A.O. Smith ATI-310U-N Technical Documents

On-Demand Water Heater
Installation Manual and Owner’s Guide
ANSIZ21.10.3andCSA4.3
Models
510U(T-D2U)
modelsonly
• 110U Indoor (T-KJr2U-IN) • 110U Outdoor (T-KJr2U-OS)
• 310U Indoor (T-K4U-IN) • 310U Outdoor (T-K4U-OS)
• 510U Indoor (T-D2U-IN) • 510U Outdoor (T-D2U-OS)
If the information in these
instructions is not followed
exactly,afireorexplosionmay
resultcausingpropertydamage,
WARNING personalinjuryordeath.
- Do not store or use gasoline or other
flammablevaporsandliquidsinthevicinity
ofthisoranyotherappliance.
- WHATTODOIFYOUSMELLGAS
• Donottrytolightanyappliance.
• Donottouchanyelectricswitch,donot
useanyphoneinyourbuilding.
• Immediatelycallyourgassupplierfrom
aneighbor'sphone.Followthegas
supplier'sinstructions.
Gas Tankless Water HeaterTM
• Ifyoucannotreachyourgassupplier,call
Suitable for potable water heating and space-heating*
thefiredepartment.
* Please refer to local codes for space-heating compliance.
- Installation and service must be performed
byaqualifiedinstaller,serviceagencyorthe
gassupplier.
FEATURING
• ENDLESSHOTWATER
• ON-DEMANDUSAGE
• COMPACT,SPACESAVING
• ENERGYCONSERVATION
• COMPUTERIZEDSAFETY
• NOPILOTLIGHT
• Satisfiesthe2012SCAQMDRule
1146.2forUltra-LowNOx
Emissions
• EASY-LINKSYSTEMAND
MULTI-UNITSYSTEM
(510U (T-D2U) models only)
Ifyouhaveanyquestions,please
callorwriteto:
500TennesseeWaltzParkway
AshlandCity,TN37015
TollFree:1-877-737-2840
CONTENTS
Installation Manual
SPECIFICATIONS.......................................................................................................................... 4
INTRODUCTION.......................................................................................................................... 5
SAFETYGUIDELINES.................................................................................................................... 6
INSTALLATION............................................................................................................................. 7
General.....................................................................................................................................7
Clearances................................................................................................................................9
IncludedAccessories...............................................................................................................9
OptionalItems........................................................................................................................9
WarningforInstallations..........................................................................................................9
High-altitudeInstallations......................................................................................................12
VentingInstructions...............................................................................................................13
Gassupplyandgaspipesizing...............................................................................................18
WaterConnections................................................................................................................20
ElectricalConnections............................................................................................................21
TemperatureRemoteController...........................................................................................22
Easy-linkSystem.....................................................................................................................25
Multi-UnitSystem..................................................................................................................29
APPLICATIONS............................................................................................................................30
INITIALOPERATION...................................................................................................................32
Owner's Guide
OPERATINGSAFETY.................................................................................................................. 34
NORMALOPERATION............................................................................................................... 36
General..................................................................................................................................36
TemperatureSettings.............................................................................................................37
Flow.......................................................................................................................................40
Freezeprotectionsystem.......................................................................................................40
Maintenanceandservice.......................................................................................................41
UnitDrainingFilterCleaning..................................................................................................41
TROUBLESHOOTING...................................................................................................................42
General...................................................................................................................................42
ErrorCodes...........................................................................................................................44
COMPONENTSDIAGRAM...........................................................................................................47
PARTSLIST.................................................................................................................................51
OUTPUTTEMPERATURECHART................................................................................................54
LIMITEDWARRANTY..................................................................................................................55
2
Page
Installation Manual
Contents
Installation Manual
CONGRATULATIONS
Congratulationsandthankyouforchoosingourtanklesswaterheater.
Beforeuse,werecommendthatyoureadthroughthissafetymanual
carefully.Pleaserefertothebackofthemanualfordetailsaboutthe
warranty.Keepthismanualforfuturereference.
If you lose the manual, contact the manufacturer or your local
distributor. When you call, please tell us the product name and the
serial number of your unit written on the rating plate of the water
heater.
3
Page
Installation Manual
Specifications
SPECIFICATIONS
110U
Indoor
Model
110U
Outdoor
310U
Indoor
310U
Outdoor
BTU/h
Min.:15,000
Max.:140,000
Min.:15,000
Max.:190,000
Gas Connection
3/4"NPT
Water Connections
3/4"NPT
Water Pressure*
Natural gas
Inlet Pressure
Manifold
Pressure**
Natural
Gas
Weight
psi
(Mpa)
"W.C.
(kPa)
"W.C.
(Pa)
Min.:15,000
Max.:199,000
15-150(0.1-1)
1.8
(448)
1.5
(373)
lbs.(kg)
Dimensions
Min.5.0(1.24)
Max.10.5(2.61)
3.0
2.9
(747)
(722)
37(16.9)
inch
mm
3.3
(821)
2.9
(722)
39(17.9)
H20.5xW13.8xD8.5
H520xW351xD216
Ignition
Consumption
510U
Outdoor
(T-KJr2U-IN) (T-KJr2U-OS) (T-K4U-IN) (T-K4U-OS) (T-D2U-IN) (T-D2U-OS)
Natural Gas Input
(OperatingRange)
Electric
510U
Indoor
ElectricIgnition
Supply
VAC/Hz
120/60
Operation
W/A
52.1/0.54
75.8/0.83
81.6/0.86
Standby
W/A
5.4/0.08
5.5/0.08
6.5/0.09
FreezeW/A
131/1.1
131/1.1
132/1.1
Protection
*40psioraboveisrecommendedformaximumflow.
**TheManifoldPressureisthefactorysettingandgenerallyshould not need adjustment.
NOTE:
• Checktheratingplatetoensurethisproductmatchesyourspecifications.
• InaccordancewithANSIZ21.10.3,COemissiondoesnotexceed400PPMfornormalinput.
• The manufacturer reserves the right to discontinue, or change at any time, specifications or designs
without notice and without incurring obligations.
4
Page
Installation Manual
Introduction
INTRODUCTION
• Thismanualprovidesinformationnecessaryfortheinstallation,operation,andmaintenance
ofthewaterheater.
• Themodeldescriptionislistedontheratingplatewhichisattachedtothefrontpanelofthe
waterheater.
• Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
• Ifyouhaveanyproblemsorquestionsregardingthisequipment,consultwiththemanufacturer
oritslocalrepresentative.
• Thisequipmentisanon-demand,tanklesswaterheaterdesignedtoefficientlysupplyendless
hotwaterforyourneeds.
• The 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models
are to be installed indoor (direct-vent convertible). The 110U Outdoor (T-KJr2U-OS), 310U
Outdoor(T-K4U-OS)and510UOutdoor(T-D2U-OS)modelsaretobeonlyinstalledoutdoor.
• Theprinciplebehindtanklesswaterheatersissimple:
Exhaustventcollar
Burners
Heatexchanger
Burners
Flowadjustmentvalve
Computerboard
Gasvalves
Flowsensor
Thermistor
Fanmotor
Thermistor
Hotwateroutlet
Gasinlet
Coldwaterinlet
*Thisdiagramillustratestanklesswaterheaterdesignconceptsonlyanddoesnotaccurately
representthewaterheater’sphysicaldescription.
1.
2.
3.
4.
5.
6.
7.
Ahotwatertapisturnedon.
Waterenterstheheater.
Thewaterflowsensordetectsthewaterflow.
Thecomputerinitiatesthefanmotorandsendsasignaltotheignitertocreateanignitionspark.
Thegasignitesandflamesappearwithintheburnerchamber.
Watercirculatesthroughtheheatexchangerandthengetshot.
Usingthermistorstomeasuretemperaturesthroughoutthewaterheater,thecomputermodulates
thegasandwatervalvestoensureproperoutputwatertemperature.
8. Whenthetapisturnedoff,theunitshutsdown.
5
Page
Installation Manual
Safety Guidelines
SAFETY GUIDELINES
SAFETY DEFINITION
DANGER
WARNING
CAUTION
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultin
deathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
indeathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.
GENERAL
1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionoftheNational
FuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGasInstallationCode
inCanada.
2. Properlygroundtheunitinaccordancewithalllocalcodesorintheabsenceoflocalcodes,withthe
NationalElectricalCodes:ANSI/NFPA70intheUSAorCSAstandardC22.1CanadaElectricalCode
Part1inCanada.
3. Carefullyplanwhereyouintendtoinstallthewaterheater.Pleaseensure:
•Yourwaterheaterwillhaveenoughcombustibleairandproperventilation.
•Locateyourheaterwherewaterleakagewillnotdamagesurroundingareas(pleasereferto
p.8).
4. ChecktheratingplateforthecorrectGAS TYPE, GAS PRESSURE, WATER PRESSURE and ELECTRIC
RATING.
*Ifthisunitdoesnotmatchyourrequirements,do not install and consult with the manufacturer.
5. Ifanyproblemshouldoccur,turnoffallhotwatertapsandturnoffthegas.Thencallatrained
technicianortheGasCompanyorthemanufacturer.
• Watertemperaturesover125°F(52°C)cancausesevereburnsinstantlyor
deathfromscalding.Thewatertemperatureissetat120°F(49°C)fromthe
factory to minimize any scalding risk. Before bathing or showering always
checkthewatertemperature.
WARNING
• Do not store or use gasoline or other flammables, vapors, or liquids in the
vicinityofthisappliance.
• Donotreversethewaterand/orgasconnectionsasthiswilldamagethegas
valvesandcancausesevereinjuryordeath.Followthediagramonp.20when
installingyourwaterheater.
• Do not use this appliance if any part has been in contact with or been
immersedinwater.Immediatelycallalicensedplumber,alicensedgasfitter,
or a professional service technician to inspect and/or service the unit if
necessary.
• Do not disconnect the electrical supply if the ambient temperature will
drop below freezing. The Freeze Prevention System only works if the unit
haselectricalpower.Thewarrantywillnotbecoverediftheheatexchanger
is damaged due to freezing. Refer to the section on the Freeze Prevention
Systemonp.39formoreinformation.
6
Page
Installation Manual
Installation
INSTALLATION
GENERAL
1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionoftheNational
FuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGasInstallationCodein
Canada.
2. Allgaswaterheatersrequirecarefulandcorrectinstallationtoensuresafeandefficientoperation.This
manualmustbefollowedexactly.Readthe“SafetyGuidelines”section.
3. The manifold gas pressure is preset at the factory. It is computer controlled and should not need
adjustment.
4. Maintain proper space for servicing. Install the unit so that it can be connected or removed easily.
Refertothe"Clearances"sectiononp.9forproperclearances.
5. Thewaterheatermustbeinstalledinalocationwheretheproperamountofcombustibleairwillbe
availabletoitatalltimeswithoutobstructions.
