTALLATION CODES and /or local installation codes.
• 2. Carefully plan where you install the heater. Correct combustion air
supply and vent pipe installation are very important. If not installed
correctly, fatal accidents can occur, such as carbon monoxide
poisoning or fire.
• 3. When the unit is installed indoors and ROOM SEALED (twin pipe)
it is permitted to be located in bathrooms, bedrooms and occupied
rooms that are normally kept closed. See chapter 4.3 (page 12). If
the unit will be installed indoors and use indoor combustion air, the
place where you install the heater must have enough ventilation. The
National Fuel Gas Codes do not allow UNSEALED gas fired water
heater installations in bathrooms, bedrooms or any occupied
rooms normally kept closed. See chapter 4.4 (page 27).
• 4. You must correctly vent your heater. See chapter 4.3 (page 12) on
VENTING.
• 5. The appliance and its gas connection must be leak tested before
placing the appliance in operation.
The appliance must be isolated from the gas supply piping system by
closing its individual manual gas shutoff valve (not supplied with
heater) during any pressure testing at pressures in excess of ½ Psig
(3.5 kPa).
• 6. Keep water heater area clear and free from combustibles and
flammable liquids. Do not locate the heater over any material which
might burn.
• 7. Correct gas pressure is critical for the proper operation of this
heater. Gas piping must be sized to provide the required pressure at
the maximum output of the heater, while all the other gas appliances
are in operation. Check with your local gas supplier, and see the
section on connecting the gas supply. See chapter 4.9 (page 30).
10
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Appliance details
3.5
Dimensions and minimum installation clearances
Fig. 6
Dimensions
[1]
[2]
[3]
[4]
[5]
[6]
On/Off button
Reset button
Program key
LCD display
Up button
Down button
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
11
Installation instructions
4
Installation instructions
4.1
Specialized tools
The following specialized tools may be required for installation:
• Manometer
• Multi-meter
• Combustion Gas Analyzer
4.2
Introduction
Please follow these instructions. Failure to follow instructions may
result in:
▶ Damage or injury.
▶ Improper operation.
▶ Loss of warranty.
DANGER:
▶ The water heater must be installed by a qualified
installer in accordance with these instructions. If
improperly installed, a hazardous condition such as
explosion or carbon monoxide poisoning could
result. Manufacturer is not responsible for
improperly installed appliances.
Fig. 7
Common installation practice is to first determine the
venting/combustion air point of termination, then
design the piping layout back to the heater.
Side view
For servicing access, a 2ft clearance is recommended to
the front cover.
TL-Pro 175/199 C
TOP (A)
12”
FRONT (B)
1”
BACK
0”
SIDES
1”
FLOOR (C)
12”
Table 4 Recommended minimum clearances
4.3
Venting
NOTICE:
▶ Do not reduce the exhaust or combustion air vent
pipe sizes.
▶ Do not common vent with any other vented appliance
or stove.
▶ Do not use Type-B vent as the actual exhaust vent
system for the appliance.
DANGER: Flue gas poisoning!
▶ Failure to vent the exhaust gases to the outside (see
table 5 for proper material) may result in dangerous
flue gases filling the structure in which it is installed.
NOTICE:
▶ In areas where outside temperatures routinely come
close to freezing, sealed combustion operation is
required. Concentric termination or separate
terminations for combustion and vent, must be
installed on the same wall or roof surface; however,
never facing the direction of prevailing winds. Failure
to do so may result in heat exchanger freezing and
bursting. This failure is not covered under the
manufacturer's warranty.
WARNING: Appliance malfunction!
▶ Protect the exhaust and inlet from leaves and debris
by installing a screen on the end of the termination.
¼ " mesh minimum opening recommended on
screen.
12
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
4.3.1 Vent options
The water heater is approved with the following venting options:
All combustion air and vent pipe materials and fittings must comply with
the following:
Item
Vent
or
air
pipe
and
fitting
Material
PP concentric single
United States
PP common vent
Canada
ULC-S636
certified only
PP twin pipe
PVC schedule 40
ANSI/ASTM D1785
PVC-DWV
ANSI/ASTM D2665
CPVC schedule 40
ANSI/ASTM F441
ABS-DWV schedule
ANSI/ASTM D2661
Pipe
cement CPVC
/ primer
ABS
PVC
ANSI/ASTM D2564
ANSI/ASTM F493
ABS. Generic PP twin pipe can be used if certified to ULC-S636 and only
with 90° elbow or T terminals. Maximum vent lengths and equivalent
lengths per tables 8 and 9 apply.
Description
3- In. Rain Cap
4- In. Diameter SDR-26 Pipe
3- In. Y
Concentric Fitting
2- ½ In. Diameter SDR-26 Pipe
3- In. Condensate drain Tee
1.5- In. Condensate drain bushing
Length
N/A
24 In. long
N/A
37-1/8 in.
long
N/A
N/A
Kit part no. and
quantity
239-44069-01
1
1
1
1
1
1
Table 6 PVC concentric vent part breakdown
ANSI/ASTM D2235
Table 5 Approved vent material
For specific questions concerning vent material, specifications,
usage or installation, please contact the vent manufacturer directly.
The use of cellular core PVC (ASTM F891), cellular
core CPVC, or Radel® (polyphenolsulfone) in nonmetallic venting systems is prohibited.
Covering non-metallic vent pipe and fittings with
thermal insulation is prohibited.
Fig. 8
PP Concentric up and out system
The concentric up and out vent system simplifies installations where the
water heater is mounted on an outside wall that can be direct vented
through that wall. This vent system only consists of the concentric
appliance adapter, one 90° elbow, and the termination, and can not be
extended further.
Concentric up and out kit
The concentric up and out system must be installed according to the
respective Installation Manual.
All vent connections must be glued, except for the PP vent systems, and
the exhaust adapter (chapter 4.3.4) which is screwed into place on
the top of the appliance. Slide the vent pipe into the exhaust adapter.
The exhaust pipe must be properly supported and must be pitched a
minimum of a ¼ inch per foot back to the appliance. This allows the
condensate to drain properly.
Fig. 9
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[LA]
Concentric vent kit example
Exhaust
Combustion air
Roof boot/flashing (field supplied)
Exhaust pipe
Drain tee
Intake pipe
Concentric vent kit (239-44069-01)
Maintain 12 in. (18 in. for Canada) minimum clearance above
highest anticipated snow level maximum of 24 in. above roof
An optional concentric vent/air intake termination can be used for the
installation of a vertical or horizontal venting system when using PVC,
CPVC, or ABS (see fig. 9).
The concentric vent/air intake body can be ordered from your local
wholesaler.
The appliance can also be installed with separate air intake and exhaust
piping (see fig. 12, fig. 20 and fig. 21, page 20) in PP, PVC, CPVC, and
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
13
Installation instructions
4.3.2 Vent specifications
Establish vent clearances that comply with the vent manufacturer's
specifications and all applicable national/local codes.
Venting specifications
Diam.
3 or 4 inches
E
x
h 2, 3 or 4 inches
a
3 inches
u
s
t
3 or 4 inches
I
3 or 4 inches
n
t 2, 3 or 4 inches
a
3 inches
k
e
3 or 4 inches
Approved terminals
“T” terminal
4" Venting Maximum
allowable
total vent
Length
Twin pipe
126ft
Concentric
Maximum
allowable
Exhaust
Length
63ft
Maximum
allowable
Intake
Length
63ft
43ft
43ft
86ft
Elbow
Equivalency
90°
45°
5ft
2.5ft
5ft
2.5ft
Table 9 Maximum Allowable Exhaust and Combustion Air Lengths for 4"
PP, PVC, CPVC, and ABS venting
90° elbow
PVC Flue Cap*(ECAP321)Vertical terminations
3" diameter only
2" Venting
Concentric
“T” terminal
Twin pipe
with two
terminations
90° elbow
PVC Flue Cap*(ECAP321)Vertical & horizontal
terminations approved 3" diameter only
Concentric
Table 7 Venting specifications for intake and exhaust
[*]
ULC S636-95, UL1738 certified
Condensate drain requirements
When the Water Heater is installed in a residential single family dwelling
without direct recirculation an external condensate drain is not required.
If the Water Heater is installed in an application other than a residential
single family dwelling an external condensate drain (not supplied with
the Water Heater) is required in the following circumstances:
• Vertical terminating exhaust vent installations.
• Horizontal terminating exhaust vent installations greater than 6 feet
(1.8 m) linear measurement, (NOT total equivalent length).
• Vent installations where any section of the exhaust vent pipe passes
through an unconditioned space.
Note: An external condensate drain is recommended in all installations
as best practice in order to maximize the longevity of the Water Heater.
Maximum
allowable
total vent
Length
19ft
Maximum
allowable
Exhaust
Length
9.5ft
Maximum
Elbow
allowable Equivalency
Intake
90°1) 45°
Length
9.5ft
5 ft / 2.5 ft
2.5 ft
Table 10 Maximum Allowable Exhaust and Combustion Air Lengths for
2" PVC venting
1) If using 90° short sweep elbow equivalent length is 5 ft.
If using 90° long sweep elbow equivalent length is 2.5 ft.
Use of elbows
It is recommended to limit the amount of elbows used in the exhaust and
combustion air piping to reduce friction in the air flow. The following lists
the maximum amount of 90° elbows allowed in either the exhaust or
combustion air piping:
Max. number of 90° elbows
3" venting 4" venting 2" venting
Twin pipe system
5
7
1 or 2 1)
Concentric system
4
7
_
Table 11
1) If using 90° short sweep elbow the max. number is 1.
If using 90° long sweep elbow the max. number is 2.
Two 45° elbows are equal to one 90° elbow. Any combination of 45° and 90° elbows may be used in the
vent system as long as the combination does not exceed the maximum listed in table 11 above.
Minimum combustion air and exhaust pipe length
The minimum exhaust pipe length is 1 foot (0.3m) of straight vent pipe.
The minimum combustion air pipe length is one 90° elbow, except with
the Common Vent System where the provided air intake grill cap is used.
Maximum combustion air and exhaust pipe length
The following tables display the maximum allowable straight pipe
lengths for combustion air and exhaust piping with consideration to the
number of elbows used. Reduce the equivalent length for each elbow
used from the maximum allowable length depending on the system
used. Refer to table 8 if using 3" diameter venting. Refer to table 9 if
using 4" diameter venting. Refer to table 10 if using 2" diameter venting.
Calculation example for 3" PVC, CPVC, or ABS venting:
Exhaust
3" Venting Maximum
allowable
total vent
Length
Table 12
Maximum
allowable
Exhaust
Length
Maximum
allowable
Intake
Length
Elbow
Equivalency
90° 45°
Twin pipe
62 ft
31ft
31ft
5 ft 2.5 ft
Concentric
46 ft
23ft
23ft
5 ft 2.5 ft
Table 8 Maximum Allowable Exhaust and Combustion Air Lengths for 3"
PP, PVC, CPVC, and ABS venting
System used
Concentric
Number of 90° elbows needed:
1
Number of 45° elbows needed:
2
Calculation of example
Max. length
23’
90° elbow reduction
- 5’
sub-total =
18’
45° elbow reduction
- 5’
Total =
13’
Table 13
14
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
For this example, the maximum allowable exhaust pipe
length is 13 feet.
Combustion air
System used
Concentric
Number of 90° elbows needed:
2
Number of 45° elbows needed:
1
Table 14
For this example, the maximum allowable combustion
air pipe length is 48 feet.
Calculation example for 2" PVC venting:
Exhaust
System used
Number of 90° elbows needed:
Number of 45° elbows needed:
Twin pipe
1
0
Table 20
Calculation of example
Max. length
23’
90° elbow reduction
- 10’
sub-total =
13’
45° elbow reduction
- 2.5’
Total =
11.5’
Calculation of example
Max. length
90° elbow reduction
sub-total =
45° elbow reduction
Total =
9.5’
- 5’
4.5’
- 0’
4.5’
Table 21
Table 15
For this example, the maximum allowable exhaust pipe
length is 4.5 feet.
For this example, the maximum allowable combustion
air pipe length is 11.5 feet.
Combustion air
Calculation example for 4" PP, PVC, CPVC, or ABS venting:
Exhaust
System used
Number of 90° elbows needed:
Number of 45° elbows needed:
Twin pipe
1
2
Table 16
Calculation of example
Max. length
90° elbow reduction
sub-total =
45° elbow reduction
Total =
63’
- 5’
58’
- 5’
53’
System used
Number of 90° elbows needed:
Number of 45° elbows needed:
Twin pipe
0
2
Table 22
Calculation of example
Max. length
90° elbow reduction
sub-total =
45° elbow reduction
Total =
9.5’
- 0’
9.5’
- 5’
4.5’
Table 23
For this example, the maximum allowable combustion
air pipe length is 4.5 feet.
Table 17
For this example, the maximum allowable exhaust pipe
length is 53 feet.
Combustion air
System used
Number of 90° elbows needed:
Number of 45° elbows needed:
Twin pipe
2
2
Table 18
Calculation of example
Max. length
90° elbow reduction
sub-total =
45° elbow reduction
Total =
63’
- 10’
53’
- 5’
48’
Table 19
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
15
Installation instructions
Required direct vent terminal clearances (twin pipe / concentric penetration) for PVC, CPVC, ABS, and PP.
Fig. 10
Canadian installations1)
U.S. installations2)
A
Clearance above grade, veranda, porch, deck or balcony
12 in.
12 in.
B
Clearance to window or door that may be opened
36 in.
12 in.
C
Clearance to permanently closed window
*
*
D
*
*
E
Vertical clearance to ventilated soffit located above the vent
termination within a horizontal distance of 2 feet (61cm) from
the center line of the termination
Clearance to unventilated soffit
*
*
F
Clearance to outside corner
*
*
G
Clearance to inside corner
*
*
H
Clearance to each side of center line extended above meter/
regulator assembly
Clearance to service regulator vent outlet
36 in. within a height 15 feet above
meter/ regulator assembly
36 in.