6. Theelectricalconnectionrequiresameansofdisconnection,toterminatepowertothewaterheater
forservicingandsafetypurposes.
7. Donotinstalltheunitwheretheexhaustventispointingintoanyopeninginabuildingorwherethe
noise may disturb your neighbors. Make sure the vent termination meets the required distance by
localcodefromanydoorwayoropeningtopreventexhaustfromenteringabuilding(refertop.14).
8. Particlesfromflour,aerosols,andothercontaminantsmayclogtheairventorreducethefunctions
oftherotatingfanandcauseimproperburningofthegas.Regularlyensurethattheareaaroundthe
unitisdust-ordebris-free;regularmaintenanceisrecommendedforthesetypesofenvironment.
9. Ifyouwillbeinstallingthewaterheaterinacontaminatedareawithahighlevelofdust,sand,flour,
aerosolsorothercontaminants/chemicals,theycanbecomeairborneandenterandbuildupwithin
thefanandburnercausingdamagetothewaterheater.
10.Forthe110UIndoor(T-KJr2U-IN),310UIndoor(T-K4U-IN)and510UIndoor(T-D2U-IN)models:
•Theseunitsmaybeconvertedtoadirect-vent(sealedcombustion)appliancebyinstalling
adirect-ventconversionkitPartNo.9007667005(TK-TV10)whichwillbringinallrequired
combustibleairfromoutsidethebuilding.Wheninstallingthedirect-ventconversionkit,please
followallinstructionsincludedwiththekit.
•Ifthewaterheaterisusedasadirect-ventappliance,theunitrequiresa3in.(76mm)
combustibleairsupplypipe.Theintakepipemustbesealedairtight.Airsupplypipecanbe
madeofABS,PVC,galvanizedsteel,corrugatedaluminum,corrugatedstainlesssteelorCategory
IIIstainlesssteel.
•Terminatingtheventingthroughasidewallisrecommendedforthedirect-ventsystem.
•Runningtheexhaustventandtheintakepipeparallelisrecommended.
•Terminatingtheexhaustandintakeonthesamewall/surfaceisrecommended.Terminatingin
thesamepressurezoneallowsforpressurebalancing,whichpreventsnuisanceshutdowns.
11.Forthe110UOutdoor(T-KJr2U-OS),310UOutdoor(T-K4U-OS)and510UOutdoor(T-D2U-OS)models:
•Tobeinstalledoutdoorsandonlyinareaswithmild,temperateclimates.
7
Page
Installation Manual
Installation
• Installation and service must be performed by a qualified installer (for
example, a licensed plumber or gas fitter), otherwise the warranty will be
void.
WARNING • The installer (licensed professional) is responsible for the correct installation
of the water heater and for compliance with all national, state/provincial,
and local codes.
• The manufacturer does not recommend installing the water heater in a pit or
location where gas and water can accumulate.
• Donothavetheventterminalpointingtowardanyoperatingwindow,door,or
openingintoabuilding.
• Do not install next to any source of airborne debris, such as a clothes dryer,
thatcancausedebristobetrappedinsidethecombustionchamber,unlessthe
systemisdirect-vented.
• The manufacturer does not recommend installing the water heater in an attic
due to safety issues.Ifyouinstallthewaterheaterinanattic:
• Makesuretheunitwillhaveenoughcombustionairandproper
ventilation.
• Keeptheareaaroundthewaterheaterclean.Whendustcollectsonthe
flamesensor,thewaterheaterwillshutdownonanerrorcode.
• Iftheaboveconditionscannotbemet,usethedirectventconversionkit
PartNo.9007667005(TK-TV10).
• Placetheunitforeasyaccessforserviceandmaintenance.
• Adrainpan,orothermeansofprotectionagainstwaterdamage,is
requiredtobeinstalledunderthewaterheaterincaseofleaks.
INCLUDED ACCESSORIES
CAUTION
• The warranty will not cover damage caused by water quality.
• Onlypotablewaterorpotablewater/glycolmixturescanbeusedwith
thiswaterheater.Donotintroducepoolorspawater,oranychemically
treatedwaterintothewaterheater.
• Waterhardnesslevelsmustnotexceed7grainspergallon(120ppm)for
singlefamilydomesticapplicationsormorethan4grainspergallon(70
ppm)forallothertypesofapplications.Waterhardnessleadstoscale
formationandmayaffect/damagethewaterheater.Hardwaterscaling
mustbeavoidedorcontrolledbyproperwatertreatment.
• WaterpHlevelsmustbebetween6.5and8.5
• Wellwatermustbetreated.
• Donotinstalltheunitwherewater,debris,orflammablevaporsmaygetinto
theflueterminal.
• The manufacturer recommends using the direct vent kit when the water
heater is installed in a beauty salon.Somechemicalsusedinabeautysalon
mayaffecttheflamesensor.Waterheatermaynotworkproperly.
• Although the water heater is designed to operate with minimal sound, the
manufacturer does not recommend installing the unit on a wall adjacent to a
bedroom, or a room that is intended for quiet study or meditation, etc.
• Locateyourheaterclosetoadrainwherewaterleakagewillnotdodamage
to surrounding areas. As with any water heating appliance, the potential for
leakageatsometimeinthelifeoftheproductdoesexist.Themanufacturer
willnotberesponsibleforanywaterdamagethatmayoccur.Ifyouinstalla
drainpanundertheunit,ensurethatitwillnotrestrictthecombustionairflow.
OPTIONAL ITEMS
8
Page
Installation Manual
Installation
CLEARANCES
Top
Black
Side
Maintain all clearances around
thewaterheater.
Front
Side
Bottom
Model
Top
Bottom
Front
Back
Sides
110UIndoor(T-KJr2U-IN)*
310UIndoor(T-K4U-IN)*
510UIndoor(T-D2U-IN)*
12in.
(305mm)
12in.
(305mm)
4in.**
(102mm)
0.5in.
(13mm)
2in.
(51mm)
110UOutdoor(T-KJr2U-OS)
36in.
310UOutdoor(T-K4U-OS) (914mm)
510UOutdoor(T-D2U-OS)
12in.
(305mm)
24in.
(610mm)
0.5in.
(13mm)
2in.
(51mm)
*Standardindoorinstallationsanddirect-ventindoorinstallationshavethesameclearances.
**24inchrecommendedformaintenance.
INCLUDED ACCESSORIES
Checkthattheseitemsbelowareincludedwiththewaterheater.
Installation Manual Temperature
Communication Cable
and Owner’s Guide Remote Controller Kit* 510U (T-D2U) models only
Qty:1
Qty:1
Qty:1
*Refertothep.22.
OPTIONAL ITEMS
#
Model
1.
BackflowPreventer
Direct-Vent
ConversionKit
Pipecovers
2.
3.
110U
110U
Indoor
Outdoor
(T-KJr2U-IN) (T-KJr2U-OS)
✓
✓
✓
4.
Recessbox
T-VentWallThimble
5.
withTermination
Direct-VentConcentric
6.
Termination
✓
✓
✓
✓
310U
Indoor
(T-K4U-IN)
✓
✓
✓
✓
✓
9
Page
310U
Outdoor
(T-K4U-OS)
✓
✓
510U
Indoor
(T-D2U-IN)
✓
✓
✓
✓
✓
510U
Outdoor
(T-D2U-OS)
✓
✓
Installation Manual
Installation
1. Backflow Preventer: 9007678005 (TK-BF01)
TheBackflowpreventerpreventsthebackflowof
air through the exhaust vent. This helps prevent
harmfulexhaustgasesfromenteringthehome,as
wellashelpingtopreventtheunitfromfreezingin
areaswherecoldaircanbeblownordrawninto
the exhaust system. Install this vent damper in
accordance with the installation instructions and
anyapplicablecodes.
3. Pipe covers: 9007670005 (TK-PC01)
2. Direct-Vent Conversion Kit: 9007667005
(TK-TV10)
This kit can be used to convert the water
heaterfromastandardventsystemtoadirectvent (or sealed combustion) system. Install
this conversion kit in accordance with the
installation instructions and any applicable
codes.
4. Recess box: 9007674005 (TK-RB02)
The Recess box will allow for
“clean” installations. The water
heater fits inside the recess box,
whichhidesandprotectsthewhole
water heater and plumbing. The
Recessboxwillfitin-betweenmost
wallstuds.
Thepipe coverprotectstheplumbing pipes to
thewaterheaterfromunexpectedadjustments.
This pipe cover is fixed to the bottom of the
water heater, which hides the plumbing and
improves the visual aspects of the whole
installationforthewaterheater.
5. T-Vent Wall Thimble with Termination: 9007608005 (TK-KPWL4) and 9007609005 (TK-KPWH4)
Theseterminationsareusedwhenventingoutthroughthewalland
arecompatiblewiththeT-Ventpipesystem.Theseterminationsare
special stainless steel vents for gas appliances and are UL listed as
CategoryII,IIIandIV.Therearetwotypesofterminations:theLouver
terminationandtheHoodtermination.Fordifferentwallthicknesses,
Louver Termination Hood Termination therearetworangesoflengthsavailable(refertotheT-Ventbrochure
9007609005
9007608005
fordetails).Installtheseventterminationsinaccordancewiththeir
(TK-KPWL4)
(TK-KPWH4)
installationinstructionsandanyapplicablelocalcodes.
6. Direct-Vent Concentric Termination: 900768005 (TK-KPCT43)
Usedwhenterminatingdirect-vent(sealed-combustion)systems,with
direct-ventmodelsthatrequirea3in.(76mm)intakeanda4in.(102
mm) exhaust. This concentric termination provides the convenience
of only having to make one penetration through a sidewall instead
of two separate penetrations for the intake and exhaust piping. The
termination includes a bird screen, restricting small animals, pests,
andforeignobjectsfromenteringintotheventsystem.Thissidewall
terminationisavailableinthreedifferentsizes,tocoverallrangesof
wallthicknesses.
Part#
9007680005(TK-KPCT43-1)
9007772005(TK-KPCT43-2)
9007773005(TK-KPCT43-3)
10
Convering wall thicknesss
3.9–7.1in.(99-180mm)
6.9–10.1in.(175-257mm)
9.8–13.0in.(249-330mm)
Page
WARNING FOR INSTALLATIONS
FOR YOUR SAFETY, READ BEFORE INSTALLATION:
Do not install the heater where water, debris or
flammablevaporsmaygetintotheflueterminal.
Thismaycausedamagetotheheaterandvoidthe
warranty.
Prohibited
Donothavetheventterminalpointingtoward
anyopeningintoabuilding.Donotlocateyour
heaterinapitorlocationwheregasandwater
canaccumulate.
Prohibited
Do not install this water heater under an
overhanglessthan3ft.(914mm)fromitstop
oreaves.Theareaunderanoverhangmustbe
opentothreesides.(Outdoormodelsonly)
Donotinstallthewaterheaterventterminator
within1ft.(305mm)intheUSAofanyairintake
orbuildingopening,andwithin3ft.(914mm)
inCanadaofanyairintakeorbuildingopening.
(Outdoormodelsonly)(Refertop.15)
1ft.(305mm)USA
3ft.(914mm)Canada
3ft.
(914mm)
1ft.(305mm)USA
3ft.(914mm)Canada
Do not install next to a dryer or any source
of airborne debris that can be trapped inside
the combustion chamber, unless the system is
directvented.
11
Page
1ft.(305mm)USA
3ft.(914mm)Canada
Installation Manual
Installation
HIGH-ALTITUDE INSTALLATIONS
Check the elevation where your water heater is installed. Set DIPswitches shown in the table below
dependingonthealtitude.
Indoor models
DIPswitches
Altitude
0 (DEFAULT)
1
O N
2
3
4
5 6
7
8
9 1 0
O F F
110U(T-KJr2U)and
310(T-K4U)models
Up to 2,500 ft Up to 5,000 ft Up to 7,500 ft Over 7,500 ft
1
O N
3
4
5 6
7
8
9 1 0
O F F
1
O N
2
3
4 5 6
O F F
1
O N
2
3
4
5 6
7
8
9 1 0
O F F
No.3:OFF
No.4:OFF
No.5:OFF
510U(T-D2U)models
(Lower bank of
DIPswitches)
2
1
2
3
No.3:OFF
No.4:OFF
No.5:ON
4 5 6
1
O N
O F F
3
4
5 6
7
8
9 1 0
2
3
No.3:OFF
No.4:ON
No.5:ON
4 5 6
O F F
No.2:OFF
No.3:OFF
No.4:OFF
2
O F F
No.3:OFF
No.4:ON
No.5:OFF
O N
1
O N
1
O N
2
3
4 5 6
No.2:OFF
No.3:ON
No.4:OFF
O F F
No.2:OFF
No.3:OFF
No.4:ON
Consultour
Technical
Services
at1-888479-8324
No.2:OFF
No.3:ON
No.4:ON
Outdoor models
DIPswitches
Altitude
0 (DEFAULT)
O N
110U(T-KJr2U)and
310(T-K4U)models
2
3
4
5 6
7
8
9 1 0
O F F
O N
1
2
3
4
5 6
7
8
9 1 0
O F F
No.3:OFF
No.4:OFF
No.5:OFF
O N
510U(T-D2U)models
(Lower bank of
DIPswitches)
1
Up to 2,000 ft Up to 4,000 ft Up to 6,000 ft Over 6,000 ft
1
2
3
4 5 6
O F F
No.3:OFF
No.4:ON
No.5:OFF
O N
1
2
3
4
5 6
7
8
9 1 0
O F F
1
2
3
O N
O N
1
2
3
4 5 6
O F F
No.2:OFF
No.3:ON
No.4:OFF
1
2
3
4
5 6
7
8
9 1 0
O F F
No.3:OFF
No.4:OFF
No.5:ON
4 5 6
O F F
No.2:OFF
No.3:OFF
No.4:OFF
O N
No.3:ON
No.4:OFF
No.5:ON
O N
1
2
3
4 5 6
O F F
No.2:OFF
No.3:OFF
No.4:ON
Consultour
Technical
Services
at1-888479-8324
No.2:ON
No.3:OFF
No.4:ON
NOTE: ThedarksquaresindicatethedirectiontheDIPswitchesshouldbesetto.
110U (T-KJr2U) and 310U (T-K4U) models
Computer board
510U (T-D2U) models
Computer board
DIPswitches(Lowerbank)
DIPswitches
WARNING
DO NOT adjust any DIPswitches on the upper bank for the 510U (T-D2U)
models.
12
Page
Installation Manual
Installation
VENTING INSTRUCTIONS
For indoor models
-General• Improper venting of this appliance can result in excessive levels of carbon
monoxidewhichcanresultinseverepersonalinjuryordeath.
• Improperinstallationcancausenauseaorasphyxiation,severeinjuryordeath
fromcarbonmonoxideandfluegasespoisoning.Improperinstallationwillvoid
DANGER
productwarranty.
Wheninstallingtheventsystem,allapplicablenationalandlocalcodesmustbe
followed. If you install thimbles, fire stops or other protective devices and they
penetrateanycombustibleornoncombustibleconstruction,besuretofollowall
CAUTION applicablenationalandlocalcodes.
Thewaterheatermustbeventedinaccordancewiththesection“VentingofEquipment"ofthelatest
editionoftheNationalFuelGasCode:ANSIZ223.1/NFPA54intheUnitedStatesand/orSection7ofthe
CAN/CSAB149.1NaturalGasInstallationCodeinCanada,aswellasapplicablelocalbuildingcodes.
The manufacturer recommends the “T-Vent” line manufactured by TAKAGI(Referto“T-Vent”brochure
for details). However, the following are also UL listed manufacturers: ProTech Systems Inc. (FasNSeal),
Flex-LInc.,Z-FlexInc.(Z-VentIII),Metal-FabInc.,andHeat-FabInc.(Saf-TVent).
General rules for venting water heaters are:
• Placethewaterheaterascloseaspossibletotheventterminator.
• Theventcollarofthewaterheatermustbefasteneddirectlytoanunobstructedventpipe.
• Donotweldtheventpipetothewaterheater’sventcollar.
• Donotcuttheventcollaroftheunit.
• The vent must be easily removable from the top of the water heater for normal service and
inspectionoftheunit.
• Thewaterheaterventmustnotbeconnectedtoanyothergasapplianceorventstack.
• Avoidusinganoversizedventpipeorusingextremelylongrunsofthepipe.
• For rooftop venting, a rain cap or other form of termination that prevents rain water from
enteringintothewaterheatermustbeinstalled.
• Donotcommonventorconnectanyventfromotherappliancestothewaterheatervent.
General rules for vent terminations:
• Avoidlocatingthewaterheaterventterminatornearany air intake devices.Thesefanscanpick
uptheexhaustflueproductsfromthewaterheaterandreturnthemtothebuilding.Thiscan
createahealthhazard.
• Locatetheventterminatorsothatitcannotbeblockedbyanydebris,atanytime.Mostcodes
requirethattheterminatormustbeatleast12in.(305mm)abovegrade,buttheinstallermay
determineifitshouldbehigherdependingonthejobsiteconditionandapplicablecodes.
• A proper sidewall terminator is recommended when the water heater is vented through a
sidewall.
• Regardingtheclearancesfromtheexhaustterminatortotheairinletoropening,refertothe
nextfewpages.
13
Page
Installation Manual
Installation
-Vent length and No. of ElbowThisisaCategoryIIIapplianceandmustbeventedaccordingly.Theventsystemmustbesealedairtight.
Allseamsandjointswithout gaskets mustbesealedwithhighheatresistantsiliconesealantorULlisted
aluminumadhesivetapehavingaminimumtemperatureratingof350°F(177°C).Forbestresults,avent
systemshouldbeasshortandstraightaspossible.
• ThiswaterheaterisaCategoryIIIapplianceandmustbeventedaccordinglywithany4in.(102
mm)ventapprovedforusewithCategoryIIIorSpecialBHtypegasvent.
• Follow the vent pipe manufacturer’s instructions when installing the vent pipe.
• Do not common vent this appliance with any other vented appliance(Donotterminatevent
intoachimney.Iftheventmustgothroughthechimney,theventmustrunallthewaythrough
thechimneywithCategoryIIIapprovedorSpecialBHventpipe).
• Whenthehorizontalventrunexceeds5ft.(1.5m),supporttheventrunat3ft.(0.9m)intervals
withoverheadhangers.
• The maximum length of exhaust vent piping must not exceed 50 ft. (15.2 m) (deducting 5 ft.
(1.5m)foreachelbowusedintheventingsystem).Donotusemorethan5elbows.
Diameter
Max. No. of Elbow Max. Vertical and Horizontal (Total) Vent Length
4in.(102mm)
5
50ft.(15.2m)
*For each elbow added, deduct 1.5m (5 ft.) from max. vent length.
No. of Elbows
0
1
2
5
Max. Vertical or Horizontal Vent Length
50ft.(15.2m)
45ft.(13.7m)
40ft.(12.2m)
25ft.(7.6m)
Excludeselbowtermination,raincaps,orthe4in.(102mm)PVCConcentricTermination
-DIPswitch settings for Direct Vent modelsSetDIPswitchesshowninthetablebelowdependingontheventlength.
110U Direct vent (T-KJr2U-IN) 510U Direct vent (T-D2U-IN)
310 Direct vent (T-K4U-IN) (Upper bank of DIPswitches)
O N
1 2 3 4 56 7 8 9 1 0
1 2 3 4 56 7 8
O N
O F F
O F F
No.6:ON
No.7:OFF
O N
No.3:ON
No.4:OFF
1 2 3 4 56 7 8 9 1 0
O F F
O F F
No.3:ON
No.4:ON
14
0 to 30 ft
1 2 3 4 56 7 8
O N
No.6:ON
No.7:ON
Vent length
Page
31 to 50 ft
Installation Manual
Installation
-Venting Illustrations-
For the 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models
Fordetailsoftheoptionalitems,refertotheInstallationmanualforeachOptionalitem.
Vertical Installation Diagram
Horizontal Installation Diagram
RainCap
Wall
RoofFlashing
Roof
Backflow
Preventer*
SidewallVent
Terminator
Backflow
Preventer*
VerticalCondensationDrain**
VerticalCondensationDrain**
Horizontal Installation Diagram
(With direct-venting)
Vertical Installation Diagram
(With direct-venting)
Wall
RainCap
Roof
Roof
Flashing
SidewallVent
Terminator
Backflow
Preventer*
VerticalCondensation
Drain**
Backflow
Preventer*
Firestop
VerticalCondensationDrain**
Seethepicturebelowfordetailedconnection
instructionstoDirect-VentConversionKit.
*BackflowPreventer(Recommendedforfreezingweatherconditions:36°F(2°C)andbelow).
**VerticalCondensationDrainmustbeinstalledinaccordancewithlocalcodes.
Horizontal Installation Diagram With
Direct-Vent Concentric Termination
Installation Diagram of Direct-Vent
Conversion Kit with water heater
Wall
IntakeportofDirect-Vent
ConversionKit
(FordetailsseeP.10)
Direct-vent
Concentric
Termination
Thewaterheater
PlateofDirect-VentConversionKit
15
Page
Installation Manual
Installation
-Vent termination clearancesINSIDECORNERDETAIL
V Ventterminal
X Airsupplyinlet
V
Areawhereisnotpermitted
G
H
A
D
E
V
B
B
B
C
V
F
V
FIXED
ED
CLOS E
BL
A
OPER
V
L
V
ED
ABLE FIXLOSED
C
OPER
V
B
B
V
I
X
M
V
X
K
J
A
Gasmeter/regulator
B
Canada
Directventandother Direct
thanDirectVent
vent
A
Clearanceabovegrade,veranda,porch,deck,or
balcony.