*
*
Clearance to non-mechanical air supply inlet to building or the
combustion air inlet to any other application
Clearance to mechanical air supply inlet
36 in.
12 in.
72 in.
Clearance above paved sidewalk or paved driveway located on
public property
Clearance under veranda, porch deck or balcony
84 in. 3)
36 in. above if within 10 feet
horizontally
*
12 in. 4)
*
I
J
K
L
M
Table 24
1) In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.
2) In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
[*]
16
For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:
a) A minimum clearance value determined by testing in accordance with section 2.20, or;
b) A reference to the following footnote:
“Clearance in accordance with local installation codes and the requirements of the gas supplier.”
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
Required other than direct vent terminal clearances (single pipe penetration) for PVC, CPVC and ABS systems.
Fig. 11
Canadian installations1)
U.S. installations2)
A
Clearance above grade, veranda, porch, deck or balcony
12 in.
12 in.
B
Clearance to window or door that may be opened
36 in.
C
Clearance to permanently closed window
*
4 feet below or to side of opening;
1 foot above opening
*
D
*
*
E
Vertical clearance to ventilated soffit located above the vent
termination within a horizontal distance of 2 feet (61cm) from the
center line of the termination
Clearance to unventilated soffit
*
*
F
Clearance to outside corner
*
*
G
Clearance to inside corner
*
*
H
Clearance to each side of center line extended above meter/
regulator assembly
Clearance to service regulator vent outlet
36 in. within a height 15 feet above
meter/ regulator assembly
36 in.
*
Clearance to non-mechanical air supply inlet to building or the
combustion air inlet to any other application
Clearance to mechanical air supply inlet
36 in.
Clearance above paved sidewalk or paved driveway located on
public property
Clearance under veranda, porch deck or balcony
84 in. 3)
4 feet below or to side of opening;
1 foot above opening
36 in. above if within 10 feet
horizontally
84 in.
12 in. 4)
*
I
J
K
L
M
72 in.
*
Table 25
1) In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code
3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.
[*]
For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:
a) A minimum clearance value determined by testing in accordance with section 2.20, or;
b) A reference to the following footnote:
“Clearance in accordance with local installation codes and the requirements of the gas supplier.”
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
17
Installation instructions
4.3.3
Vent configuration examples for PP, PVC, CPVC, or ABS
systems
Below are approved examples of vertical and horizontal venting
installations.
WARNING:
▶ Single pipe penetration should be used in nonfreezing climates only and steps must be taken to
ensure that adequate combustion air is available to
the water heater at all times!
Fig. 14 Horizontal venting system (concentric vent)
Fig. 12 Vertical venting system (single pipe penetration)
[1]
[2]
[3]
[LA]
Drain tee (when required)
Intake
Exhaust
Maintain 12 in. (18 in. for Canada) minimum clearance above
highest anticipated snow level maximum of 24 in. above roof.
[1]
[2]
[3]
[4]
[5]
[LA]
Exhaust
Combustion air
Exhaust pipe
Drain tee (when required)
Intake pipe
Minimum 1"
NOTICE:
▶ The air intake connection on the concentric
termination can be oriented in any possible
direction.
Fig. 13 Horizontal venting installation (combustion air piping not
shown)
[1]
[2]
[3]
[4]
[5]
18
Termination
Minimum above ground or normally expected snow accumulation
level
Appliance
Elbow (note: minimum 1ft of straight vent pipe required)
Horizontal run ¼ " per foot down to termination
Fig. 15 Horizontal parallel venting system (twin pipe direct vent)
[A]
3 ft minimum (only when terminations are at the same height)
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
▶ If using 4" venting, a 3" to 4" increaser should be installed directly
after this accessory. If using 2" venting, a 3" to 2" reducer should be
installed directly after this accessory. If using the PP twin pipe
system, adapters from the appliance adapter (3" PVC compatible) to
the PP system are needed.
NOTE: Vent pipe must be completely vertical when
inserting or blue gasket inside exhaust accessory can
become displaced. Exhaust accessory can be removed
with vent pipe attached to check gasket position.
Fig. 16 Vent and air intake pipe position of a sealed combustion system
[1]
[2]
[X]
Intake
Exhaust
At least 1 foot (305mm)
Fig. 18 Exhaust connection
▶ Attach the combustion air inlet accessory to the top of the unit fig. 19
(position 2) using the 3 screws and gasket provided, and install 3" air
intake pipe over the accessory.
Fig. 17 Horizontal venting system (single pipe penetration)
[1]
[2]
[3]
[LA]
Exhaust pipe
Drain tee (when required)
Intake pipe
Minimum 4"
NOTICE: Risk of appliance freezing!
▶ Single pipe penetration should be used in nonfreezing climates only and steps must be taken to
ensure that adequate combustion air is available to
the water heater at all times!
Fig. 19 Inlet connection
4.3.4
Vent connections for PP, PVC, CPVC, and ABS systems
Attaching the exhaust and air inlet connection adaptors to the top of
the heater
▶ Attach the flue gas exhaust accessory to the top of the unit fig. 18
(position 1) using the 4 screws and gasket provided, and fully insert
vent pipe into the accessory.
Note: Adhesive backing needs to be removed prior to
installation.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
NOTE: The combustion air accessory can be installed on
the top right or on the top left side of the heater. The
combustion air inlet that is not used must be kept sealed.
4.3.5
Connecting the condensate water drain
NOTICE: Risk of appliance freezing!
▶ Failure to properly install condensate drain can
damage the appliance and will void the warranty.
19
Installation instructions
NOTICE: Risk of appliance freezing!
▶ Do not install condensate drain tubing in areas where
it may freeze.
The condensate must be disposed of in accordance with
local codes.
See chapter 4.12 “Filling the condensate trap”.
Use materials approved by the authority having
jurisdiction. In the absence of other authority, PVC, and
CPVC pipe must comply with ASTM D1785, F441
orD2665. Cement and primer must comply with ASTM
D2564 or F493. For Canada, use CSA or ULC certified
PVC or CPVC pipe, fittings and cement, see table 5.
PP pipe must be certified under ULC S636.
Appliance condensate drain installation
The appliance comes equipped with an internal condensate drain and
siphon. This drains condensation formed in the secondary heat
exchanger. Piping must be installed under the condensate drain outlet
on the water heater and piped for disposal in accordance with local
codes.
Fig. 21 External condensate drain installation
[1] Condensate drain
[2] Dispose of condensate in accordance with local codes
[LA] Minimum 4"
4.3.6 Freeze prevention for PVC, CPVC, and ABS systems
In cold climates, components of a tankless water heater can freeze and
burst from negative draft. A leading cause of negative draft is
combustion appliances in the building not being supplied with sufficient
combustion air. A wood stove or furnace can pull its combustion air from
the water heater‘s vent pipe, allowing the cold incoming air to freeze the
cold water in the heat exchanger. Supplying more combustion air for all
combustion appliances is the solution. A HVAC specialist should be
consulted to design solutions for providing more combustion air.
Listed below is an additional measure designed to further limit backdraft
in extreme conditions assuming all other possible causes have been
addressed.
Fig. 20 Appliance drain installation
[1]
[2]
[3]
Leave minimum ¼ " air gap
Trap required
1 ½ " x ½ " PVC reducer
Backdraft reducer
The Heat Fab backdraft reducer (9301BFP) is the preferred option for
limiting backdraft (see fig. 22).
Note: The following solution is available only for 3" diameter
venting.
External condensate drain installation
If an external condensate drain (installer supplied) must be installed
(chapter 4.3.2), the following is recommended:
• 1. Install condensate drain on a horizontal section of the exhaust pipe
as close to the heater as possible.
• 2. The condensate must be disposed of according to local codes.
• 3. To install condensate drain in vent system, use PVC 3" X 3" X 1.5"
tee (part# 196278) and reduce for drain connection
6720608643-18.1V
Fig. 22 Part # 9301BFP
20
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
Installation
For this solution to be effective, the internal flapper must be 100%
closed when the water heater is not running. Refer to Figures 24 and25
for preferred installation positions in the vent system.
Installation considerations:
• Install damper per the supplied manufacturer‘s instructions.
• The damper is only to be used in the exhaust vent piping.
• Ensure directional arrow on damper label faces in the same direction
as exhaust flow.
• If installed horizontally, the axis must be horizontal or slightly pitched
up towards termination to ensure damper closes 100% when heater
is not running.
• To allow accessibility, damper must not be installed in an enclosed
section of vent pipe.
• Do not install damper in unconditioned spaces (e.g. attics)
Condensation can build up while the heater is running which can later
freeze and potentially block the flapper.
6720608643-19.1V
Fig. 23 Blackflow reducer (9301BFP) installed
Fig. 25
[1]
[2]
[3]
[4]
[5]
[6]
Good
Better
Best
Enclosed vent pipe (Do not install damper)
Unconditioned space (Do not install damper)
Preferred damper position for vertical terminations
Fig. 24
[1]
[2]
[3]
Good
Better
Best
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
21
Installation instructions
4.3.7 Common venting of 2 to 4 units
2 to 4 unit cascades can be common vented using the optional PP
common venting system. The water heaters can be installed in a back to
back configuration as shown in fig. 27, or side by side as shown in fig.
28.
The systems are custom configurable for vent lengths from 40” (1m) up
to 100’ (30m) and either a vertical or horizontal termination (see fig.
26).
The following configurations are available:
Units
2
4
2
3
4
Configurations
Back to Back
Back to Back - see fig. 27
Side by Side - see fig. 26
Side by Side
Side by Side - see fig. 28
Table 26
Where no empty wall space is available a powder coated steel racking
system is also available for water heaters in side by side or back to back
configurations. See the respective product brochure for details.
Fig. 27 Back to back configuration
Fig. 28 Side by side configuration
Fig. 26 Common venting for 2 to 4 water heaters available with vertical
or horizontal termination
22
NOTICE: Figures 26 to 28 depict the conceptual
configurations available.
▶ For installation details and requirements consult the
respective common vent installation instructions
listed on the manufacturers website.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
4.3.8
Fan speed adjustment
necessary adjustments to fan speed values may result in improper
operation of the appliance.
NOTICE: IMPORTANT INFORMATION!
▶ Natural gas heaters with installation altitudes below
2,000 ft above sea level disregard this section.
Installation adjustment:
After installing the tankless water heater, the fan speed values for
minimum power (P2) and maximum power (P1) may need adjustment
due to variations in altitude and vent pipe length. Failure to make
First calculate the total equivalent vent length. This is the straight pipe
length of both exhaust and combustion air plus the number of elbows
used. To determine the length equivalency of each elbow refer to tables
8 and 9.
Use the equivalent vent length value to determine the appropriate fan
speed values found in table 28 and 29. Refer to page 26 on how to adjust
the fan speeds if an adjustment is necessary. After changing fan speed
values, proceed to chapter 7.5 to confirm CO2 values are within
specified ranges.