B Clearancetowindowordoorthatmaybeopened
C
U.S.A
Otherthan
DirectVent
1foot
1foot
1foot
3feet
1foot
4feetfrombelowor
sideopening.1foot
fromaboveopening.
Clearancetopermanentlyclosedwindow
*
*
*
Verticalclearancetoventilatedsoffitlocatedabove
theventterminatorwithinahorizontaldistance
D
*
*
*
of2feet(61cm)fromthecenterlineofthe
terminator.
E Clearancetounventilatedsoffit
*
*
*
F Clearancetooutsidecorner
*
*
*
G Clearancetoinsidecorner
*
*
*
Clearancetoeachsideofcenterlineextended
H
3feet
*
*
abovemeter/regulatorassembly
I Clearancetoserviceregulatorventoutlet.
3feet
*
*
Clearancetonon-mechanicalairsupplyinletto
4feetfrombelowor
J buildingorthecombustionairinlettoanyother
3feet
1foot
sideopening.1foot
application
fromaboveopening.
K Clearancetomechanicalairsupplyinlet.
6feet
3feet
3feet
Clearanceabovepavedsidewalkorpaveddriveway
L
7feet
*
7feet
locatedonpublicproperty.
M Clearanceunderveranda,porchdeck,orbalcony.
1foot
*
*
*ForclearancesnotspecifiedinANSIZ223.1/NFPA54orCAN/CSA-B149.1,pleaseuseclearancesinaccordance
withlocalinstallationcodesandtherequirementsofthegassupplier.
16
Page
Installation Manual
Installation
-For sidewall terminations2ft.
1ft.
(610mm)
(305mm)
1ft.
(305mm)
Exhaust
termination
Inside
corner
2ft.
(610mm)
1ft.
(305mm)
1ft.
(305mm)
Combined
intakeand
exhaust
termination
Inside
corner
Exhaust
termination
3ft.
(915mm)
3ft.
(915
mm)
3ft.
(915mm)
For multiple sidewall exhaust terminations (e.g. multiunit systems), an exhaust termination must be at least 1
ft. (305mm) away from another exhaust termination. An
exhaust termination must also be at least 2 ft. (610 mm)
awayfromaninsidecorner(iftheadjacentwallislessthan
2ft.(610mm)oflength,theminimumrequireddistance
awayfromtheinsidecornerwillbeequaltothelengthof
thatadjacentwall).
For multiple-unit, direct-vent sidewall terminations that
combinetheintakeandexhaustintoasinglepenetration,
spaceeachdirect-ventterminationatleast1ft.(305mm)
awayfromeachother,nomattertheorientation.Adirectventterminationmustalsobeatleast2ft.(610mm)away
fromaninsidecorner(iftheadjacentwallislessthan2ft.
(610mm)oflength,theminimumrequireddistanceaway
fromtheinsidecornerwillbeequaltothelengthofthat
adjacentwall).
For direct-vent sidewall
terminationsthatusetwo
separatepenetrationsfor
the intake and exhaust,
distance the intake and
exhaust terminations at
least3ft.(915mm)away
from each other, no
mattertheorientation.
Airsupplyinlet
A
Exhaust
and/or
direct-vent sidewall
terminations should
be at least 2 ft. (610
mm) away from an
opposite surface/
wall.Donotplacethe
termination directly
infrontofanopening
intoabuilding.
2ft.
(610mm)
Exhaust
termination
-For rooftop terminations-
A
2ft.
(610mm)
A
A
A
Airintake
Exhausttermination
Exhaust
termination
A:Inaccordancewithlocalcodes
Air intake
For multiple-unit rooftop terminations (whether for standard or direct-vent installations) space all
exhaustandintaketerminationsinaccordancewithlocalcodes.Anexhaustterminationmustbespaced
fromawallorsurfaceinaccordancewithlocalcodesaswell.Intheabsenceofsuchacode,anexhaust
terminationmustbeahorizontaldistanceofatleast2ft.(610mm)awayfromawallorsurface.
Please follow all local and national codes in regards to proper termination
clearances.Intheabsenceofsuchcodes,thefollowingclearancescanbeusedas
CAUTION guidelines.Localcodessupersedetheseguidelines.
17
Page
Installation Manual
Installation
GAS SUPPLY AND GAS PIPE SIZING
-General-
CAUTION
• Check that the type of gas matches the rating plate first.
• Ensure that any and all gas regulators used are operating properly and
providing gas pressures within the specified range shown below. Excess gas
inlet pressure may cause serious accidents.
• Conversion of this unit from natural gas or vise versa will void all warranty.
Contact your local distributor to get the correct unit for your gas type. The
manufacturer is not liable for any property and/or personal damage resulting
from gas conversions.
• Theminimumandmaximuminletgaspressuresare:
Gas type
Inlet gas pressure
NaturalGas
Min.5.0”W.C.(1.24kPa)–Max.10.5”W.C.(2.61kPa)
• Gas pressure above this specified range for the water heater and/or insufficient gas volume will
adverselyaffectperformance.Thesepressuresaremeasuredwhenthewaterheaterisinfulloperation.
• Inletgaspressuremustnotexceedtheabovemaximumvalues;gaspressureabovethespecifiedrange
willcausedangerousoperatingconditionsanddamagetotheunit.
• Untiltestingofthemaingaslinesupplypressureiscompleted,ensurethegaslinetothewaterheater
isdisconnectedtoavoidanydamagetothewaterheater.
-Gas connections1. Installamanualgasshut-offvalvebetweenthewaterheaterandthegassupplyline.
2. Whenthegasconnectionsarecompleted,itisnecessarytoperformagasleaktest(seebelow)either
byapplyingsoapywatertoallgasfittingsandobservingforbubblesorbyusingagasleakdetection
device.
• Thewaterheateranditsindividualshutoffvalvemustbedisconnectedfromthegassupply
pipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2psi
(3.5kPa).
• Thewaterheatermustbeisolatedfromthegassupplypipingsystembyclosingitsindividual
manualshutoffvalveduringanypressuretestingofthegassupplypipingsystemattest
pressuresequaltoorlessthan1/2psi(3.5kPa).
3. Alwayspurgethegaslineofanydebrisand/orwaterbeforeconnectingtothegasinlet.
NOTICE
Sizethegaspipeappropriatelytosupplythenecessaryvolumeofgasrequired
forthewaterheaterusingANSI233.1/NFPA54intheUSAorCAN/CSAB149.1in
Canadaorlocalcodes.Otherwise,flowcapabilitiesandoutputtemperatureswill
belimited.
18
Page
Installation Manual
Installation
-Natural Gas Supply PipingMaximumdeliveryCapacityofCubicFeetofGasperHourofIPSPipecarryingNaturalGaswith0.60SpecificGravity
BasedonPressureDropof0.5"W.C.
Based on Energy Content of 1,000 BTU/Cubic ft.: The water heater requires 140 Cubic ft./hr for the 110U (T-KJr2U)
models, 190 Cubic ft./hr for the 310U (T-K4U) models, and 199 Cubic ft./hr for the 510U (T-D2U) models.
Unit: Cubic Feet per Hour
Pipe Size
Diameter
3/4"
1"
1 1/4"
1 1/2"
2"
Length
10'
20'
30'
40'
50'
60'
70'
80'
90' 100' 125' 150'
363 249 200 171 152 138 127 118 111 104
93
84
684 470 377 323 286 259 239 222 208 197 174 158
1,404 965 775 663 588 532 490 456 428 404 358 324
2,103 1,445 1,161 993 880 798 734 683 641 605 536 486
4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936
Gas Sizing Example
(Natural Gas)
Water
Heater
199,000BTU/h
5'Length
1-1/4"PipeSize
10'Length
3/4" Pipe Size
B
A
5'Length
1-1/4"PipeSize
Gas Meter
Dryer
35,000BTU/h
10'Length
1"PipeSize
15'Length
1"PipeSize
10'Length
3/4"PipeSize
Furnace
120,000BTU/h
10'Length
1/2"PipeSize
15'Length
1/2"PipeSize
C
Range
65,000BTU/h
BasedonEnergyContentof1,000BTU/Cubicft:
Divideeachappliance'sBTUrequirementby1,000BTU/htogettheappliancesCubicFt.requirement.
Takeintoaccountthedistancetheapplianceisfromthegasmeter,lookintheabovegascharttoproperly
sizetheline.
Forsectionsofthegaslinesupplyinggastomorethanoneappliance(Ex:PointAtoPointB),addupthecubic
ft.requirementsoftheappliancesthatarebeingsuppliedbythatsection,andsizetothefarthestappliance.
For Example: The section from A to B supplies gas to the furnace, range and dryer. Adding up the BTU
requirementsanddividingby1,000yieldsacubicft.requirementof220cubicft.ofgas.Thefarthestappliance
istherange,whichis50ft.awayfromthemeter.Lookingattheabovechart,andunderthecolumnof50ft.,
SectionAtoBneedstobe1"inordertosupply220cubicft.
19
Page
200'
72
135
278
416
801
Installation Manual
Installation
-Measuring inlet gas pressure1. Turnoffallelectricpowertothewaterheaterifserviceistobeperformed.
2. Turnthemanualgasvalvelocatedontheoutsideoftheunitclockwisetothe
offposition.
Thewaterheatercannotperformproperlywithoutsufficientinletgaspressure.Belowareinstructionson
howtochecktheinletgaspressure.THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL.
1. Shutoffthemanualgasvalveonthesupplygasline.
2. Remove the screw for the pressure port located on the
gasinletofthewaterheatershowninthediagramright.
3. Connectthemanometertothepressureport.
4. Re-open the manual gas valve. Check to see that there
arenogasleaks.Opensomeofthefixturesthatusethe
highestflowratetoturnonthewaterheater.
5. Check the inlet gas pressure. When the water heater is
onmaximumandminimumburn,themanometershould
readfrom5.0”to10.5”W.C.(1.24to2.61kPa)forNatural
gas.
Pressureport
WATER CONNECTIONS
• Do not use this water heater if any part has been submersed under water.
Immediatelycallalicensedprofessionaltoinspectthewaterheatertoreplace
anydamagedparts.
• Do not reverse the hot outlet and cold inlet connections to the water heater.
CAUTION
Thiswillnotproperlyactivatethewaterheater.
Allpipes,pipefittings,valvesandothercomponents,includingsolderingmaterials,mustbesuitablefor
potablewatersystems.
1. Amanualshutoffvalvemustbeinstalledonthecoldwaterinlettothewaterheaterbetweenthemain
watersupplylineandthewaterheater.
2. Inaddition,amanualshutoffvalveisalsorecommendedonthehotwateroutletoftheunit.Ifthe
waterheaterisinstalledwithin,orsubjectedto,aclosedloopwatersystem,athermalexpansiontank
mustbeinstalled.