TL-Pro 199 C Fan Speed Adjustment
Altitude (above sea
level)
Vent
terminal
Total equivalent vent
length1)
0 - 2000 ft
(0 - 610 m)
Twin
system
2000 - 4500 ft2)
(610 - 1372 m)
Twin
system
3.5 - 11 ft
12 - 19 ft
3.5 - 11 ft
12 - 19 ft
Natural Gas
Liquid
propane
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
123)
123)
133)
133)
Minimum
power fan
speed (P2)
173)
173)
173)
173)
Maximum
power fan
speed (P1)
523)
523)
523)
523)
Maximum
power fan
speed (P1)
523)
523)
523)
523)
Table 27 TL-Pro 199C Fan speed adjustment for 2" piping
1) Full equivalent length (inlet + outlet piping + fittings)
2) When installing in altitude, the unit may not reach the rated Input
3) When adjusting the unit, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
Altitude (above sea
level)
0 - 2000 ft
(0 - 610 m)
Vent
terminal
Total equivalent vent
length1)
Concentric
Twin
system
2000 - 4500 ft
(610 - 1372 m)
Concentric
Twin
system
4500 - 8000 ft
(1372 - 2439 m)
6 - 25 ft
26 - 46 ft
Concentric
Twin
system
6 - 37 ft
Natural Gas
Liquid
propane
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
No
modification
required
Minimum
power fan
speed (P2)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
11*
14*
52*
52*
38 - 62 ft
6 - 25 ft
26 - 46 ft
11*
14*
53*
53*
6 - 37 ft
10*
13*
52*
52*
38 - 62 ft
11*
14*
53*
53*
6 - 25 ft
11*
14*
53*
53*
26 - 46 ft
13*
16*
53*
53*
6 - 37 ft
11*
14*
53*
53*
38 - 62 ft
12*
15*
53*
53*
For operation at
elevations above
2,000 ft (610 m)
the equipment
ratings shall be
reduced at the rate
of 4% for each
1,000 ft (305 m)
above sea level
* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
Table 28 TL-Pro 199C Fan speed adjustment for 3" piping
1) Full equivalent length (inlet + outlet piping + fittings)
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
23
Installation instructions
Altitude (above
sea level)
0 - 2000 ft
(0 - 610 m)
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
No
modification
required
Minimum
power fan
speed (P2)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
3.5 - 39 ft
11*
14*
52*
52*
40 - 86 ft
11*
14*
53*
53*
3.5 - 59 ft
10*
13*
52*
52*
60 - 126 ft
11*
14*
53*
53*
3.5 - 39 ft
11*
14*
53*
53*
40 - 86 ft
13*
16*
53*
53*
3.5 - 59 ft
11*
14*
53*
53*
60 - 126 ft
12*
15*
53*
53*
Total equivalent vent
length1)
Concentric
3.5 - 39 ft
40 - 86 ft
3.5 - 59 ft
60 - 126 ft
Concentric
Twin
system
4500 - 8000 ft
(1372 - 2439 m)
Liquid
propane
Vent
terminal
Twin
system
2000 - 4500 ft
(610 - 1372 m)
Natural Gas
Concentric
Twin
system
For operation at
elevations above
2,000 ft (610 m) the
equipment ratings
shall be reduced at
the rate of 4% for
each 1,000 ft (305
m) above sea level
* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
Table 29 Fan speed adjustment for 4" piping
1) Full equivalent length (inlet + outlet piping + fittings)
TL-Pro 175 C Fan Speed Adjustment
Altitude (above sea
level)
Vent
terminal
Total equivalent vent
length1)
0 - 2000 ft
(0 - 610 m)
Twin
system
2000 - 4500 ft2)
(610 - 1372 m)
Twin
system
3.5 - 11 ft
12 - 19 ft
3.5 - 11 ft
12 - 19 ft
Natural Gas
Liquid
propane
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
123)
123)
133)
133)
Minimum
power fan
speed (P2)
173)
173)
173)
173)
Maximum
power fan
speed (P1)
483)
483)
483)
493)
Maximum
power fan
speed (P1)
483)
483)
483)
493)
Table 30 TL-Pro 175C Fan speed adjustment for 2" piping
1) Full equivalent length (inlet + outlet piping + fittings)
2) When installing in altitude, the unit may not reach the rated Input
3) When adjusting the unit, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
24
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
Altitude (above sea
level)
0 - 2000 ft
(0 - 610 m)
Vent
terminal
Total equivalent vent
length1)
Concentric
6 - 25 ft
26 - 46 ft
Twin
system
2000 - 4500 ft
(610 - 1372 m)
6 - 37 ft
Liquid
propane
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
No
modification
required
Minimum
power fan
speed (P2)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
38 - 62 ft
Concentric
Twin
system
4500 - 8000 ft
(1372 - 2439 m)
Natural Gas
6 - 25 ft
11*
14*
47*
47*
26 - 46 ft
11*
14*
48*
48*
6 - 37 ft
10*
13*
47*
47*
38 - 62 ft
11*
14*
48*
48*
Concentric
Twin
system
6 - 25 ft
11*
14*
48*
48*
26 - 46 ft
13*
16*
48*
48*
6 - 37 ft
11*
14*
48*
48*
38 - 62 ft
12*
15*
48*
48*
For operation at
elevations above
2,000 ft (610 m)
the equipment
ratings shall be
reduced at the rate
of 4% for each
1,000 ft (305 m)
above sea level
* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
Table 31 TL-Pro 175C Fan speed adjustment for 3" piping
1) Full equivalent length (inlet + outlet piping + fittings)
Altitude (above
sea level)
0 - 2000 ft
(0 - 610 m)
Natural Gas
Liquid
propane
Minimum
power fan
speed (P2)
No
modification
required
Minimum
power fan
speed (P2)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
Maximum
power fan
speed (P1)
No
modification
required
3.5 - 39 ft
11*
14*
47*
47*
40 - 86 ft
11*
14*
48*
48*
3.5 - 59 ft
10*
13*
47*
47*
60 - 126 ft
11*
14*
48*
48*
3.5 - 39 ft
11*
14*
48*
48*
40 - 86 ft
13*
16*
48*
48*
3.5 - 59 ft
11*
14*
48*
48*
60 - 126 ft
12*
15*
48*
48*
Total equivalent vent
length1)
Concentric
3.5 - 39 ft
40 - 86 ft
3.5 - 59 ft
60 - 126 ft
Concentric
Twin
system
4500 - 8000 ft
(1372 - 2439 m)
Liquid
propane
Vent
terminal
Twin
system
2000 - 4500 ft
(610 - 1372 m)
Natural Gas
Concentric
Twin
system
For operation at
elevations above
2,000 ft (610 m) the
equipment ratings
shall be reduced at
the rate of 4% for
each 1,000 ft (305
m) above sea level
* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see chapter 7.5 for instructions.
Table 32 Fan speed adjustment for 4" piping
1) Full equivalent length (inlet + outlet piping + fittings)
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
25
Installation instructions
PP Concentric up and out venting - only TL-Pro 199 C
Altitude
0 - 2000
2000 - 4500
4500 - 8000
NG P2
no change
no change
no change
LP P2
no change
no change
no change
NG P1
no change
no change
no change
LP P1
50
50
50
Adjusting minimum power fan speed (P2)
To select fan speed:
▶ Press ON/OFF button
into ON.
▶ Immediately following, press and hold simultaneously buttons +
or
and P for 3 seconds, until display reads P2.
Table 33 Fan speed adjustment for concentric up and out vent
Cascade common venting system - 199C
Altitude
Total
NG P2
equivalent
length
0 - 2000
4 - 100ft
19
2000 - 4500 4 - 100ft
20
4500 - 8000 4 - 100ft
20
LP P2
19
20
20
NG P1
LP P1
no change no change
52
53
53
53
Table 34 Fan speed adjustment for cascade vent
Cascade common venting system - 175C
Altitude
Total
NG P2
equivalent
length
0 - 2000
4 - 100ft
19
2000 - 4500 4 - 100ft
20
4500 - 8000 4 - 100ft
20
LP P2
19
20
20
Fig. 29
NG P1
LP P1
no change no change
47
47
48
48
▶ Press P to enter P2 adjustment. The current setting will appear on
the display (factory default).
▶ Press + or
to choose the fan speed suitable with your
installation, see table 28 and table 29.
▶ Press and hold ( 5 sec.) “Program” button P until the display
flashes, then the selected value is memorized.
Table 35 Fan speed adjustment for cascade vent
Proceed directly to chapter 7.5 to confirm CO2 values
are within range.
Adjusting maximum power fan speed (P1)
To select fan speed:
▶ Press ON/OFF button
into ON.
▶ Immediately following, press and hold simultaneously buttons +
or
and P for 3 seconds, until display reads P2.
Fig. 30
▶ Press the minus button
to display P1.
▶ Press “Program” button P to enter P1 adjustment. The current
setting will appear on the display.
▶ Press + or
to choose the fan speed suitable with your
installation, see table28 and table 29.
▶ Press and hold ( 5 sec.) “Program” button P until the display
flashes, then the selected value is memorized.
Proceed directly to chapter 7.5 to confirm CO2 values
are within range.
Attention residents of the Commonwealth of Massachusetts:
In the Commonwealth of Massachusetts the following regulation went
into effect on 12/30/2005:
(a)For all side wall horizontally vented gas fueled equipment installed in
26
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following
requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of
installation of the side wall horizontal vented gas fueled equipment, the
installing plumber or gas fitter shall observe that a hard wired carbon
monoxide detector with an alarm and battery back-up is installed on the
floor level where the gas equipment is to be installed. In addition, the
installing plumber or gas fitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment. It shall be the
responsibility of the property owner to secure the services of qualified
licensed professionals for the installation of hard wired carbon
monoxide detectors.
a.In the event that the side wall horizontally vented gas fueled equipment
is installed in a crawl space or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be installed on the next
adjacent floor level.
b. In the event that the requirements of this subdivision can not be met
at the time of completion of installation, the owner shall have a period of
thirty (30) days to comply with the above requirements; provided,
however, that during said thirty (30) day period, a battery operated
carbon monoxide detector with an alarm shall be installed.
2.APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above provisions
shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of eight (8)
feet above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or equipment. The sign
shall read, in print size no less than one half (1/2) inch in size, "GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon
monoxide detectors and signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a)1 through 4.(b)
EXEMPTIONS: The following equipment is exempt from 248 CMR
5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required
To Be Vented" in the most current edition of NFPA 54 as adopted by the
Board; and
2. Product approved side wall horizontally vented gas fueled equipment
installed in a room or structure separate from the dwelling, building or
structure used in whole or in part for residential purposes.
(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM REQUIRED. When the manufacturer of Product Approved side
wall horizontally mounted gas equipment provides a venting system
design or venting system components with the equipment, the
instructions provided by the manufacturer for the installation of the
equipment and the venting shall include:
1. Detailed instructions for the installation of the venting system or the
venting system components: and
2. A complete parts list for the venting system design or venting system.
(d)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED. When the manufacturer of a product approved
side wall horizontally vented gas fueled equipment does not provide the
parts for the venting of flue gases, but identifies "special venting
systems," the following requirements shall be satisfied by the
manufacturer:
1. The referenced "special venting system" instructions shall be included
with the appliance or equipment installation instructions; and
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
2. The "special venting systems" shall be product approved by the
Board, and the instructions for that system shall include a parts list and
detailed installation instructions.
(e) A copy of all installation instructions for all products approved side
wall horizontally vented gas fueled equipment, all venting instructions,
all parts lists for venting instructions, and/or all venting design
instructions shall remain with the appliance or equipment at the
completion of the installation.
4.4
Combustion air requirements
CAUTION:
▶ In areas where outside temperatures routinely come
close to freezing, sealed combustion operation is
required. Use a concentric termination or separate
terminations for combustion and vent, which must
be installed on the same wall or roof surface,
however never facing the direction of prevailing
winds. Failure to do so may result in heat exchanger
freezing up and bursting. This failure is not covered
under the manufacturer's warranty.
CAUTION:
▶ When installed in an environment where corrosive
chemicals or dirty air (e.g. hair salons, car washes)
are present the twin pipe system is required.
Twin pipe and Concentric pipe
The water heater is designed as a sealed combustion appliance. It is
recommended that the combustion air be provided by a dedicated 3” or
4” pipe from the outside (twin pipe) or by connecting to the Concentric
vent kit (see Fig.9). The combustion air pipe may be PVC or any other
rigid sealed 3" or 4" pipe. The combustion air piping must pitch down 1/
4 inch per foot towards termination to prevent rain water from entering
the appliance. In twin pipe penetrations, the combustion air inlet,
whether terminating vertically or horizontally, must be located in such a
manner as to provide a minimum 3 foot clearance from the exhaust vent
termination. See Fig.10 and 11 Letter I, page 16.
For the maximum length of the combustion air pipe, see Tables 8 &9.
CAUTION:
▶ Terminations must prevent rain and debris from
entering the combustion air and exhaust vent piping.
Single pipe
Note: This appliance requires 9950 cubic feet of available combustion
air, or a minimum of 1243 square feet of space with an 8 foot ceiling to
operate. If the large amount of air space, which equates to about half of
most average sized homes, is not available, the appliance must pull air
from the outside (see twin pipe above).
Although it is permissible to draw combustion air from the inside, it is not
the manufacturer’s recommended installation method. Always install a 3
inch 90° elbow on the top of the combustion air inlet adaptor to prevent
foreign objects from falling into the unit.
If a single pipe installation is utilized, follow guidelines below for
providing adequate combustion air for the water heater as well as any
other appliances that may consume air in the same space. Always follow
local codes if they are more stringent and regulations.
• Appliances located in unconfined spaces:
– a) An unconfined space is one whose volume is greater than 50
cubic feet (1.42 cubic meter) per 1000 BTU/hr (292.81 Watts)
of the combined rating of all appliances installed in the space.
That would be 9950 cubic feet (281.8 cubic meters) for the
water heater alone.
27
Installation instructions
– b) In unconfined spaces in buildings of conventional frame,
masonry, or metal construction, infiltration air is normally
adequate to provide air for combustion.
• Appliances located in confined spaces:
The confined space must be provided with two permanent openings,
one commencing within 12 inches (304.8mm) of the top and one
commencing within 12 inches (304.8mm) of the bottom of the
enclosure. Each opening must have a minimum free area of one
square inch per:
– 1000 BTU/hr (292.81 Watts) if all air is taken from inside the
building
– 2000 BTU/hr (585.62 Watts) if all air is taken from the outside by
horizontal ducts
– 4000 BTU/hr (1171.24 Watts)if all air is taken from the outside
by direct openings or vertical ducts
4.7
WARNING: Severe personal injury and property
damage!
Before mounting appliance:
▶ Check that there are no loose or damaged parts
inside the appliance.
▶ Confirm that the gas type of the heater matches the
gas supply you will be connecting the heater, see
Fig.2, page 9.
Front cover should be removed (see instructions on page
9) in order to inspect components visually.
Or the confined space must be provided with one permanent opening or
duct that is within 12 inches (304.8mm) of the ceiling of the enclosure.
This opening must have a minimum free area of one square inch per:
WARNING:
▶ Do not install this appliance on a carpeted wall. The
heater must be mounted on a wall using appropriate
anchoring materials.
– 3000 BTU/hr (878.43 Watts) if all air is taken from the outside by
a direct opening or vertical duct.
Louvers, grills and screens have a blocking effect, when used, increase
the sizes of your openings by 300% for wood louvers (as wood type will
reduce the free air by 75%) and 43% for metal louvers (as metal will
reduce the free air by 30%). Refer to the National Fuel Gas Code for
complete information. In buildings of tight construction all air should be
taken from outside.
4.5
NOTICE: Risk of appliance freezing!
▶ In areas where outside temperature is routinely
below 32°F (0 °C) and the heater is to be installed on
the inside of an exterior wall, a minimum 2" air gap or
rigid insulation between the heater back and the wall
is recommended.
Proper location for installing your heater
Carefully select the location of the water heater. For your safety and for
proper heater operation, you must provide combustion air to the heater
and a proper exhaust vent system.
Follow the guidelines below:
▶ 1. Locate the heater where venting, gas and plumbing connections
are feasible and convenient.
▶ 2. The hot water lines should be kept short and insulated to save
energy. Centrally locating the water heater is recommended to keep
hot water distribution times even throughout the structure.
Hanging appliance on the wall
If wall is sheathed with plaster or drywall, it is recommended that two
support boards, either 1"x 4" or 1/2" (minimum) plywood first be
attached across a pair of studs, see fig. 31, page 29.
▶ Secure the wall mounting bracket provided with the heater to a wall
surface. The heater must be kept level on the wall surface, see fig.
32, page 29.
▶ Hang the appliance on the bracket, see fig. 33, page 30.
NOTICE: Risk of appliance freezing!
▶ The water in this water heater is cold and always
remains cold except for the times the burner is on. In
the event of power outage in conjunction with
freezing temperatures, it is recommended that the
heater be drained.
See chapter 7.2, page 42 “Winterizing” for draining
instructions.
WARNING:
▶ Flammable materials, gasoline, pressurized
containers, or any other items or articles that are
potential fire hazards must NOT be placed on or
adjacent to the heater. The appliance area must be
kept free of all combustible materials, gasoline and
other flammable vapors and liquids.
4.6
Heater placement and clearances
The water heater design is approved for installation on a combustible
wall (see chapter 4.7 Mounting installation) provided the floor covering
below the heater is noncombustible.
For installations in an alcove or closet, maintain the minimum clearances
to combustible and non-combustible materials. See fig. 6, page 11.
Fig. 31 Distance between support boards
[1]
28
Studs 16" (406mm) on center
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
bottom of the unit as shown in fig. 31.
Fig. 32 Leveling wall mounting bracket
Fig. 34 Mounting the heater
Fig. 33 Mounting the heater
CAUTION: Personal injury and property damage.
▶ Appliance must be installed vertically.
4.8
Mounting installation
When installing this appliance the unit must be additionally secured at
the bottom of the water heater as shown in fig. 34. Use the included
screws to secure the brackets at the bottom of the water heater to the
wall. If the wall is sheathed with plaster or drywall, it is recommended
that a support board be first attached across a pair of studs at the
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
29
Installation instructions
4.9
Gas piping & connections
Before connecting the gas supply, check the rating plate on the right side
of the heater to be sure that the heater is rated for the same gas to which
it will be connected. Example rating plate can be found in fig. 2, page 9.
In the United States: The installation must conform with local codes or,
in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/
NFPA 54.
In Canada: The Installation must conform to CGA B149 INSTALLATION
CODES and/or local installation codes.
DANGER: Explosion hazard!
▶ DO NOT connect to an unregulated or high pressure
propane line or to a high pressure commercial
natural gas line.
GAS LINE SIZING
The gas supply piping for a single heater should be sized for a maximum
draw of 199,000 BTU/hr. Measure the length of gas supply line from the
building's gas main to the heater and use the chapter 4.9.1 and 4.9.2,
page 31 or the gas line manufacturer’s sizing tables to determine the
pipe diameter necessary. If there are more gas drawing appliances on
the line, size the gas line according to the total maximum amount of BTU
draw input rating of for all appliances combined.
Note: Undersizing the gas line may result in diminished hot water flow
rate and temperature. See chapter 4.15, page 37 for the procedure to
measure gas pressure. Proper gas pressure must be confirmed at time of
installation.
DANGER: Explosion hazard!
▶ The heater must be isolated from the gas supply
piping system during any pressure testing of that
system at test pressures equal to or more than 0.5
psig. If overpressure has occurred, such as through
improper testing of the gas lines or malfunction of the
supply system, the gas valve must be checked for
safe operation.
GAS CONNECTIONS
▶ Install a manual gas shut off valve on the gas supply line within easy
reach of the appliance.
▶ Install a union when connecting gas supply.
▶ The minimum internal diameter required for any appliance connector
is ¾ ”, see chapter 4.9.1 for more details on pipe sizing.
▶ Undersized flexible appliance connector not permitted.
▶ National Fuel Gas Code requires that a sediment trap (drip leg) be
installed on gas appliances not so equipped. The drip leg must be
accessible and not subject to freezing conditions. Install in
accordance with the recommendations of the serving gas supplier,
see fig. 2.
Fig. 35 Gas connection
[1] Gas supply
[2] Cap
[LA] Minimum 3"
Once connections are made, check for gas leaks at all joints. Apply some
gas leak detection solution to all gas fittings. Bubbles are a sign of a leak.
A combustible gas detector may also be used to detect for leaks.
DANGER: Explosion hazard!
▶ If you detect a leak, shut off the gas. Tighten
appropriate fittings to stop leak. Turn the gas on and
check again with a gas leak detection solution. Never
test for gas leaks using a match or flame.
30
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
4.9.1 Gas Line Sizing Tables for NATURAL GAS
For your convenience see below for an excerpt from gas line sizing tables for a single NG appliance. For details see the current NFPA 54.
Required input for 175C is 175000 BTU/hr and 199000 BTU/hr for the 199C. The gas supply system must be sized for the combined total maximum
BTU/hr load requirements of all gas appliances running simultaneously.
The tables below show the maximum capacity of the gas supply pipe in cubic feet per hour. Please contact your local gas supplier for the energy content
of the gas to determine the BTU/hr capacity. Use 1,000 BTU/cubic foot for rough estimations.
Maximum pipe capacity in cubic feet of Natural Gas per hour for gas pressures of 14" W.C. (0.5 psig or 25 mbar) or less and a pressure drop of 0.3”
W.C. (0.75mbar) based on 0.60 specific gravity gas).
Nominal Iron
Pipe Size,
inches
Internal
Diameter
inches
Length of Black Iron Pipe (Schedule 40 Metallic Pipe), Feet
10
20
30
40
50
60
70
80
90
100
3/4
0.824
273
188
151
129
114
104
95
89
83
79
1
1.049
514
353
284
243
215
195
179
167
157
148
1 - 1/4
1.380
1060
726
583
499
442
400
368
343
322
304
1 - 1/2
1.610
1580
1090
873
747
662
600
552
514
482
455
Table 36
Maximum pipe capacity in cubic feet of Natural Gas per hour for gas pressures of <2.0 psig (55" WC or 138 mbar) and a pressure drop of 3.0” W.C. (7.5
mbar) based on 0.60 specific gravity gas).
Minimum Gas Pressure 8.0" WC (20 mbar)
Nominal Iron
Pipe Size,
inches
Internal
Diameter
inches
Length of Black Iron Pipe (Schedule 40 Metallic Pipe), Feet
10
20
30
40
50
60
70
80
90
100
1/2
0.622
454
312
250
214
190
172
158
147
138
131
3/4
0.824
949
652
524
448
397
360
331
308
289
273
1
1.049
1787
1228
986
844
748
678
624
580
544
514
Table 37
Maximum pipe capacity in cubic feet of Natural Gas per hour for gas pressures of 14" W.C. (0.5 psig or 25 mbar) or less and a pressure drop of 0.5”
W.C. (1.25mbar) based on 0.60 specific gravity gas).
Tube
size,
inches
EHD*
Length of Corrugated Stainless Steel Tubing (CSST), Feet
10
20
30
40
50
60
70
80
90
100
1
30
330
231
188
162
144
131
121
113
107
101
1
31
383
269
218
188
168
153
141
132
125
118
1 - 1/4
37
639
456
374
325
292
267
248
232
219
208
1 - 1/4
38
746
526
442
386
347
318
295
277
262
249
Table 38
* EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater the gas capacity of the tubing.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
31
Installation instructions
4.9.2 Gas Line Sizing Tables for LP GAS
For your convenience see below for an excerpt from gas line sizing tables for a single LP appliance. Their intended use of is for pipe sizing between the
the 2nd stage (low pressure) regulator and the appliance. For details see the current NFPA 54 or NFPA 58.
Required input for 175C is 175000 BTU/hr and 199000 BTU/hr for the 199C. The gas supply system must be sized for the combined total maximum
BTU/hr load requirements of all gas appliances running simultaneously.
The tables below show the maximum capacity of the gas supply pipe in thousands of BTU per hour of Undiluted LP Gas at 11" W.C (0.4 psig or 27.4
mbar) based on a pressure drop of 0.5" W.C (1.25 mbar).
Nominal Iron
Pipe inches
Internal
Diameter
inches
Length of Black iron Pipe (Schedule 40 Metallic Pipe), Feet
10
20
30
40
50
60
80
100
1/2
0.622
291
200
160
137
122
110
101
94
3/4
0.824
608
418
336
287
255
231
212
197
1
1.049
1150
787
632
541
480
434
400
372
Table 39
Tube size,
inches
Length of Corrugated Stainless Steel Tubing (CSST), Feet
EHD*
10
20
30
40
50
60
70
80
90
100
3/4
23
254
183
151
131
118
107
99
94
90
85
3/4
23
303
216
177
153
137
126
117
109
102
98
1
30
521
365
297
256
227
207
191
178
169
159
1
31
605
425
344
297
265
241
222
208
197
186
Table 40
* EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater the gas capacity of the tubing.
Nominal Iron
Pipe inches
Internal Diameter
inches
Length of Semirigid (soft) Copper ACR Tubing, Feet
10
20
30
40
50
5/8
0.527
188
129
104
89
79
3/4
0.652
329
226
182
155
138
Table 41
Maximum Capacity of Semi-Rigid (flexible, non corrugated) Tubing in Thousands of BTU/hr of Undiluted Liquefied Petroleum Gases (at 11 inches Water
Column Inlet Pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)* Source National Fuel Gas Code NFPA 54, ANSI Z223.1 - No Additional
Allowance is necessary for an ordinary number of fittings.
32
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
4.10
Water connections
NOTICE:
▶ This heater is not approved for preheated water
applications exceeding 140°F (60°C).
NOTICE:
▶ In applications where inlet water temperature can
exceed 140°F (60°C), a 3-way valve or mixing valve
must be installed before the appliance to prevent
water exceeding 140°F (60°C) from entering the
appliance.
▶ When facing the heater, the ¾ ” cold connection is on the bottom
right and the hot connection is on the bottom left. Centrally locating
the water heater is recommended to keep hot water distribution
times even throughout the structure.
▶ If the cold and hot connections to the heater are reversed, the heater
will not function. Be certain there are no loose particles or dirt in the
piping. Blow out or flush the lines before connecting to the water
heater.
▶ Full port shutoff valves should be installed on both the cold water
supply and hot water outlet lines to facilitate servicing the heater (see
fig. 38).
▶ For installation on a private well system with the use of a pressure
tank, the lowest pressure range setting recommended is 40-60 psi
(2.75 - 4.15bar).
4.11
Water quality
Water quality can have an impact on appliance longevity and may void
the manufacturer's warranty.
For water analysis data call your local water department, or if on a well,
have well water analyzed periodically. If water quality exceeds one or
more of the values specified below, consulting a local water treatment
professional for water softening/conditioning options is recommended.
Description
pH
Max. Levels
pH
6.5 - 8.5
TDS (total Dissolved Solids)
mg/l or ppm
500
Total hardness
mg/l or ppm
100 (6 grains)
Aluminum
mg/l or ppm
2.0
Chlorides
mg/l or ppm
250
Copper
mg/l or ppm
1.0
Iron
mg/l or ppm
0.3
Manganese
mg/l or ppm
0.05
Zinc
mg/l or ppm
5.0
Table 42
Fig. 36
[1]
[2]
Cold connection
Hot connection
Connecting the pressure relief valve (PRV)
A listed pressure relief valve must be installed at the time of installation.
No valve is to be placed between the PRV and the heater. No reducing
coupling or other restriction may be installed in the discharge line. The
discharge line must be a minimum of 4” above a drain and installed such
that it allows complete drainage of both the PRV and the line. The
discharge line must be placed where it will not cause any damage.
The location of the PRV must be readily accessible for servicing or
replacement, and be mounted as close to the water heater as possible.
See fig. 38. To install the PRV, a suitable fitting connected to an
extension on a “T” fitting can be sweated to the hot water line.
Support all piping.
Fig. 37 Water filter
▶ The use of unions when connecting both water pipes to the inlet and
outlet connections is required. This will facilitate any necessary
servicing.
▶ Plastic or PEX type plumbing line materials are not suitable for
connecting directly to the water heater.
▶ Never sweat any piping directly to or beneath the water connections,
as damage will occur to the internal water valve from heating of the
pipe.
▶ Keep water inlet and outlet pipes to no less than ¾" (19.05mm)
diameter to allow the full flow capacity.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
33
Installation instructions
▶ Open the four clips and remove the combustion cover, see fig. 5,
page 10.
▶ Remove the clip and disconnect the drain tube, see fig. 40.
Fig. 40 Disconnect drain tube
Fig. 38 Plumbing Connections (with shutoff valves) and Pressure Relief
Valve
4.12
▶ Fill the condensate trap by pouring approx.14 oz. (400ml) of water
into the top of the drain tube. To avoid damage to the appliance use
a funnel in this operation, see fig. 41, page 34.
Filling the condensate trap
The condensate trap can be filled before or after connecting the vent
pipe.
Filling the condensate trap before vent pipe installation
DANGER: Flue gas poisoning!
▶ Prior to initial start up, and after appliance has been
out of use for a long time or after cleaning the
condensate trap, make sure that you fill the
condensate trap with water. This is to prevent
dangerous exhaust gases from entering the building.
▶ Fill the condensate trap by pouring approx.14 oz. (400ml) of water
into the exhaust accessory on the top of the appliance, see fig. 39.
Fig. 41 Filling the condensate trap after installation
▶ Loosen the three screws of the control unit.
Fig. 39 Filling the condensate trap at start up
Filling the condensate trap after vent pipe installation
After appliance has been out of use for a long time or after cleaning
siphon, refill the condensate trap with water.
Please proceed as follows:
Fig. 42
▶ Put the control unit in service position by engaging its tabs with the
holes in the bottom horizontal sheet metal, see fig. 43.
CAUTION: Electric shock!
▶ Disconnect power to water heater by unplugging
from wall outlet prior to filling condensate trap.
▶ Remove front cover, see fig. 4, page 9.
34
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Installation instructions
▶ Check water level in the condensate trap.
4.14
Space heating applications
CAUTION:
▶ If the set point temperature is above 120°F,
precautions should be taken to protect users of
potable water from scalding.