3. Beforeinstallingthewaterheater,flush
thewaterlinetoremovealldebris,and
after installation is complete, purge
theairfromtheline.Failuretodoso
maycausedamagetotheheater.
4. There is a wire mesh filter within
the cold inlet to trap debris from
As Close as
Possible
entering your heater. This will need
tobecleanedperiodicallytomaintain
Gas
optimumflow.(RefertoP.36)
inlet
Hot
Cold
Pressure Relief Valve outlet inlet
20
Page
Installation Manual
Installation
-Pressure relief valveThewaterheaterhasahigh-temperatureshutoffswitchbuiltinasastandardsafetyfeature(calleda
Hi-Limitswitch)thereforea“pressure only”reliefvalveisrequired.
• Thisunitdoesnotcomewithanapprovedpressurereliefvalve.
• Anapprovedpressurereliefvalvemustbeinstalledonthehotwateroutlet.
• ThepressurereliefvalvemustconformtoANSI Z21.22orCAN 1-4.4andinstallationmustfollowlocalcode.
• Thedischargecapacitymustbeatleast140,000BTU/hforthe110U(T-KJr2U)models,190,000BTU/h
forthe310U(T-K4U)models,and199,000BTU/hforthe510U(T-D2U)models.
• Thepressurereliefvalveneedstoberatedforamaximumof150psi(1MPa).
• Thedischargepipingforthepressurereliefvalvemustbedirectedsothatthehotwatercannotsplash
onanyoneoronnearbyequipment.
• Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in.
(150 mm) from the floor. This discharge tube must allow free and complete drainage without any
restrictions.
• Ifthepressurereliefvalveinstalledonthewaterheaterdischargesperiodically,thismaybeduetoa
defectivethermalexpansiontankordefectivepressurereliefvalve.
• Thepressurereliefvalvemustbemanuallyoperatedperiodicallytocheckforcorrectoperation.
• Novalvemustbeplacedbetweenthereliefvalveandthewaterheater.
ELECTRICAL CONNECTIONS
Followtheelectricalcoderequirementsofthelocalauthorityhavingjurisdiction.
In the absence of such requirements, follow the latest edition of the National
Electrical Code ANSI/NFPA 70 in the U.S. or the latest edition of CSA C22.1
WARNING CanadianElectricalCode,Part1,inCanada
CAUTION
Whenservicingorreplacingpartswithinthewaterheater,labelallwirespriorto
disconnectiontofacilitateaneasyanderror-freereconnection.Wiringerrorscan
causeimproperanddangerousoperation.Verifyproperoperationafterservicing.
All indoor models come with a power plug instead of a junction box. The following procedure is for
outdoor models only.
1. Thewaterheatermustbeelectricallygrounded.Donotattachthegroundwiretoeitherthegasorthe
waterpiping.
2. Thewaterheaterrequires120 VAC, 60 Hz electrical power supply that is properly grounded.
• Aproperdisconnect(i.e.on/offswitch,powerplug,etc.)controllingthemainpowertothewater
heatermustbeprovidedforservicereasons.(Mustcomplywithlocalcodes).
• Connectthepowersupplytothewaterheaterexactlyasshowninthewiringdiagram.
3. Agreenscrewisprovidedinthejunctionboxtogroundtheconnection.
4. Canbehardwiredorwiredtoaplug-in.
5. Theuseofasurgeprotectorisrecommendedinordertoprotecttheunitfrompowersurges.
Indoor models only
Outdoor models only
Green screw
Connect
Power supply
120VAC, 60Hz
Ground
Bottomviewofwaterheater
21
Page
Viewofelectrical
connectionsofwaterheater
Installation Manual
Installation
TEMPERATURE REMOTE CONTROLLER
-INCLUDED ACCESSORIESCheckthattheseitemsbelowareincludedwiththeremotecontroller.
Temperature
Remote Controller
Screws
Qty:1
Manual
Qty:2
Qty:1
Remote controller cable
Qty:1
-INSTALLATION-
CAUTION
• This remote controller is NOT waterproof
Donotinstallinhightemperatureenvironments,steamyconditions(suchasa
bathroom),outdoors,indirectsunlight,orwithinthereachofchildren.
Makesuretheremotecontrollerdoesnotcomeintocontactwithwateroroil.
• Donotplacetheremotecontrolwiringclosetootherwiresfromother
products.
• Donotextendtheremotecontrolwiringmorethan400ft.(122m)
<Mounting and Wiring the Remote Controller>
1. Takeoffthe“Back plate”fromtheremotecontrollerwithaflatheadscrewdriver.(Fig. A and B)
2. Attachthe“Back plate”onthewallwiththetwoprovidedscrews.(Fig. B)
Fig. A
Pressandtwistflathead
screwdriveragainstthecutout.
Mainbody
Fig. B
Twist
Attachedthescrews
Backplate
3-1/4Inch
Mainbody
Cutoutthepartitionwithpliers
22
Page
3. Tightenthetwo"Fork terminals"beneaththetwo"Remote controller terminal"screwson
thebackofthemainbody.(Fig. C-1)
4.Cutouttheinletfortheremotecontrollercablefromthebottomofthemainbody.(Fig. C-2)
5. Placethe“Main body”backonthe"Back plate",withthe"Remote controller cable"running
outofthebottominlet.
6. Connectthe "Remote controller cable"totheremotecontrollerterminalonthecomputer
board.Seep.22fordetails.
Fig. C-1
Remotecontroller
terminals
Fig. C-2
Inletfortheremote
controllercable
Twoforkterminals
Cutout
Remotecontrollercable
<How to connect the remote controller to the water heater>
1. Disconnectpowersupplyfrom
thewaterheater.
2. Takeoffthewaterheater’sfront
cover.
3. Locatetheremotecontroller
terminal,picturedtotheright
(locatedaroundthelowerrighthandsideofthecomputer
board).
4. Opentheplasticcoverofthe
remotecontroller,andthen
attachthetwoforkterminalsto
connectorbaseofthebackside
theremotecontrollerwithtwo
screws.Makesuretheterminals
arefirmlyfixed.
110U (T-KJr2U) and 310U (T-K4U) models
9008172005
(TM-RE40)
Connect other end to these terminals
23
Page
Front of remote
5. Pulltheremote’swiresthroughtheholeatthebottomofthewaterheater’scasing.
6. Properlyattachtheremote’swirestotheremotecontrollerterminalonthecomputerboard.
(Nopolarity)
* Do NOT jump or short-circuit the wires or computer will be damaged.
7. ReplaceFrontCoversecurely.
8. Wiresusedfortheremotecontrollerconnectionmustbe:
• Minimum18AWGwire(Nopolarity)
• Maximum400ft.(122m)long
510U (T-D2U) models
9008172005 (TM-RE40)
Connect other end to these terminals
24
Page
Front of remote
Installation Manual
Installation
EASY-LINK SYSTEM
(Available on the 510U (T-D2U) models only)
-GeneralThe510U(T-D2U)modelswaterheaterscanbeconnectedwithotherallowableheaters(seethe
tablebelow)withcommunicationcablestoworkasamultiple-unitmanifoldsystem.
• TheEasy-Linksystemallowsupto4unitstomanifoldtogether.
• Acommunicationcable(graycolor)comeswitheach510U(T-D2U)models.
Youcanmanifoldfrom2to4unitswithouttheneedforamulti-systemcontroller.A4-unitsystem
hasfullautomaticmodulationbetween15,000BTU/hand796,000BTU/h.
Easy-Link connection with other allowable heaters
T-K3
T-K3-Pro
510models(T-D2-IN/T-D2-OS)
510Umodels(T-D2U-IN/T-D2U-OS)
Gas In
Hot Out
Cold In
CAUTION
WARNING
• TheEasy-Linksystemislimitedupto4 units.Ifyouconnectmorethan4units,
only the first 4 units will work as a part of the Easy-Link system. The other
additionalunitswillnotwork.
• Only listed models on the table above can be combine together as an EasyLink System. Different model cannot be combine together to form an EasyLink System.
When the 510U (T-D2U) model is connected to previous models as part an Easylink system with the 9008172005 (TM-RE40), Contact the manufacturer.
-Easy-Link Connection Procedures1. Verifythesettemperaturesofallunitswithinthesystem.Everysinglewaterheatermustbesettothe
samesettemperature.
25
Page
Installation Manual
Installation
2. Selectoneunittobethe“PARENT” unit.
3. “PARENT”unit
LocatethetwobanksofDIPswitchesatthebottomleftofthecomputerboardoftheunitthatyou
selecttobethe“PARENT”unit.ChangeDIPswitchNo.1ontheupper bank of DIPswitches to the ON
position.Seethecomputerboarddiagramasshowninthenextpage.DonotchangeanyDIPswitches
onanyofthe“CHILD”units.
4. Betweenthe “PARENT” andthe“CHILD-1”units
Connectthe “PARENT”connectorofthe“PARENT”unittothe“1”connectorofthe “CHILD-1”unit.
5. Betweenthe“CHILD-1”andthe“CHILD-2”units
Connectthe“2”connectorofthe“CHILD-1”unittothe“1” connectorofthe“CHILD-2”unit.
6. Betweenthe“CHILD-2” andthe “CHILD-3” units
Connectthe“2”connectorofthe“CHILD-2”unittothe“1” connectorofthe“CHILD-3”unit.
7. Makesuretheremotecontrollerdisplaytheunit#.Thenumberingsystemautomaticallyallocatesthe
unit#toeachwaterheaterintheEasy-Linksystem,inaccordancewiththetablebelow.
Type of unit
Parent
Child
Unit # of easy-link
1
2, 3 and 4
(A) 510U (T-D2U) models Computer board
TochangetheDIPswitch
settingsfortheEasy-Link
system,locatethebankof
DIPswitchesatthebottom
leftofthecomputerboard.
Do not adjust the upper
bank of DIPswitches.
Easy-Link /
Multi-unit
connectors
are next to
the computer
board.
UpperbankofDIPswitches
Lower bank of DIPswitches
(B) Basic diagram of connections between the Easy-Link System units.
Remotecontroller
PARENTunit
Connectors
CHILD-1unit
Connectors
CHILD-3unit
Connectors
2 1
2 1
2 1
2 1
1 2 3 456
1 2 3 456
1 2 3 456
Lower bank of
DIPswitches
ON
OFF
ON
OFF
ON
OFF
1 2 3 456
Lower bank of
DIPswitches
PARENT
PARENT
PARENT
PARENT
ON
OFF
Lower bank of
DIPswitches
CHILD-2unit
Connectors
Lower bank of
DIPswitches
Communicaon cable
NOTE: ThedarksquaresindicatethedirectiontheDIPswitchesshouldbesetto.
26
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Installation Manual
Installation
NOTICE
• AremotecontrollerisrequiredfortheEasy-Linksystemforeaseofusageand
maintenance.
• Ifaremotecontrollerisused,thetemperatureonalltheunitsinthesystem
willautomaticallybesettothesametemperaturethatissetontheremote.