CAUTION:
▶ Propylene glycol may be used for freeze prevention
ONLY on the space heating side of the heat
exchanger. Do not use ethylene glycol (automotive
antifreeze).
Fig. 43 Water level in condensate trap
▶ After filling reassemble all parts in reverse order.
4.13
Domestic hot water recirculation
Although recirculation directly through the tankless water heater is
allowed, temperature stability is improved by recirculating through a
tank as shown in fig. 44. By using the design in fig. 44, there is no
recirculation of hot water through the tankless water heater and
therefore, does not affect the heat exchanger warranty. Direct
recirculation through the tankless water heater is permissible, however,
the heat exchanger warranty is reduced; contact manufacturer for
further installation requirements. The following drawing is provided to
outline one possible recirculation design using the water heater in
conjunction with an electric storage water heater. This schematic is for
illustration only and must not be used for actual Installation without
appropriate engineering and technical advice from a properly licensed
professional in the locality where the installation is made.
CAUTION:
▶ The use of a flow switch is recommended to ensure
DHW priority and to prevent “cold-blow” situations
when the tankless water heater is used with an airhandling system. The flow switch should be used to
disable the blower on the air-handling system when
domestic water is used.
CAUTION:
▶ Ensure the primary pump is properly sized to provide
adequate flow for the system heat load. Ensure the
primary pump is properly sized to provide adequate
flow for the system heat load.
For Pump sizing please refer to the pressure drop
curves, fig. 45. Also remember to account for system
piping pressure loss. A minimum of 1.7 GPM is
recommended to provide adequate flow through the
water heater when determining the size of the primary
pump.
PurePro tankless water heaters are approved for use in combination
DHW and space heating applications (open-loop setup). These water
heaters are not approved for use in space heating only applications
(closed-loop setup). Applications of combination DHW and space
heating in an open loop configuration is acceptable if plumbed similar to
fig. 46. Use of a this tankless water heater in a combination DHW and
space heating application will result in the product warranty being
reduced to 3 years.
Fig. 44 Recirculation application
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Full port isolation valve
Circulator pump on timer
Check valve
PRV
Expansion tank
Tankless water heater
Electric storage water heater
The use of a small electric tank after heater (4-6 gallon size) should be
used for this application and designed so the pump will circulate the
water through the tank and the building's hot water return loop only.
Timed or thermostatically controlled operation of the pump is commonly
done. Contact manufacturer if further information is needed.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
35
Installation instructions
Fig. 45 Pressure drop curve
Fig. 46 Space heating diagram
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
36
Hot water outlet
Cold water inlet
Pressure relief valve
Gas supply
Shut off gas valve
Thermal expansion tank (as required)
Atmospheric vacuum breaker
Cold inlet
Check valve
Pump
[11]
[12]
[13]
[14]
[17]
[18]
[19]
[20]
[21]
[22]
Thermostatic mixing valve
Thermometer (optional)
DHW outlet
Water to water heat exchanger
Thermostat
Space heating zone
Zone controller
Space heating pump
Expansion tank
Pressure relief valve
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Electrical connections
4.15
Measuring gas pressure
Confirm gas pressure upon installation.
Connecting manometer
▶ Shut off gas supply at installer supplied shutoff valve for this water
heater.
▶ Remove front cover and locate inlet gas pressure test port (see
Fig.48).
▶ Loosen screw inside left test point fitting (do not remove) and
connect manometer tube to test point.
Static Pressure Test
▶ Turn gas supply back on.
▶ Record static gas pressure reading in table 44.
Operating Pressure Test
▶ Press ON/OFF button
into ON.
▶ Immediately following, press and hold simultaneously buttons +
or
and P for 3 seconds, until display reads P2.
Fig. 48 Gas pressure test port (left tapping)
Static Gas Pressure Reading (see chapter 4.15)
enter here: ___________________ Date: ___________
Operating Gas Pressure Reading (see chapter 4.15)
enter here: ___________________ Date: ___________
Table 44
Fig. 47
▶ Press P to enter P2 adjustment. The current setting will appear on
the display (factory default).
▶ Press + or
until P1 appears.
5
Electrical connections
5.1
Electrical power supply
WARNING:
▶ For safety reasons, disconnect the power supply
cord to the heater before any service or testing is
performed.
Note: While in this mode the appliance will run constantly at maximum
power and allow maximum water flow.
For inlet gas pressure adjustment consider the following table:
Gas type
pin
NG
LPG
3.5” WC
8” WC
Table 43 Minimum inlet gas pressure under full operation
▶ Operate all other gas appliances (except heater) on same gas piping
system at maximum output.
▶ Turn on high volume of hot water flow (at least 6 gpm, 1 tub and 2
sinks should be sufficient) and burner will light. If heater display
reverts to P2, open more hot water fixtures to allow sufficient flow.
Press + until P1 reappears on the display.
▶ Record lowest operating gas pressure reading in table 44.
WARNING:
▶ This heater must be electrically grounded in
accordance with the most recent edition of the
National Electrical Code. NFPA 70. In Canada, all
electrical wiring to the heater must be in
accordance with local codes and the Canadian
Electrical Code, CSA C22.1 Part 1. Do not rely on
the gas or water piping to ground the metal parts
of the heater.
The water heater requires an electrical power supply from a 120VAC /
60Hz properly rated receptacle and must be properly grounded.
The heater is wired as shown in the wiring diagram (chapter 10, Fig.76).
Gas pressures lower than 3.5" W.C. for Natural Gas or 8" W.C. for LPG
will result in insufficient degree rise to the hot water being used, reduced
hot water volume, possible error code faults and must be corrected. See
Gas Connections, chapter 4.9, page 30.
P1 fan speed:
Factory default: NG: 51, LP: 52
Lowering P1 fan speed reduces the maximum BTU input.
As a temporary measure if the gas pressure in P1 is below specification,
lower P1 fan speed incrementally until minimum inlet gas pressure
reaches specified range (table 43). After upgrading gas line, reset
appliance to P1 factory default setting (NG: 51, LP: 52) or setting from
Section 4.3.8.
Fig. 49 Connecting power supply cord
[1]
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Power cord length: 3ft.
37
Electrical connections
Note: The outlet the appliance is plugged into should be clear from
possible water damage.
5.2
Position of the fuses in control unit
To check fuses, proceed as follows:
▶ Remove the front cover, see fig. 4, page 9.
▶ Remove the three screws from the control unit.
Fig. 50
▶ Remove the six screws from the back cover of the control unit, see
fig. 51, pos. 2.
▶ Check the fuses in the printed circuit board, see fig. 51, pos. 3.
Fig. 51 Fuses position
▶ After checking the fuses, reinstall all parts in reverse order.
38
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Operation instructions
6
Operation instructions
Fig. 52
[1]
[2]
[3]
[4]
[5]
[6]
6.1
On/Off button
Reset button
Program Key
LCD display
Up button
Down button
Description LCD Display
WARNING:
▶ Do not use any cleaning aggressive or corrosive
agents to clean the window.
Fig. 56 Locked condition indicator (only with remote control)
Fig. 57 Flame indicator
Fig. 53 Power bar indicator (input)
Fig. 58 Solar mode indicator (see chapter 6.4, page 40)
Fig. 54 Temperature indicator
Fig. 59 Remote control indicator
Fig. 55 Error indicator
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
39
Operation instructions
▶ Press buttons + or
in order to reach desired temperature.
Fig. 60 Activation water flow (see chapter 12)
6.2
For your safety read before operating your water
heater
DANGER: Explosion hazard!
▶ If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or loss of life.
A. This appliance is equipped with electronic ignition for lighting the
main burner. When turning the heater on, follow these instructions
exactly.
WHAT TO DO IF YOU SMELL GAS
▶ Turn off the gas shut-off valve.
▶ Open windows and doors.
▶ Do not try to light the appliance.
▶ Do not touch any electrical switch, telephone, and do not use outlets.
▶ Extinguish all open flames. Do not smoke! Do not use lighters!
▶ Warn all occupants of the building. Do not ring doorbells!
▶ If you can hear gas leaking, leave the building immediately.
▶ Prevent others from entering the building and notify the police and
fire department from outside the building.
▶ From outside the building, call the gas utility company and a trained
and certified installer.
B. Use only your hand to press the on/off control switch. Never use tools.
If control switch is jammed, close the gas supply and call a qualified
service technician. Forceful repair may result in a fire or explosion.
C. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the appliance
and to replace any part of the control system and any gas control which
has been under water.
6.3
Power
On
▶ To start the appliance press the On/Off button.
Fig. 62
Setting the water temperature
The desired temperature of the hot water can be adjusted on the front
control panel of the heater.
The water heater has an electronically controlled gas valve that
modulates the burner input in response to both varying hot water flow
rates and/or changes in any incoming and outgoing water temperatures.
Note: The water heater, running at minimum BTU, may still achieve
temperatures above the desired set temperature. Low flowing fixtures
are the leading cause of this type of temperature overshoot. To combat
this symptom, clean fixtures or replace with higher flowing ones if
necessary.
Saving water resources:
▶ Make sure you close all the taps after any use. Avoid leaving the taps
dripping. Repair any leaking tap.
▶ Define the temperature you want, in the appliance or with the remote
control. This way you have the precise water flow needed (mixing
cold water to regulate temperature will increase the water flow with
consequent waste of water).
The water heater will not ignite if inlet water temperature exceeds the set
point temperature less 9 °F (5 °C). In this condition, the solar mode
indicator will show on the LCD display. See fig. 58, page 39.
Solar mode activation formula
Temp. inlet > Temp. set - 9 °F
(5 °C)
Example:
104 °F (40 °C) > 112 °F (44 °C) 9 °F (5 °C)
Table 45
WARNING: Appliance damage!
▶ In applications where inlet water temperature can
exceed 140°F (60°C), a thermostatic or mixing valve
must be installed before the appliance to prevent
water exceeding 140°F (60°C) from entering the
appliance.
Fig. 61
Off
▶ To shut down the appliance press the On/Off button again.
6.4
Temperature selection
To select hot water temperature:
40
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Operation instructions
Fig. 66 Reset button
If the problem persists, contact your installer.
6.7
Program button
Fig. 63
6.5
Operation
▶ When a hot water tap is opened, main burner ignites and LCD
displays indication
.
Fig. 67 “Program” key
6.7.1 Memorizing selected temperature
▶ Press buttons + or
to select desired temperature.
▶ Hold “Program” button for 3 seconds to save temperature.
When LCD stops blinking, temperature is saved in memory.
Using “Program” function
In order to select memorized temperature
▶ Press “Program” key.
Fig. 64
▶ LCD flashes until selected temperature is reached.
▶ Power bar indicates power percentage in use.
6.6
Reset button
If the LCD shows the error symbol
do not shut off power or unplug
the heater. Follow instructions below to reset error first.
Record the error code on LCD and consult “Problem solving” chapter
9.1, page 50.
LCD shows pre-memorized temperature, which is now the hot water
selected temperature.
6.8
Locked condition
This condition is only valid for appliances with one or more remote
controls installed.
Fig. 68 Locked condition
Whenever LCD shows
, the temperature setting cannot be
adjusted because the appliance is in use by a user which already
selected a different temperature. Appliance will be automatically unlock
5 minutes after closing hot water tap.
Fig. 65
After following instructions indicated in “Troubleshooting” section,
▶ press reset button firmly in order to return heater to normal
operation.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
41
Maintenance and service
7
Maintenance and service
DANGER:
▶ Always shut off the electrical power supply, shut off
the manual gas valve and shut off the water valves
whenever servicing.
NOTICE:
▶ Inspect and clean the complete water heating system
once a year.
▶ Carry out a maintenance as necessary. Immediately
repair all faults to avoid damage to the system.
Annual maintenance table
Every year
1.
Inspect venting system
X
2.
Inspect combustion chamber
X
3.
Inspect burner
X
4.
Inspect condensate trap
X
5.
Inspect water filter
X
Table 46 Annual maintenance
7.1
Annual maintenance
(To remove front cover, see page 9.)
Venting System
• Venting system - inspect inside of flue pipe for any blockage or
restriction. Observe burner flames during heater operation. (front
cover must be removed). Inspect the combustion air inlet pipe for
blockage or debris. Inspect combustion air and exhaust terminations
for blockage or debris. Inspect combustion chamber for blockage or
debris.
Fin Coils
• Inspect heat exchanger fin coils for soot build-up or blockage. If there
is evidence of soot build-up or blockage, the heat exchanger should
be removed by a professional and cleaned thoroughly.
Condensate trap
• Check water level in the condensate trap, see fig. 43, page 35.
• If appliance is out of service for more than 10 days, fill as described
on page 34.
• Check for debris and clean if needed.
7.2
Winterizing for seasonal use
The water heater must not be installed in a location where it may be
exposed to freezing temperatures. If the heater must be left in a space
which is likely to experience freezing temperatures, all water must be
drained from the heater. If precautions are not taken, resulting damage
will not be covered under the warranty. NOTE: Use of agents such as
anti-freeze is not permitted and voids the warranty, as they may cause
damage to the water heater's internal components.
1. Press ON/OFF switch on the water heater to turn OFF the heater and
unplug power supply cord. The display should be blank.
2. Shut off gas supply to heater.
3. Shut off the water supply to the water heater using installer supplied
shutoff valve.
4. Open hot water taps to drain and relieve pressure from the plumbing
system. If water continues to flow after 5 minutes, a crossover of the
hot and cold water pipes is present and must be corrected before
proceeding.
5. Disconnect inlet and outlet water pipes from the water heater. Place
a small bucket underneath the water heater to catch residual water
remaining inside the water heater.
6. Using an air compressor, blow short bursts of air (100psi max)
through the inlet water connection until there is no water present
coming through the outlet water connection of the heater.
7. Reconnect water fittings and return heater to service when danger of
freezing has passed.
8. Empty condensate trap by removing lower condensate trap cover.
Combustion Chamber
• Inspect burner observation window (Fig.80, #14, page 56) for
cracks or spillage of flue gases. Observe burner flames during heater
operation. Flames should be steady and blue with no signs of
yellowing. Yellow burner flames are an indication of improper
combustion. Refer to Section 4.4, page 27, chapter 4.3, page 12 of
this manual to verify exhaust system and combustion air supply
meets manufacturer's specifications.
7.3
Pressure Relief
• Manually open the pressure relief valve to ensure proper operation.
Descaling using a pump
▶ Disconnect electrical supply from the water heater.
▶ Shut off the water supply to the water heater using (installer
supplied) shutoff valve.
▶ Open hot water taps to drain and relieve pressure from the plumbing
system.
▶ Drain water from the unit's heat exchanger by disconnecting inlet and
outlet water connections from the heater.
▶ Connect a line (A) from the outlet of the circulating pump (installer
supplied) to the inlet water fitting on the water heater (see fig. 69.)
▶ Using another line (B), connect the water outlet fitting on the water
heater. Route the other end of this line into a descaling reservoir.
▶ Using a 3rd line (C) from the descaling reservoir, connect to the inlet
side of circulating pump. Install a filter on the end of the line in the
descaling reservoir.
▶ Make sure all connections are "water tight.".
Inlet Water Filter
• Verify the inlet filter screen is clean and undamaged. The inlet water
filter is located on the bottom of the appliance, to the right of the cold
water inlet fitting. (See Fig.37, page 33). Close installer supplied
water shutoff and remove wireform spring clip from filter. Remove
filter, clean and or replace if damaged.
Descaling
• In areas where the water supply has a high mineral content, the heat
exchanger should be flushed with a descaling solution. Scale build up
will shorten the life of the water heater and damage resulting from
scale is not covered under warranty. Refer to section7.3 for detailed
instructions on descaling the heat exchanger.
42
Mineral scale build-up
Periodic descaling may be necessary in areas with high mineral content
in the water. Scale buildup in the heat exchanger may result in lower flow
rates, error codes of A7 and E9 and boiling sounds in the heat
exchanger.
A water softener is required if the water hardness exceeds 6 grains/gal
(103 mg/l) calcium carbonate. Damage to the water heater resulting
from hard water/scale deposits will not be covered under warranty.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Maintenance and service
▶ Fill tank with descaling solution so both lines inside are submersed.
We recommend a straight white vinegar solution. If using a
commercial descalant, refer to manufacturer's instructions for
proper dilution ratio.
▶ Operate the circulating pump.
▶ Make sure there are no leaks and the solution is flowing from the
descaling reservoir through the heater and returning to the reservoir.
▶ Run solution through the heater until the solution returning to the
descaling reservoir comes out clear. (Changing to a fresh solution
may be necessary during this process).
▶ Disconnect all lines and drain all solution from heat exchanger.
Properly discard of solution.
▶ Position a container below the hot water outlet and connect cold
water supply. Open cold water supply shutoff valve and flush heat
exchanger with clean water.
▶ Shut cold water shutoff valve and reconnect hot water supply to the
water heater.
▶ Reconnect electrical supply to unit, open water shutoff valves, and
return the unit to service.
▶ Disconnect power cord.
▶ Drain water heater.
Note: be sure to remove condensing heat exchanger rear
mounting hardware.
▶ Dismantle all inlet, outlet pipes and the condensate tube from the
condensing heat exchanger unit.
▶ Remove the condensing heat exchanger unit from the appliance by
pulling it towards you.
▶ Dismantle all parts for inspection and cleaning.
Fig. 71 Condensing heat exchanger
▶ Check the condensing heat exchanger for any obstruction.
▶ Flush the condensing heat exchanger unit with water.
▶ Check all gasket and o-rings for damage and replace if necessary.
Fig. 69
[1]
7.4
Pump
Condensing heat exchanger unit
The condensing heat exchanger unit must be checked once a year by a
qualified and trained technician.
It is important to inspect and properly replace the
gaskets and o-rings using the available kit
(8 704 701 116 0).
▶ Assemble the condensate unit and all other parts in reverse order of
disassembly.
Fig. 70 Condensing heat exchanger unit
Condensing heat exchanger unit maintenance;
▶ Shut off power.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
43
Maintenance and service
7.5
Adjusting CO2
The CO2 can only be adjusted by a certified gas technician with a
calibrated CO2 analyzer.
CO2 adjustment is required in Natural Gas
installations where energy content is less than 900
BTU/cuft, and in installations with repeated
unresolved EA and EC errors (ref. to page 50
“Problem solving”).
CAUTION:
▶ One factor that may affect CO2 levels is improper gas
pressure. Please see Chapter 4.15 for the procedure
to measure gas pressure and record your findings
below:
Static Gas Pressure:
P1 Operating Pressure:
B. Measuring CO2 (Combustion cover Installed):
▶ Open all hot water taps to achieve a flow rate of at least 6 gpm. (1 tub
and 2 sinks should be sufficient). If heater display reverts back to P2,
open more hot water fixtures to allow sufficient flow. Press + until P1
reappears on the display.
▶ Record the CO2 reading in P1 below. (Analyzer reading may take
several minutes to stabilize).
▶ Press the ‘+’ button until P2 appears. Unit will ramp down to low fire
and the water flow should decrease.
▶ Record the CO2 reading in P2 below.
P1 CO2 Reading:
% CO2
P2 CO2 Reading:
% CO2
Note: When making adjustments, make sure combustion cover is
installed.
“ WC
CO2 range (%)
Max. CO level
(measured)
“ WC
The P1 minimum operating gas pressure is 3.5" WC for Natural Gas and
8" WC for Propane. Do not proceed in adjusting CO2 until pressure is at
or above these levels, but not to exceed 10.5" WC for Natural Gas and
13" WC for Propane.
A. Once Gas Pressure is adequate
▶ Press ON/OFF button to turn OFF the heater.
▶ Remove brass flat head screw on the exhaust collar as seen in Fig.72.
▶ Insert CO2 analyzer probe into the measuring port. The tip of the
probe should be in the center of the flue pipe (approx 1.5" inserted).
Avoid air gaps between probe and measuring port as they can alter
readings.
TL-Pro 175 C
TL-Pro 199 C
Nat. Gas
Nat. Gas
max. input
P1
7.2 % - 7.8 %
7.8 % - 8.4 %
< 250 ppm
min. input
P2
1.5 % - 1.8 %
1.5 % - 1.8 %
< 60 ppm
LP Gas
LP Gas
max. input
P1
8.8 % - 9.4 %
9.5 % - 10.1 %
< 250 ppm
min. input
P2
1.9 % - 2.2 %
1.9 % - 2.2 %
< 60 ppm
* Values above are for climate controlled conditions. Inputs such
as gas pressure, heating value of the gas, humidity and
temperature of combustion air all impact CO and CO2 values.
Changes in these inputs can result in different CO and CO2 values
on the same appliance.
Table 47 CO2 & CO target numbers
C. Adjusting CO2:
Note: P1 adjustment will change the P2 reading. Confirm the P1
value BEFORE adjusting the P2 level.
Fig. 72 Measuring port
▶ Press the ON/OFF button to turn ON the heater.
▶ Immediately following, press and hold simultaneously buttons +
or
and P for 3 seconds, until display reads P2.
1. If P1 CO2 level is off:
▶ Loosen yellow painted Phillips screw (1) and cover should rotate
down (2) revealing a recessed brass slotted screw. Fig.74.
▶ Turning the slotted screw counter clockwise will raise P1 CO2 levels
and clockwise will lower P1 CO2 levels. Adjustments to the slotted
screw will also change P2 CO2 levels.
▶ After bringing the P1 CO2 readings in proper range, press the +
button to enter the P2 mode. Verify CO2 readings in P2 mode.
2. If P2 CO2 level is off:
▶ Remove yellow painted #40 Torx cover from the front of the gas
valve. (Fig.75) A plastic #40 Torx screw will be revealed.
▶ Turning the plastic #40 Torx screw counter clockwise will lower P2
CO2 levels and clockwise will raise P2 CO2 levels.
Note: This screw adjustment is very sensitive and should be made in
small increments. It may take several minutes for readings to stabilize.
3. Verify both P1 and P2 CO2 readings are within the ranges specified in
table47. Repeat steps 1 and 2 as necessary until CO2 values are within
the specified ranges.
Fig. 73
▶ Press
44
Final Readings
P1 CO2 Reading:
% CO2
P2 CO2 Reading:
% CO2
button until “P1” appears on display.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Maintenance and service
D. Returning to Service:
1. Return slotted screw cover to original position.
2. Reinstall Torx cover.
3. Remove CO2 analyzer probe and reinstall flathead screw with gasket
in exhaust collar.
4. Press ON/OFF button to turn OFF the heater and then turn ON the
heater.
5. Heater is ready for normal operation.
Fig. 74 Adjusting P1 CO2 level
Fig. 75 Adjusting P2 CO2 level
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
45
Maintenance and service
7.6
Program values
This section describes details on programming the appliance. For most
applications the factory default values will provide robust and stable
operation. Only adjust the factory settings if the installation requires
changes as indicated in the appropriate section of this manual.
Refer to chapter 7.7 Control board diagnostics (page 46) regarding how
to access these P-modes.
CAUTION: Appliance malfunction!
▶ Misadjusted program values can lead to appliance
malfunction, errors, and service calls.
Program
Description
Factory Default
MIN
MAX
Comment
P0
By-pass calibration
-
-
-
Contact manufacturer for details.
P1
Maximum Power
NG: 51,
LP: 52
21
NG: 53,
LP: 53
P2
Minimum Power
NG: 10,
LP: 13
NG: 8,
LP: 11
20
see chapter 4.15, page 37
note: reducing P1 values below maximum will
reduce maximum power of the appliance.
see chapter 4.3.8, page 23
P3
_0
_0
6
Not available
E
0d
10f
see chapter 7.7, page 46
P5
P6
P7
Remote
Controls installed
Access to
Diagnostic Mode
Cascade Mode
Temperature Unit
Gas type selection
NO
°F
LP or NG
NO
°F
CC
°C
Contact manufacturer for details.
P8
Back light
dE
dE
On
P9
Fan Purge
PH
Cascading type
IC
IC
SC
PC
Primary/Secondary
mode
CS
CS
Cn
P4
Preset from factory.
Contact manufacturer for details.
dE turns back light off after 60 seconds from
last button pushed, ON turns backlight on
permanently.
Runs secondary fan and primary fan when P9
is selected by depressing the “P” - button
This menu is only available when cascade
mode is selected CC.
Contact manufacturer for details.
Table 48 Program values, factory default settings and ranges.
7.7
Control board diagnostics
1. Press ON/OFF button
into ON.
2. Immediately following, press and hold simultaneously buttons +
or
and P for 3 seconds, until display reads P2.
3. Press P to enter P2 adjustment. The current setting will appear on
the display. If not, repeat process.
4. Press and release the P button on the control panel until the
display reads 'P4'. You are now in the diagnostic mode of the control
board.
5. When the display reads 'P4', press and release the + button once
again and the display should read 'E'.
6. Use the + and
button on the control board to cycle through
different diagnostic modes available.
7. Once in the selected diagnostic mode of your choice, press and
release the P button to display the diagnostic information.
EXAMPLE: to read the flow rate in gallons per minute while the unit is
flowing water, cycle to the '3d' mode and press the P button. A
reading of 25 on the display would indicate the heater is reading a flow
rate of 2.5 gallons/minute.
8. Once the information is obtained, press the P button again to
return to the diagnostic mode menu and scroll to addition diagnostic
information.
9. Press ON/OFF button to turn OFF the appliance and back ON again to
return heater to normal function.
Diagnostic menu
E
Entry/Exit into sub-modes
0d
Heat exchanger water temperature
1d
Inlet water temperature (°F)
2d
Outlet water temperature (°F)
3d
Water flow (gallons/min)
4d
Bypass control monitor (°F) [0d - 2d]
5d
Fan speed (Hz)
6d
Burner power (%)
7d
Maximum power (kW)
8d
Back flow temperature (°C)
9d
Exhaust temperature (°C)
1F
Most recent error/failure
2F
2nd most recent error
3F
3rd most recent error
4F
4th most recent error
Table 49 * Settings define from factory
46
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Maintenance and service
▶ Select the sub-mode “C0”.
Write the number that shows in the display.
▶ Select the sub-mode “C1”.
Write the number that shows in the display.
▶ Select the sub-mode “C2”.
Write the number that shows in the display.
Diagnostic menu
5F
5th most recent error
6F
6th most recent error
7F
7th most recent error
8F
8th most recent error
9F
9th most recent error
10F
10th most recent error
1P*
Appliance type - Cd (Condensing)
Appliance type - nC (Non condensing)
2P*
Appliance power - 175 / 199 (kBTU/hr)
3P*
Temperature range - H (100-140°F)
Temperature range - C (100-184°F)
H0
Numbers of hours - mode 0
H1
Numbers of hours - mode 1
H2
Numbers of hours - mode 2
C0
Number of cycles - mode 0
C1
Number of cycles - mode 1
C2
Number of cycles - mode 2
After checking the sub-modes C0, C1 and C2, introduce the values in a
table as the example;
Example:
Calculation of number of cycles (1 cycle = 1 ignition),
Number of cycles
Number in C0
40
40 +
Number in C1
6 (X 100) =
600 +
Number in C2
1 (X 10 000) =
10 000
(C0 + C1 + C2) = Total of cycles
10 640
Table 52
Table 49 * Settings define from factory
7.7.1 Working hours
To see how many hours the appliance has worked, please enter the
“Diagnostic menu” (chapter 7.7);
▶ Select the sub-mode “H0”.
Write the number that shows in the display.
▶ Select the sub-mode “H1”.
Write the number that shows in the display.
▶ Select the sub-mode “H2”.
Write the number that shows in the display.