(C) Examples of incorrect settings and /or connections
CASE 1: Wrong DIPswitch setting on the "PARENT" unit
• UnlessyouchangeDIPswitchNo.1
ofthe“PARENT”unittothe“ON”
position,thesystemwillnotwork
as an Easy-Link system. The units
willoperateasindividualunits.
PARENTunit
Connectors
CHILD-1unit
Connectors
2 1
2 1
PARENT
PARENT
1 2 3 4 5 6
1 2 3 4 5 6
Lower bank of
DIPswitches
ON
OFF
ON
OFF
WrongSetting
Lower bank of
DIPswitches
Communicaon cable
CASE 2: Wrong connections between the "PARENT" unit and the
"CHILD-1" unit
• If you connect the “1" (or "2") connector of the “PARENT” unit to the “PARENT" (or "1")
connectorofthe“CHILD-1” unit,thesystemwillnotworkasanEasy-linksystem.Theunitswill
operateasindividualunits.
PARENTunit
Connectors
CHILD-1unit
Connectors
2 1
2 1
PARENT
PARENT
1 2 3 4 5 6
1 2 3 4 5 6
Lower bank of
DIPswitches
ON
OFF
ON
OFF
1 2 3 4 5 6
Communicaon cable
Wrong
Connections
2 1
ON
OFF
1 2 3 4 5 6
OR
Lower bank of
DIPswitches
Connectors
2 1
PARENT
PARENT
ON
OFF
Lower bank of
DIPswitches
CHILD-1unit
PARENTunit
Connectors
Lower bank of
DIPswitches
Communicaon cable
Wrong
Connections
27
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Installation Manual
Installation
CASE 3: Wrong connections between the "CHILD-1" unit and the "CHLD-2" unit
• If you connect the “PARENT” connector of the “CHILD-1” unit to the “1” connector of the
“CHILD-2”unit,the “CHILD-2”unitwilloperateasanindividualunit,andwillnotbepartofthe
Easy-Linksystem.
PARENTunit
Connectors
CHILD-1unit
Connectors
2 1
2 1
2 1
PARENT
PARENT
PARENT
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
Lower bank of
DIPswitches
ON
OFF
ON
OFF
ON
OFF
Lower bank of
DIPswitches
CHILD-2unit
Connectors
Lower bank of
DIPswitches
Communicaon cable
Wrong
Connections
Connecting two “PARENT” connectors together from two separate units may
damage the computer board. The communication cable has a female end and
amaleendsoit’simpossibletohaveaPARENT-to-PARENTconnectionwiththe
WARNING communicationcable.Donotspliceormodifyconnectors.
CASE 4: Remote controller connected to incorrect unit
• Remote controller has to be connected to the “PARENT” unit. If the remote controller is
connectedtoa“CHILD”unit,itwillonlycontrolthatparticularindividual“CHILD”unitandwill
notcontroltheEasy-Linksystemasawhole.
PARENTunit
Connectors
CHILD-1 unit
Connectors
Remotecontroller
2 1
2 1
PARENT
PARENT
ON
OFF
ON
OFF
1 23 456
1 23 456
Lower bank of
DIPswitches
Lower bank of
DIPswitches
Communicaon cable
28
Page
WrongConnections
MULTI-UNIT SYSTEM
Multiple510U(T-D2U)modelscanbecombinedforaMulti-Unitsystem,alongwiththemulti
unitcontroller(Parts9007675005(TM-MC02))andremotecontroller(9008172005(TM-RE40)).
Each set of multi-unit controller and remote controller can control from 2 units to 20 units
for commercial or residential applications. For a 20-unit system, the computer can modulate
betweentheusagesof15,000BTU/hto4.0MillionBTU/h
510U
(T-D2U)
9007675005
(TM-MC02)
Hot Out
Cold IN
Anindividualcut-offswitchisrecommendedforeachunitinamulti-unitsystemforthepurpose
ofmaintenance.
Unit3
C o n n e c to rs
2
Multi-Unit System Connection Diagram
Multi-unitcontrollerandtemperatureremotecontrollerwiring:
Remotecontroller
Unit1
Unit2
C o n n e c to rs
C o n n e c to rs
9007675005
(TM-MC02)
2
2
1
1
1
P A R E N T
P A R E N T
P A R E N T
O N
O F F
O N
O F F
O N
O F F
1
1
1
L o w e r b a n k o f
D IP s w it c h e s
2 3 4 56
L o w e r b a n k o f
D IP s w it c h e s
2 3 4 56
Terminalsfor
waterheaters
Remotecontroller
terminals
2 3 4 56
Remotecontrollercable
L o w e r b a n k o f
D IP s w it c h e s
Communicationcable
• Thedarksquaresshouldnotneetadjustment
• Thisistheconnectiondiagrambetween510(T-D2U)andmulti-unitcontrollerfor
2to20waterheaters.Asshownisasamplefor3waterheaters.
• TheMulti-unitcontrollerautomaticallyallocatestheunit#(1-20)toeachwater
heaterthatispartoftheMulti-unitsystem.
• InaMulti-Unitsystem,connectthe“[1]”connectorandthe“[2]”connectorwith
thecommunicationcable.(Refettop.26).Orthecablesuse18gagewireandcan
beupto250ft.long.
Fordetailedinstructionstothemult-unitcontroller,refertothe
instructionsthatarepackagedwiththemulti-unitcontroller.
29
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Installation Manual
Installation
APPLICATIONS
-Space-Heating Applications• In order to purge air in water pipes within a closed-loop system, an air vent
and air separator should be installed in the system. Required circulation
flow rates are labeled next to each application diagram. These flow rate
requirements must be followed.
WARNING
• Toxicchemicalsusedinboilertreatmentssuchasalcohol,glycerolandglycol
groupsmustnotbeintroducedintothesystemifthesystemincorporatesan
open-looppotablewatersystem.
• Thewaterheatercanbeusedtosupplypotablewaterandspaceheatingand
shall not be connected to any heating system or component(s) previously
usedwithnon-potablewaterwhereanychemicalswereaddedtothewater
heatingappliances.
• When the system requires water for space heating at temperatures higher
thanrequiredforotheruses,ameanssuchasamixingvalveshallbeinstalled
to temper the water for those other uses in order to reduce scald hazard
potential.
• Water temperature over 125 °F (52 °C) can cause severe burns instantly or
deathfromscalding.
• ChemicalssuchasdilutedGlycolcanbeusedforradiantfloor,Hydro/fancoil
air or Baseboard heating only. The diluted solution of glycol must contain
between25and55%ofGlycol.Beawarethatinclosed-loopglycolsystems,
low pressure in the heat exchanger can cause low-temperature boiling,
resultinginexcessivenoiseanddamagetothewaterheater.Consultwiththe
glycolmakerforspecificationspriortouse.
-Recirculation*The recirculation pump is to be controlled by:
-Dual-set aquastat (recommended w/timer)
*The recirculation pump is to provide no less than 2 GPM (7.5 L/min) and no more than 4 GPM (15 L/min) through
each activated unit in the system.
Hotwateroutlettofixtures
Pressure
reliefvalve
Coldwaterinlet
Gasinlet
Hotwateroutlet
Airvent
Unions
Ballvalves
Gassupply
Recirculation
pump
S
Checkvalve
Air
separator
Expansiontank
Checkvalve
Coldwaterinlet
Thisisaconceptdrawingonly.
Y-Strainer
30
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Installation Manual
Installation
-Dual-purpose hot water heating(Domestic and Space Heating):
Diagrammaticlayoutofradiantheatinganddomesticwaterheaterpermass.code.
Allwaterpipingshouldbeinsulated
inaccordancewith780CMR
(Massachusettsenergycode)
Shut-off
valve
Pressure
gauge
Atmospheric
vacuum
breaker
Thermostaticmixingvalve
Heating Coil
(usedwithair-handler)
Checkvalves
Hotwater
supplyand
returnto
heatingcoil
Drain
plug
Gasinlet
Temperedwaterto
plumbingfixtures.Must
meettemperature
requirementsof248CMR
4"gasexhaustvent
(Dischargemust
complywithlocaland
statecodes).Cannot
becommonvented
withotherappliances
Checkvalvewillhave
1/8"holedrillingin
clapperoptional
Coldwaterinlet
Pipingloop
betweenwater
heaterandfan
coilshallbein
compliancewith
248CMR
Coldwatersupply
Hotwateroutlet
Automatictemperingdevice
mustbeinstalledbelow
thetopofthewaterheater
aspermanufacturer’s
recommendations
Applycorrectthermal
expansiontank-size
perapplication
Water
filter
Shut-offvalves
Shut-offvalves
Systeminstalledwithreverse
actingaquastattoshutofffan.
Suggestedbutnotrequiredby
248CMR
50’-0”maximumdistancefrom
waterheatertofancoilandblack.
(Develoedlength)Notincluding
coilinheatingunit
Checkvalve
Unions
NSF-61product
approvedpump
T-handlegasshut-offvalve
Electronicallycontrolled
pumptimer.Activates
every6hoursfor
60seconds.Wireto
productapprovedpump
120VAC
switchor
outlet
AnapprovedTemperatureandPressure
ReliedValve,TietoLocationapprovedBy
LocalCodesandMustMeetBTURatingof
waterheaterModelUsed
The recirculation pump is to provide no less than 2 GPM (7.5 L/min) and no more than 4 GPM (15 L/min)
through each activated unit in the system.
NOTICE
• Priority Control Devices such as a flow switch, an Aquastat or other
electroniccontrollercanbeusedtoprioritizethedomesticwatersystemover
theheatingsystem.
• Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecent
editionoftheNationalStandardCode,ANSIZ21.10.3.
• This illustration is a concept design only. The reference to the 1/8th hole in
check is only for the State of Massachusetts. There are a wide variety of
variationstotheapplicationofcontrolsandequipmentpresented.Designers
must add all necessary safety and auxiliary equipment to conform to code
requirementsanddesignpractice.Formoredetails,contactthemanufacturer.
31
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Installation Manual
Installation
INITIAL OPERATION
FOR YOUR SAFETY, READ BEFORE OPERATING
• Check the GAS and WATER CONNECTIONS forleaksbeforefiringunitforthefirsttime.
• Openthemaingassupplyvalvetotheunitusingonlyyourhandtoavoidanyspark.Never
usetools.Iftheknobwillnotturnbyhand,donottrytoforceit;callaqualifiedservice
technician.Forcedrepairmayresultinafireorexplosionduetogasleaks.
• Besuretocheckforthepresenceof leakinggas toward the bottom of the unit because
somegasesareheavierthanairandmaysettletowardsthefloor.
• Check the GAS PRESSURE.Refertop.20.
• Do not try to light the burner manually. It is equipped with an electronic ignition device
whichautomaticallylightstheburner.
• Check for PROPER VENTING and COMBUSTIBLE AIR tothewaterheater.