After checking the sub-modes H0, H1 and H2, introduce the values in
the table below;
Working hours
Number in H0
______
_______ +
Number in H1
______ (X 100) =
_______ +
Number in H2
______ (X 10 000) =
_______
(H0 + H1 + H2) = Total of hours
__________
Table 50
Example:
Calculation of number of working hours,
Working hours
Number in H0
60
60 +
Number in H1
5 (X 100) =
500 +
Number in H2
0 (X 10 000) =
(H0 + H1 + H2) = Total of hours
0
560
Table 51
7.7.2 Number of cycles
To see how many cycles the appliance has done, please enter the
“Diagnostic menu” (chapter 7.7);
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
47
Troubleshooting
8
Troubleshooting
CAUTION:
▶ If you are unable to perform the tasks listed below, or
need additional assistance please contact your
original installer or a licensed gas technician.
8.1
Introduction
Many of the questions customers ask regarding operation of this unit can
be answered by following the troubleshooting steps as outlined below.
For best results, perform each step before proceeding to the next. The
suggested solutions may require that the cover be taken off. (See fig. 3,
page 9).
8.2
Burner does not ignite when hot water is turned ON
It is recommended to use “Control board diagnostics” page 46, chapter
7.7 as a tool for problem solving. If the display is showing a blinking two
digit code, refer to this section.
1. If the display is blank, verify power to outlet. (120VAC/60Hz
properly grounded circuit required). Verify that the heater power
button is pressed ON.
2. Verify the fuses in the control board are good. To access fuses, the
control board must be removed. See chapter 5.2, page 38.
3. Make sure cold water inlet connection is plumbed to the right side of
heater when facing unit. See Fig.36, page 33.
4. A minimum of 0.5 gallons per minute (1.9 l/m) of hot water demand
is required to activate the heater. Confirm at least 0.5 gpm flow by
timing how long it takes to fill a container. A quart container should fill
in 23 seconds or less, from hot water tap only, to activate heater. In
unusual circumstances with high inlet water temperatures and low
set temperatures, the heater may increase the activation rate above
0.5 gpm to avoid overheating at low flows. Gradually increase water
flow (hot water demand) through the heater to determine if the
heater activates with higher flow.
5. Clean inlet filter screen per chapter 7.1, page 42.
6. Inspect the water path for obstructions. Make sure all shower heads,
faucet aerators and whole house filters are clear of debris.
7. Check for plumbing crossover. A crossover in the hot and cold
plumbing pipes creates back pressure on the water flowing through
the heater. Therefore, a higher flow rate than normal is needed to
force the heater to activate. To check for a plumbing crossover, shut
off the cold water supply to the water heater. Then open all of the hot
water taps served by the heater. Wait 10 minutes and check for water
flow at each tap. There should be no water flowing. Any continuous
flow of water, small or large, indicates a crossover is present and
must be corrected. Consult a professional plumber for help in
correcting a crossover. Failing single lever faucet mixing valves are
common causes of plumbing crossovers.
8. With the power button pressed switch turned to OFF and the power
supply cord unplugged, remove the unit's front cover (See fig. 3,
page 9). Check wire connections between the water valve, control
unit and electrode set.
9. Water heater in solar mode. If inlet water temperatures exceed the
water heater's set temperature, the burners will not ignite and the
solar mode indicator will show on the display. See fig. 58, page 39.
8.3
Water is too hot
4. Confirm the heater's gas type coincides with the type of gas being
supplied. See fig. 2, page 9 for location of rating plate.
5. Avoid restrictive outlets. Clean all shower heads and faucet aerators.
It may be necessary to upgrade to higher flow rate shower heads if
allowable by local code.
6. In areas where the water has a high mineral content, periodic
descaling may necessary. See chapter7.3, page 42 for directions.
8.4
Water is not hot enough
1. Selected temperature on the unit is too low. To raise output
temperature, see chapter6.4, page 40.
2. Clean inlet filter screen. See chapter7.1, page 42 to increase flow
through the heater.
3. Inspect the water path for obstructions. Make sure all showerheads,
faucet aerators and whole house filters are clear of debris.
4. Confirm the heater's gas type coincides with the type of gas being
supplied. See fig. 2, page 9 for location of rating plate.
5. Check inlet gas particle screen for blockage at gas inlet connection on
bottom of unit.
6. Verify gas pressure is in accordance with specifications in
chapter4.15, page 37. A gas pressure reading is needed to proceed
further. Contact your original installer or a local certified gas
technician to obtain this reading.
7. Cold water is mixing into the hot water lines (plumbing crossover). A
plumbing crossover can unintentionally mix cold water with the hot
water leaving the heater. The end result is a cooler water temperature
than desired. To check for a plumbing crossover, shut off the cold
water supply to the water heater. Then open all of the hot water taps
served by the heater. Wait 10 minutes and check all taps for water
flow. There should be no water flowing. Any continuous flow of water,
small or large, indicates a crossover and must be corrected. Consult
a professional plumber for help in correcting a crossover. Failing
single lever faucet mixing valves are common causes of plumbing
crossovers.
8.5
Low water flow/pressure
1. Too many hot water applications are being used simultaneously or
too much flow is demanded. The water heater will effectively support
two 2.0-2.5 GPM shower heads simultaneously or multiple sink
applications. Greater draws will result in a water pressure drop and
reduced flow at taps.
2. Ensure that gas pressure is in accordance with specifications in
chapter4.15, page 37. A gas pressure reading is needed to proceed
further. Contact your original installer or a local certified gas
technician to obtain this reading. If gas pressure is inadequate, the
water heater will close its motorized water valve, reducing the hot
water flow rate in an attempt to reach the selected output
temperature.
3. If selected temperature on the unit is set too high for the demanded
flow rate, the water heater will close its motorized water valve,
reducing the hot water flow rate in an attempt to reach the selected
output temperature. Lowering the selected temperature will allow
the motorized water valve to open up for increased water flow rate.
4. Clean inlet filter screen per chapter 7.1, page 42.
5. Inspect the water path for obstructions. Make sure all shower heads,
faucet aerators and whole house filters are clear of debris.
1. Selected temperature on the unit is too high. To lower output
temperature, see chapter 6.4, page 40.
2. Clean inlet filter screen per chapter 7.1, page 42 to increase flow
through the heater.
3. Inspect the water path for obstructions. Make sure all shower heads,
faucet aerators and whole house filters are clear of debris.
48
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Troubleshooting
8.6
Hot water temperature fluctuates at tap
1. Hot water is very hot out of the water heater, requiring mixing in cold
water in order to attain a usable hot water temperature. The addition
of too much cold will overpower hot water flow from the tankless
water heater.
If this slows the flow through the tankless water heater below its
activation point, it will shut off the burners. The end result is nothing
but cold water coming out of the outlet.
2. Unbalanced pressure in water lines. Any restriction in the water
heater, such as a clogged inlet filter screen, can result in unequal
pressures between the cold and hot water lines. In such cases, when
mixing in the higher pressure cold water at the tap, the lower
pressure hot water can be overpowered. This will shut down the
burners because the hot water flow rate fell below the minimum flow
rate required for activation. Verify inlet filter screen is clean and clear
of debris. See chapter 7.1, page 42 for inlet filter cleaning
instructions.
3. Heater deactivated by temperature balancing valves. If the outlet
water temperature is set too high, the heater can produce
temperatures that are too hot. A temperature balance shower valve
will automatically mix in cold water to reduce the hot water
temperature. In the event of any temperature instability at a fixture
using a temperature balancing valve, refer to the valve manufacturer
for instructions on internal adjustment setting. An adjustment should
be made to minimize the amount of cold water the valve is adding.
Additionally, the temperature setting on the heater can be lowered to
prevent the temperature balance valve from mixing in too much cold.
4. Inlet water pressure is erratic due to fluctuating supply water
pressure. For installation on a private well system with the use of a
pressure tank, the lowest pressure range setting recommended is 40
- 60 psi (2.75 - 4.15 bar). Consult your installer or local plumber for
effective ways to maintain constant water pressure to the appliance
when on a well system.
8.7
Noisy burner/heater during operation
1. Sealed combustion leak. Make sure combustion cover is securely
fastened. Ensure the exhaust vent adaptor is properly sealed with
supplied gasket. Leaky seals create improper combustion resulting
in noise.
2. Improper venting. Venting that is unsealed, the wrong material, too
big in diameter or too long in run will result in unstable burner flames
and noise. Ensure venting is in accordance with specifications in
chapter4.3, page 12.
3. Lack of adequate combustion air. Drawing combustion air from a
room area of inadequate size will result in unstable burner flames and
noise. Improper piping of combustion air to the outside or
insufficient space will result in unstable burner flames and noise.
Ensure adequate combustion air is provided from the unit in
accordance with specifications in Section 4.4, page 27 Combustion
Air Requirements.
4. Cross contamination. Ensure that intake and exhaust terminations
maintain required clearances as stated in chapter 4.3, page 12.
Cross contamination between intake and exhaust may cause
unstable burner flames and noise.
5. Lack of gas pressure. Inadequate gas pressure will cause the fuel-toair mixture (CO2) to be out of adjustment. This will result in unstable
burner flames and noise. Ensure gas pressure is in accordance with
specifications in Section4.15, page 37 Measuring Gas Pressure. A
gas pressure reading is needed to proceed further. Contact your
original installer or a local certified gas technician to obtain this
reading.
6. Verify proper CO2 readings per chapter7.5, page 44. CO2
adjustments must be done by a certified gas technician with a
calibrated combustion gas analyzer.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
49
Problem solving
9
Problem solving
9.1
Error code diagnostics
To remove error code from the display, press the reset
button.
Display
A2
Cause
Fault in the flue gas limiter.
Temperature above 230°F (110 °C)
inside the cabinet.
A3
A4
A7
A8
(Flashing)
A9
C5
C6
C7
(Flashing)
CA
Solution
1. Check continuity of the flue gas limiter (see fig. 80, #11, page 56). Go to steps two
and three to determine flue gas limiter fault and repair it.
2. Check for flue gas leakage around the top and bottom seals of heat exchanger, use
mirror to check around the rear as well as the viewing window.
3. Unplug heater and check that flue gas limiter connector and spade connections are
secure.
4. Check the wiring harness connections on the control board.
Wire harness defect.
1. Check wire harness.
2. Measure resistance on wire harness nearby the rubber grommet, must be 115-120
ohm.
3. Check diagnostic menu > 1P, “Cd” must be showed on the display.
Backflow temperature sensor defect - 1. Check backflow temperature sensor connection. See fig. 80, #15, page 56.
happens if sensor is disconnected or 2. Replace exhaust temperature sensor.
short circuit.
3. Check sensor (ref. page 54, chapter 11).
Outlet temperature sensor fault
1. Check wire connection at outlet temperature sensor.
(Temperature below 36°F or above 2. Sensor may trip if water temperature drops below 36°F to protect heater from
210°F).
freezing conditions. Any damage due to freezing conditions is not covered under
warranty.
3. In areas where water has a high mineral content, periodic descaling may necessary.
4. Check sensor (ref. page 54, chapter 11).
Outlet temperature sensor defect.
1. Check wire connection at outlet temperature sensor.
2. In areas where water has a high mineral content, periodic descaling may necessary.
3. Check sensor.
Outlet temperature sensor not
1. Check wire connection at outlet temperature sensor.
sensing expected output
2. Check gas pressure. Low gas pressure may prevent the heater from reaching
temperature.
desired output temperature.
(Status message, not an error).
3. Check supply voltage. It must be 120VAC and properly grounded.
4. Possible defective control unit call manufacturer for further instructions.
Bypass valve solenoid damaged or
1. Check wire connection at the bypass valve.
disconnected.
Primary fan rotation too low in
1. Disconnect power supply cord and check wire connection on back side of fan and
operation.
the connectors on the control board.
2. Check supply voltage. It must be 120VAC and properly grounded.
3. Check venting specifications are met. Long vent lengths, venting with more than
three elbows, blocked vent or combination venting may cause this failure.
4. Ensure intake and exhaust terminations maintain the required clearances stated in
the manual. Cross contamination between intake and exhaust may cause the fan to
alter its rotational speed.
5. Check gas pressure, see chapter 4.15, page 33. Low gas pressure may cause the
fan to change its speed to meet desired temperature.
6. Possible defective control unit call manufacturer for further instructions.
No rotational speed sensor signal
1. Disconnect power supply cord and check wire connections on back side of fan and
from primary fan.
the two connectors on the control board.
2. Check supply voltage. It must be 120VAC and properly grounded.
3. Possible defective component in fan or defective control unit call manufacturer for
further instructions.
Water flow signal over specified
1. Disconnect power supply cord and check wire connections on water valve and the
maximum value.
two connectors on the control board.
Water flow > 10 gallon/min.
2. Excessive water pressure and flow. Ensure water pressure is less than 150psi and
(Status message).
flow rate is below 10 gallons per minute.
Table 53
* By installer or service technician only.
50
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Problem solving
Display
E1
E2
E3
E4
E9
EA
EC
Cause
Solution
Over-temperature detected by outlet 1. Check wire connection at outlet temperature sensor.
temperature sensor.
2. In areas where water has a high mineral content, periodic descaling may be
Temperature > 185°F
necessary. See chapter7.3, page 42 for directions.
3. Check sensor (ref. page 53, chapter 10).
Inlet temperature sensor fault.
1. Check wire connection at inlet temperature sensor, see fig. 80, page 56.
2. Sensor may trip if water temperature drops below 36°F (2°C). Protect heater from
freezing conditions as any damage due to freezing conditions is not covered under
warranty.
3. Check sensor (ref. page 54, chapter 11).
Exhaust temperature sensor - the
1. Clean and check heat exchanger. See chapter 7.1, page 42.
appliance will close the burner and
2. Clean and check condensing heat exchanger. See chapter 7.4, page 43.
lock if it gets over 194°F; (only
3. Reduce maximum power (chapter 4.15, page 37).
applied for condensing unit).