• Purge the GAS and WATER LINEStoremoveanyairpockets.
• Donotusethiswaterheaterifanyparthasbeensubmersedunderwater.Immediatelycall
aqualifiedservicetechniciantoinspectthewaterheaterandtoreplaceanydamagedparts.
IF YOU SMELL GAS:
WARNING
• Donottrytostartthewaterheater.
• Donottouchanyelectricswitches;donotuseanyphoneinyourbuilding.
• Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegas
supplier’sinstructions.
• Ifyoucannotreachyourgassupplier,callthefiredepartment.
Operation
Oncetheabovecheckshavebeencompleted,pleaseclean
1. filterofanydebris.Refertop.40forinstructions.
Fully open the manual water control valve on the water
2.
3.
supplyline.
Openahotwatertaptoverifythatwaterisflowingtothat
tap.Thenclosethehotwatertap.
Fullyopenthemanualgascontrolvalveinstalled.
4.
Turn on the 120 VAC, 60 Hz power supply to the water
5.
heater.
Nowyouarereadytoenjoyhoursofendlesshotwater.
6.
32
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Owner's Guide
CONGRATULATIONS
Congratulationsandthankyouforchoosingourtanklesswaterheater.
Beforeuse,werecommendthatyoureadthroughthissafetymanual
carefully.Pleaserefertothebackofthemanualfordetailsaboutthe
warranty.Keepthismanualforfuturereference.
If you lose the manual, contact the manufacturer or your local
distributor. When you call, please tell us the product name and the
dateofyourunitwrittenontheratingplateofthewaterheater.
33
Page
Owner's Guide
Operating Safety
OPERATING SAFETY
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing
propertydamage,personalinjuryorlossoflife.
A. Thiswaterheaterdoesnothaveapilot.Itisequippedwithanignitiondevicethatautomatically
lightstheburner.Donottrytolighttheburnerbyhand.
B. BEFOREOPERATINGsmellallaroundthewaterheaterareaforevidenceofleakinggas.Besureto
smellnexttothefloorbecausesomegasisheavierthanairandwillsettleonthefloor.
WHATTODOIFYOUSMELLGAS.
• Donottrytolightanyappliance.
• Donottouchanyelectricswitch;donotuseanyphoneinyourbuilding.
• Immediatelycallyourgassupplierfromaneighbor'sphone.Followthegassupplier's
instructions.
• Ifyoucannotreachyourgassupplier,callthefiredepartment.
C. Useonlyyourhandtoturnthegasvalveknob.Neverusetools.Iftheknobwillnotturnbyhand,
don'ttrytorepairit.Callaqualifiedservicetechnician.Forcedorattemptedrepairmayresultina
fireofexplosion.
D. Donotusethiswaterheaterifanyparthasbeenunderwater.Immediatelycallaqualifiedservice
techniciantoinspectthewaterheaterandtoreplaceanydamagedparts.
OPERATING INSTRUCTIONS
1. STOP!ReadthesafetyinformationaboveorintheOwnersManual.
2. Turnoffallelectricpowertothewaterheater.
3. Donotattempttolighttheburnerbyhand.
4. Turnthemanualgasvalvelocatedontheoutsideoftheunitclockwisetotheoffposition.
5. Waitfive(5)minutestoclearoutanygas.Ifyouthensmellgas.STOP!Follow"B"inthesafety
informationaboveonthislabel.Ifyoudon'tsmellgas,gotonextstep.
6. TurnthemanualgasvalvelocatedontheoutsideoftheunitcounterclockwisetotheONposition.
7. Turnonallelectricalpowertothewaterheater.
8. Ifthewaterheaterwillnotoperate,followtheinstructions“toTurnOffGastowaterheater"and
Callyourservicetechnicianorgassupplier.
TO TURN OFF GAS TO APPLIANCE
1. Turnoffallelectricpowertothewaterheaterifserviceistobeperformed.
2. Turnthemanualgasvalvelocatedontheoutsideoftheunitclockwisetotheoffposition.
34
Page
Owner's Guide
Operating Safety
DANGER
Vapors from flammable liquids will explode and catch fire causing death or severe burns.
Donotuseorstoreflammableproductssuchasgasoline,solventsoradhesivesinthesameroom
orareanearthewaterheater.
Keepflammableproducts:
1.Farawayfromheater
2.Inapprovedcontainers
3.Tightlyclosed
4.Outofchildren'sreach
Vapors:
1.Cannotbeseen
2.Vaporsareheavierthanair
3.Goalongwayonthefloor
4.Canbecarriedfromotherrooms
tothemainburnerbyaircurrents
WARNING: Do not install water heater where flammable products will be stored.
Read and follow water heater warnings and instructions. If owner’s manual is missing,
contact the manufacturer.
WARNING
Theoutlethotwatertemperatureofthewaterheaterisfactorysetat120°F(49°C).
Usethisheateratyourownrisk.Thesetoutletwatertemperaturecancausesevereburnsinstantlyor
deathfromscalding.Testthewaterbeforebathingorshowering.
Donotleavechildrenoraninfirmpersoninthebathunsupervised.
DANGER
HotWaterHeatertemperatureover125°F(52°C)cancausesevereburns
instantlyordeathfromscalding.Children,disabledandelderlyareatthe
highest risk of being scalded. Feel water temperature before bathing or
showering.Temperaturelimitingvalvesareavailable.Askaprofessional.
WARNING: CaliforniaProposition65listschemicalsubstancesknowntothestatetocausecancer,birth
defects,death,seriousillnessorotherreproductiveharm.Thisproductmaycontainsuchsubstances,be
theiroriginfromfuelcombustion(gas,oil)orcomponentsoftheproductitself.
35
Page
Owner's Guide
Normal Operation
NORMAL OPERATION
REMOTE CONTROLLER
Theillustrationbelowshowsanexampleofthedisplay.Theexactdisplaymaydifferfromexamples.
Display for Temperature
"INFO" Button
WhenthestandbyLEDisON,the
hotwatertemperaturewillbe
displayed.
Eachtimethebuttonispressed,
theoperationmodeisselected
inthesequenceofthefollowing.
Inletwater
temperature
Outletwater
temperature
Water
flow
"COLD" Button
"HOT" Button
Pressthe"HOT"buttonorthe
"COLD"buttontosetthehot
watertemperature.
IN USE LED (Green)
Thelamplightsduringcombustion.
"ON/OFF" Button
STAND BY LED (Orange)
Press this button to
startorstopoperation.
TheindicatorisONtoshowthat
powerisON.
GENERAL
CAUTION
Temperatureabove125°F(52°C)cancausesevereburnsordeathfromscalding.
Children,disabledandtheelderlyareathighriskofbeinginjured.
1.Openahotwatertap. 2. Mixcoldwaterwiththehottoget 3.Closethehotwatertap.
thecorrecttemperaturewater.
NOTICE
• Flowratetoactivatethewaterheater:0.5gallonperminuteatthedefaultset
temperature(2.0L/min).
• Flowratetokeepthewaterheaterrunning:0.4gallonperminute(1.5L/min).
Theremotecontrollerhasanenergysavingmode.Fiveminutesafterthewater
heaterstopsoperating,thebacklightoftheremotecontrollerturnsoff.
Thebacklightoftheremotewillturnbackononcethewaterheaterbeginsfiring
again.
36
Page
Owner's Guide
Normal Operation
TEMPERATURE SETTINGS
-Set temperatureOperation
Screen
1.
Turnonthe120VACpowersupplytotheunit(thewater
heaterorthemulti-unitcontroller).
2.
Pressthe"ON/OFF"buttonontheremoteinordertoturn
theremotecontrolleron.
3.
4.
WhenON,theSTANDBYLEDislit.
It shows the set temperature on its display as shown the
picturetotheright.(EX.:120°F)
(EX.:120°F)
Press the "HOT" button or the "COLD" button to set the
temperaturesettingoftheunit.
5.
(Increasing temperature, example 140 °F to 145 °F)
Press the "HOT" button or the "COLD" button to set 140
°F. Simultaneously press and hold the "HOT" and "INFO"
buttons for at least 3 seconds. It shows the 145 °F on its
display.Thedisplaywillbeblinkingfor5secondsandset.
TEMPERATURE TABLE OF REMOTE CONTROLLER
a) For 110U (T-KJr2U) and 310U (T-K4U) models
°F
100 105 110 115 120* 125 130 135 140
°C
38
40
43
45
50*
52
55
57
60
b) For 510U (T-D2U) models
°F
100 105 110 115 120* 125 130 135 140 145 150 155 160 165 175 185
°C
38
40
43
45
50*
52
55
57
60
63
65
68
70
75
80
85
*Factorysetting(Default):120°F
NOTICE
Thiswaterheaterisanon-demand,tanklesswaterheaterdesignedtoefficiently
supplyendlesshotwaterwithoutreferencetotemperaturesettings.
DO NOT set to 185 °F (85 °C) if you use your water heater in a recirculation
system. This will cause damage to the heater and void the warranty.
WARNING (This temperature setting is only available on the 510U (T-D2U) models).
37
Page
Owner's Guide
Normal Operation
ADDITIONAL FEATURES
-Information modeYoucangetsomeinformationaboutthewaterheaterconditionbypressingthe"INFO"button.Formore
informationfollowtheproceduresbelow:
Operation
Screen
1.
Fistofall,inletwatertemperaturewillbedisplayedon
theremotecontrollerbypressingthe"INFO" button.
Inletwatertemperature
2.
Outlet water temperature will be displayed on the
remotecontrollerbypressingthe"INFO" button.
Outletwatertemperature
3.
And then, water flow will be displayed on the remote
controllerbypressingthe"INFO" button.
Waterflow
4.
Pressthe"INFO"buttontofinishinformationmode.
-Unit conversion mode-
Theremotecontrollerhasafunctionthatcanchangeunitsoftemperatureandflowratefrom"°F" to "°C"
andviceversa,pleasefollowtheproceduresbelow:(Thesameprocedureisperformedwhenchanging
into"°C" from °F." )
Operation
1.
2.
3.
4.
5.
Screen
Press the "ON/OFF" button on the remote in order to
turntheremotecontrolleron.
WhenON,theSTANDBYLEDislit.
Theprevioussettemperaturewilldisplayonthescreen.
(EX.:100°F)
Pressthe"INFO"buttonsforatleast3seconds.
The set temperature should now be displayed in the
alternateunitofmeasurement.
38
Page
Owner's Guide
Normal Operation
TEMPERATURE SETTINGS ON THE PCB
(WITHOUT REMOTE CONTROLLER)
Thereare2presettemperatures(120°F(49°C)and140°F(60°C))thatyoucanselectfrombychanging
theDIPswitchsettingsonthecomputerboardwithouttheremotecontroller.Seethetablebelow.
Whentheremotecontrollerisnormaloperation,thesettemperatureoftheremotecontrollerisgiven
priorityoverthesettemperatureoftheDIPswitchsettings.