4. Reduce water temperature.
Backflow temperature sensor over
1. Check inlet/outlet vent pipes.
309°F.
2. Check if secondary fan connections are disconnected.
The appliance will close the burner
3. Check if venting specifications are met. Long vent lengths, venting with more than
and lock (non-volatile).
three elbows, blocked vent or combination venting may cause this failure. See
chapter 4.3, page 12.
4. Call manufacturer for further instructions.
Overheat sensor (ECO) open circuit 1. Disconnect power supply cord and check wire connections on the overheat sensor
(resets when cooler temperatures are
(fig. 80, #12, page 56) and the two connectors on the control board.
detected 220°F/104 °C).
2. Check white wire connections at the overheat sensor. Clean terminals with an
eraser. If badly corroded, replace sensor and wire harness.
3. Check that venting specifications are met, see chapter 4.3. page 12. Long vent
lengths, venting with more than three elbows, blocked vent or combination venting
may cause this failure.
4. In areas where water has a high mineral content, periodic descaling may necessary,
see chapter 7.3, page 42.
5. Unplug power supply cord to the water heater. Open a hot water tap for several
minutes to allow cold water to pass through heat exchanger. Close hot water tap and
disconnect lead wires to overheat sensor. Using a multimeter, check continuity
through overheat sensor contacts. Replace sensor if open.
No flame ionization detected with
1. Verify that all manual gas shut off valves are open.
water flow.
2. Check gas type. See fig. 2, page 9.
3. Reset error code and open a water tap to cycle the heater in an effort to purge air.
Cycling hot water tap on and off multiple times may be necessary. If heater still faults
with EA error code, have a licensed gas technician properly purge air out of the gas
line leading to the water heater.
4. Check three wire connections to ignition group on the lower front of the heat
exchanger are secure.
5. Check gas pressure. See chapter 4.15, page 37.
6. Check venting specifications are met. Improper venting may cause premature
failure of the flame sensor rod. See chapter 4.3, page 12.
7. Check that the minimum power fan speed has been adjusted to the proper value.
See page 23.
8. Observe inside the viewing window of the heat exchanger when a hot water tap is
opened. Sparking should be followed by a steady blue flame. If flame is unstable/
yellow with proper gas pressure, confirm CO2 readings per chapter 7.5, page 44.
Ionization failure during operation.
1. Check gas type, fig. 2, page 9.
2. Check three wire connections to ignition group on the lower front of the heat
exchanger are secure.
3. Verify that venting specifications are met. Improper venting may cause premature
failure of the flame sensor rod. See chapter 4.3, page 12.
4. Check gas pressure. See chapter 4.15, page 37.
5. Check and adjust CO2 readings. See chapter 7.5, page 44.
6. Check that the minimum power fan speed has been adjusted to the proper value.
See page 23.
Table 53
* By installer or service technician only.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
51
Problem solving
Display
F1
Cause
Parameter in memory not found
Solution
1. Replace ECU (Electronic Control Unit) if there are repeated errors.
F2
Internal Operations error
F3
Internal memory parameter error
F4
Internal memory error
F5
Analog test fail
F6
Gas type parameter error
E7
Appliance parameter not defined
F0
Burner Control routine state error
E5
Burner Control error
E6
Burner Control routine check sum
error
F8
Fan stopping error
1. Check primary fan cable harness
2. Check fan rotation in standby
3. Check proper function of primary fan
4. Replace ECU (Electronic Control Unit)
F9
Gas Control error
1. Check Gas Valve cable harness (connection to gas valve and to ECU)
2. Check Gas Valve (Replace if necessary)
3. Replace ECU (Electronic Control Unit)
F7
Ionization error at standby.
FA
Gas leakage error, gas valve circuit
not closing properly.
1. Loose connection to the flame ionization rod. Verify that the thinner wire leading
from the control unit is securely connected to the set of electrodes located on the
lower front of the heat exchanger.
2. Flame ionization rod or control unit may be damaged. Contact manufacturer for
further instruction.
1. Disconnect power supply cord and check wire connections on gas valve and the two
connectors on the control board.
2. Flow water out of a hot water tap above the minimum activation point of 0.5 GPM.
Measure voltage at the gas valve wire plug connection. The voltage should measure
24VDC between the left pair of wires and 24VDC between the right pair of wires
when the unit is operating. If voltage is not proper, contact manufacturer for further
instruction.
3. Gas valve may be defective, contact manufacturer for further instruction.
Table 53
* By installer or service technician only.
52
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Electrical diagram
10
Electrical diagram
Fig. 76 Electrical scheme
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
[23]
[24]
Inlet water temperature sensor
Outlet water temperature sensor
Backflow temperature sensor
By-pass water valve
Cascading output connection
Cascading input connection
Ionization sensor
Water flow sensor
Flue gas limiter
Heat exchanger overheat sensor (ECO)
Gas valve
Temperature Heat Exchanger
Exhaust temperature sensor
Water valve
Communication port
Primary fan
ON/OFF switch
Secondary fan
AC plug
Main connection
Ignition electrodes
Ground post
Antifreeze kit connection
Fuse
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
53
Sensor resistance charts
11
Sensor resistance charts
Fig. 77 Outlet / Inlet and HE immersion sensor characteristics
Fig. 78
54
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Functional scheme
12
Functional scheme
Fig. 79 Functional scheme
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
55
Interior components diagram
13
Interior components diagram
13.1
Interior components
Fig. 80 Components
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
56
Exhaust temperature sensor
Flue gas collector
Heat exchanger
Ionization sensor
Primary fan (Mixer)
Hot water temperature sensor
LCD display
On/Off button
Reset button
Program key
Flue gas limiter
Heat exchanger overheat sensor (ECO)
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
Ignition electrodes
Observation window
Backflow temperature sensor
Secondary air fan
Gas valve
Condensate trap
Water valve with flow sensor and inlet temperature sensor
Control unit
Up button
Down button
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Protecting the environment
14
Protecting the environment
Packing
The packing box may be fully recycled as confirmed by the recycling
symbol
.
Components
Many parts in the heater can be fully recycled in the end of the product
life. Contact your city authorities for information about the disposal of
recyclable products.
Saving water resources:
▶ Make sure you close all the taps after any use. Avoid leaving the taps
dripping. Repair any leaking tap.
▶ Define the temperature you want, in the appliance or with the remote
control. This way you have the precise water flow needed (mixing
cold water to regulate temperature will increase the water flow with
consequent waste of water).
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
57
LIMITED TANKLESS HEATER WARRANTY
15
LIMITED TANKLESS HEATER WARRANTY
MODELS COVERED
This limited warranty is provided by Bosch Thermotechnology Corp. (BTC) and covers models TL-Pro 175C and TL-Pro 199C (hereinafter referred to
as "Water Heater"). This warranty is provided as long as the Water Heater remains in the possession of the original purchaser and installed at its original
place of installation.
WARRANTY COVERAGE
HEAT EXCHANGER Limited Warranty
BTC warrants that the heat exchanger will remain free of leaks for Fifteen (15) years from the date of original installation (or date of manufacture if proof
of installation is not available), provided that the water heater is properly installed and maintained by a qualified heating contractor and the other
conditions of this warranty are met. If during this time a leak occurs and BTC determines that this leak is the result of a defect in workmanship or
materials, BTC, will replace the heat exchanger. However, if the Water Heater is in a re-circulation or preheated application or not installed in a single
family dwelling, the heat exchanger warranty will be limited according to the table below.
Single Family Residence
Other
Application
No Recirculation
Controlled
Recirculation
Combination DHW
and Space Heating
Applications,
including Hydronic
Forced Air Heat
Uncontrolled
Recirculation
Non Single Family
Residence
Tank Loading
Applications
Heat
Exchanger
Warranty
15 years
10 Years
Other Parts
Warranty
5 years
5 years
Reasonable
Labor
1 year
1 year
10 years
5 years
1 year
3 years
5 years
1 year
Constant recirculation system without timer or aquastat
5 years
5 years
1 year
Any installation not in a single family residence.
3 years
5 years
1 year
Recirculation with a pump through water heater to a heated storage
tank
Details
Only cold water supplied to the water heater.
Controlled by aquastat, timer demand device per the Therm
Applications Manual.
Design rules in accordance to applicable local codes for allowed DHW
and combi space heating applications, including Hydronic Forced Air
Heating.
Table 54
OTHER WATER HEATER PARTS
BTC warrants that all internal components incorporated into the Water Heater at the time of shipment by BTC shall remain free from defects in
workmanship and materials for five (5) years after the original date of installation or from date of manufacture if proof of installation is not available
provided the Water heater is installed and properly maintained by qualified service contractor and the other conditions of this warranty are met.
WATER HEATER ACCESSORIES
The Water Heater may be delivered with components not manufactured by BTC ("Other Components). Other Components are warranted by their
manufacturer. BTC also will warrant the Other Components to be free from defects in workmanship and material for one year from the date of
installation, provided they are installed and properly maintained by a qualified heating contractor and the other conditions of this warranty are met. If a
defect exists in the Other Components, BTC will repair or replace them if BTC determines that a defect in workmanship or materials exists.
SERVICE LABOR COSTS
This warranty provides labor costs, at BTC approved rates, for one (1) year from the date of original installation (or from the date of manufacture if proof
of installation is not available), provided it is installed and properly maintained by a qualified heating contractor and the other conditions of this warranty
are met.
ITEMS NOT COVERED
This limited warranty does not cover the following circumstances:
1. Components or parts not provided by BTC.
2. Serviceable items and normal maintenance as required per the Installation Manual.
3. The workmanship of any installer. BTC disclaims and does not assume any liability of any nature for unsatisfactory performance caused by improper
installation, repair or maintenance.
4. Any labor or material costs for removal, reinstallation, repair and replacement of the defective component or part unless otherwise provided above.
5. Transportation to BTC, if necessary.
6. Damage caused by operation of the Water Heater in a corrosive atmosphere, scale depots and/or highly mineralized or unsoftened water supply,
electrical failures, flooding, or acts of God.
7. Any Water Heater that has a failure of malfunction resulting from operation with either the flame sensor rod or overheat sensor removed.
8. Damage caused by any attachment or modification to the Water Heater, including any energy-saving device.
9. Damage caused by operation of the Water Heater at water temperatures exceeding the maximum rating, or if the water is not supplied with potable
water.
10.Shipping charges, delivery expenses or administrative fees incurred by the purchaser in repairing or replacing the Water Heater.
58
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
LIMITED TANKLESS HEATER WARRANTY
CONDITIONS OF WARRANTY
The warranty herein is void under the following circumstances:
1. Failure or malfunction resulting from improper or negligent operation, accident, abuse, freezing, misuse, unauthorized alteration or improper
installation, repair or maintenance. See the Installation Manual for installation and maintenance information.
2. Any Water Heater that is operated without a flame sensor rod or overheat sensor.
3. Any Water Heater that is used or operated in a corrosive atmosphere or at water temperatures exceeding the maximum rating, or if the Water Heater
is not supplied with potable water.
4. Work performed without prior authorization or approval and without authorization/requisition number and without proper documentation verifying
compliance with above terms.
LIMITED WARRANTY
OTHER THAN THE OBLIGATIONS OF BTC EXPRESSLY SET FORTH HERIN, BTC DISCLAIMS ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. BTC'S SOLE OBLIGATION WITH
RESPECT TO THE WATER HEATER AND PURCHASER'S EXCLUSIVE REMEDIES ARE SET FORTH IN THE FOREGOING LIMITED WARRANTY. BTC SHALL
NOT BE LIABLE FOR ANY INDIRECT, PUNITIVE, INCIDENTAL, SPECIAL, CONSEQUENTIAL OR SIMILAR DAMAGES INCLUDING, WITHOUT LIMITATION,
INJURY OR DAMAGE TO PERSONS OR PROPERTY OR DAMAGES FOR LOSS OF USE, LOST PROFITS, INCONVENIENCE OR LOSS OF TIME.NOTE THAT
ANY REPAIRED OR REPLACED PRODUCT WILL BE WARRANTED FOR ONLY THE UNEXPIRED TERM OF THE ORIGINAL WARRANTY.
Some states do not allow the exclusion of limitation of damages, or limitations on how long an implied warranty lasts, so the above limitations and
exclusions may not apply to you.
WARRANTY CLAIMS PROCESS
If you have a warranty claim you should notify the heating contractor who installed your Water Heater and ask that the contractor notify the distributor
from whom the contractor purchased the Water Heater. If this action is not possible or you don't receive a response, contact:
Bosch Thermotechnology Corp., 50 Wentworth Avenue, Londonderry, NH 03053.
To process your claim, you will need a copy of your original invoice or other proof of purchase and documentation showing the original installation date
and location. The alleged defective components or parts must be returned to BTC in accordance with BTC procedure then in force for handling goods
returned for the purpose of inspection to determine cause of failure (contact BTC if you have questions regarding the return process). If BTC determines
that the returned components and/or parts are defective and that this warranty applies, BTC will furnish the repaired or replacement components and/
or parts to an authorized BTC distributor who, in turn, will forward the components and/or parts to the heating contractor who installed your Water
Heater.
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
59
Installer Checklist to be completed by installer upon installation
16
Installer Checklist to be completed by installer
upon installation
Serial Number
(8 digit serial number is located
on rating plate on right side
panel)
___ ___ ___ ___ ___ ___ ___ ___
Gas Pressure Reading 1)
Static
Operating
Water Pressure
Building Water Pressure
Range if on Well system
Installing Company
Installer name
Address
Phone
Table 55
1) See Chapter 4.15, page 37 and gas pressure table (to be filled out by installer)
Installation manual should be left with the owner after
the installation is tested and completed.
60
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Notes
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
61
Notes
62
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
Notes
TL-Pro 175/199 C – 6 720 821 954 (2017/06)
63
6720821954
Download PDF