• Thetemperaturehasbeenpresetatthefactoryto120°F(49°C).
110U (T-KJr2U) and 310U (T-K4U) models
120°F(49°C)
140°F(60°C)
DEFAULT
1 2 3 4 56 7 8 9 1 0
O N
O F F
Computer board
1 2 3 4 56 7 8 9 1 0
O N
O F F
No.9:OFF
No.9:ON
DIPswitches
510U (T-D2U) models
(Lower bank of DIPswitches)
120°F(49°C)
DEFAULT
140°F(60°C)
O N
O N
1 2 3 4 5 6
Computer board
1 2 3 4 56
Upperbankof
DIPswitches
No.5:ON
Lower bank of
DIPswitches
O F F
O F F
No.5:OFF
NOTE: Onlychangetheswitcheswithdarksquares. Thedarksquares
indicatethedirectiontheDIPswitchesshouldbesetto.
WARNING
• DONOTadjusttheupperbankofDIPswitches.Forthe510U(T-D2U)models.
• TurnoffthepowersupplytothewaterheaterbeforechangingtheDIPswitch
settings.
39
Page
Owner's Guide
Normal Operation
FLOW
Household Flow Rates
• The flow rate through the water heater is limited
toamaximumof6.6GPM(25L/min)forthe110U
Flow rate
Appliance/Use
(T-KJr2U)models,8.0GPM(30L/min)forthe310U
GPM (US)
L/min
(T-K4U)models,and10.0GPM(38L/min)forthe
LavatoryFaucet
1.0
3.8
510U(T-D2U)models.
BathTub
4.0–10.0 15.2-37.8
• The temperature setting, along with the supply
Shower
2.0
7.5
temperature of the water will determine the flow
rateoutputoftheunit.
KitchenSink
1.5
5.6
• Please refer to the temperature vs. gallons per
Dishwasher
1.5
5.6
minutechartsonp.54todeterminethelikelyflow
Washingmachine
4.0
15.2
ratesbasedonyourlocalgroundwatertemperature TakenfromUPC2006
andyourdesiredoutletwatertemperature.
• BasedontheUnitedStatesDepartmentofEnergymethodoftestingwaterheateroutput,thewater
heaterisratedforgallonsperhour(GPH)(litresper
Unit:GPM(L/min)
hour(L/hr))orgallonsperminute(GPM)(litresper
Model
Flow rate
minute(L/min))forNaturalGas,whenraisingthe
watertemperatureby77F°(43C°)(from58°Fto
Indoor
3.0(11.4)
110U(T-KJr2U)
135°F(14°Cto57°C)).Seethefollowingchart.
Outdoor
• Refer to the table to the top right for typical
Indoor
310U(T-K4U)
4.1(15.5)
householdplumbingfixtureflowratestodetermine
Outdoor
what the water heater can do in a household
Indoor
4.2(15.9)
application.
510U(T-D2U)
Outdoor 4.3(16.3)
FREEZE PROTECTION SYSTEM
• Thisunitcomesequippedwithheatingblockstoprotectitagainstdamagesassociatedwithfreezing.
• Forthisfreezeprotectionsystemtooperatetherehastobeelectricalpowertotheunit.Damagetothe
heatexchangercausedbyfreezingtemperaturesduetopowerlossisnotcoveredunderthewarranty.
Incaseswherepowerlossescanoccur,considertheuseofabackuppowersupply.
• The freeze protection system will activate when the surrounding and/or outside temperatures drop
below36.5°F(2.5°C).
• Forthe110UIndoor(T-KJr2U-IN),310UIndoor(T-K4U-IN)and510UIndoor(T-D2U-IN)models:
• Inanyareassubjecttofreezingtemperatures,themanufacturerhighlyrecommendsanindoor
installationwithanindoormodel.Insuchaninstallation,freezingissuescanonlyoccurifcold
airentersthroughtheventingintotheheatexchanger,whetherbynegativepressureswithin
theinstallationlocationorbystrongoutsidewinds.
• Themanufactureralsohighlyrecommendstheuseofabackflowventdampertominimize
theamountofcoldairenteringthroughtheexhaustventingwhenthewaterheaterisoff.
• Itistheinstaller’sresponsibilitytobeawareoffreezingissuesandtakeallpreventativemeasures.The
manufacturerwillnotberesponsibleforanydamagetotheheatexchangerasaresultoffreezing.
• Ifyouwillnotbeusingyourheaterforalongperiodoftime:
1.Completelydraintheunitofwater.Refertop.41
2.Disconnectpowertoyourheater.
Thiswillkeepyourunitfromfreezingandbeingdamaged.
CAUTION
Onlypipeswithinthewaterheaterareprotectedbythefreezeprotectionsystem.
Any water pipes (hot or cold) located outside the unit will not be protected.
Properlyprotectandinsulatethesepipesfromfreezing.
40
Page
Owner's Guide
Normal Operation
MAINTENENCE AND SERVICE
WARNINRG
Turnofftheelectricalpowersupplyandclosethemanualgasshutoffvalve
andthemanualwatercontrolvalvebeforeservicing.
•
•
•
•
•
Cleanthecold-waterinletfilter.(Refertodiagrambelow.)
Besurethatallopeningsforcombustionandventilationairarenotblocked.
Theventingsystemshouldbecheckedannuallyforanyleaks,corrosion,blockagesordamage.
Theburnershouldbecheckedannuallyfordust,lint,greaseordirt.
Keep the area around the water heater clear. Remove any combustible materials, gasoline or any
flammablevaporsandliquids.
• Inaccordancewithalllocalcodesandcommonsafetypractices,waterdischargedfromthepressure
reliefvalvecancausesevereburnsinstantlyfromscalding.DONOTtouchthepressurereliefvalve.
• Ifthereliefvalvedischargesperiodically,itmaybeduetothermalexpansioninaclosedwatersupply
system.Contactthewatersupplierorlocalplumbinginspectoronhowtocorrectthissituation.
• Visualcheckofburnerflames(seebelow)throughtheburnerwindowintheburnerassemblylocated
atthemiddleofthewaterheater.
Blueflame
Blueflame
Satisfactory
Burner
Flame
blowingup
Satisfactory
Burner
Unsatisfactory
The manufacturer recommends having the unit checked once a year or as necessary by a licensed
technician.Ifrepairsareneeded,anyrepairsshouldbedonebyalicensedtechnician.
UNIT DRAINING and FILTER CLEANING
Drainplug
1. Closethemanualgasshutoffvalve.
withFilter
2. Turnoffpowertotheunitandwaitacoupleofseconds. (Large)
Turnonagain.
3. Wait30seconds,andthenturnoffpowertotheunit,
yetagain.
4. Closethewatershutoffvalve.
5. Open all hot water taps in the house. When the
residualwaterflowhasceased,closeallhotwatertaps.
6. Haveabucketorpantocatchthewaterfromtheunit’s
drain plugs. Unscrew the two drain plugs (Large and
small)todrainallthewateroutoftheunit.
7. Waitafewminutestoensureallwaterhascompletely
drainedfromunit.
8. Clean the filter: Check the water filter located within
the cold inlet. With a tiny brush, clean the water
filter of any debris which may have accumulated and
reinsertthefilterbackintothecoldwaterinlet.
9. Securelyscrewthedrainplugsbackintoplace.
Hand- tighten only.
41
Page
Gas
valve
Drainplug
(Small)
Watervalve
TROUBLESHOOTING
GENERAL
TEMPERATURE and AMOUNT OF HOT WATER
PROBLEM
SOLUTIONS
Ittakeslongtimeto • The time it takes to deliver hot water from the water heater to your
gethotwateratthe
fixturesdependsonthelengthofpipingbetweenthetwo.Thelongerthe
fixtures.
distanceorthebiggerthepipes,thelongeritwilltaketogethotwater.
• Ifyouwouldliketoreceivehotwatertoyourfixturesquicker,youmay
wanttoconsiderahotwaterrecirculationsystem.(p.29)
Thewaterisnothot • Comparetheflowandtemperature.Seethechartsonp.54.
enough.
• Checkcrossplumbingbetweencoldwaterlinesandhotwaterlines.
• Isthegassupplyvalvefullyopen?(p.32)
• Isthegaslinesizedproperly?(p.19)
• Isthegassupplypressureenough?(p.20)
• Isthesettemperaturesettoolow?(p.36-37)
Thewateristoohot. • Isthesettemperaturesettoohigh?(p.36-37)
Thehotwaterisnot • Makesuretheunithas120VAC,60Hzpowersupply.
availablewhena
• Ifyouareusingtheremotecontroller,isthepowerbuttonturnedon?
fixtureisopened.
• Isthegassupplyvalvefullyopen?(p.32)
• Isthewatersupplyvalvefullyopen?(p.32)
• Isthefilteroncoldwaterinletclean?(p.41)
• Isthehotwaterfixturesufficientlyopentodrawatleast0.5GPM
(1.9L/min)throughthewaterheater?(p.36)
• Istheunitfrozen?(p.40)
Thehotwaterturns • Istheflowrateenoughtokeepthewaterheaterrunning?(p.37)
coldandstayscold. • Ifthereisarecirculationsysteminstalled,doestherecirculationlinehave
enoughcheckvalves?(p.29)
• Isthegassupplyvalvefullyopen?(p.32)
• Isthefilteroncoldwaterinletclean?(p.41)
• Arethefixturescleanofdebrisandobstructions?
• Checkiftheflowrateistoolow.(p.36-37)
Fluctuationinhot
• Isthefilteroncoldwaterinletclean?(p.41)
watertemperature. • Isthegaslinesizedproperly?(p.19)
• Isthesupplygaspressuresufficient?(p.20)
• Checkforcrossconnectionbetweencoldwaterlinesandhotwaterlines.
42
Page
Owner's Guide
Normal Operation
EASY-LINK SYSTEM
510U (T-D2U) models only
Remote controller
WATER HEATER
PROBLEM
SOLUTIONS
Unitdoesnotignite
whenwatergoes
throughtheunit.
•
•
•
•
•
•
Istheflowrateover0.5GPM(1.9L/min)?(p.37)
Checkforthefilteroncoldwaterinlet.(p.41)
Checkforreverseconnectionandcrossconnection.
Ifyouusetheremotecontroller,isthepowerbuttonturnedon?
Checkiftheinlettemperatureistoohigh.
Thefanmotoris
Thisisnormal.Afteroperationhasstopped,thefanmotorkeeps
stillspinningafter
runningfrom15to70secondsinordertore-ignitequickly,aswell
operationhasstopped.
aspurgealltheexhaustgasoutoftheflue.
Unitsoundsabnormal • Contactthemanufacturerat1-888-479-8324.
whileinoperation
Remotecontrollerdoes • Makesuretheunitissuppliedwithpower.
notdisplayanything • Makesuretheconnectiontotheunitiscorrect.(p.22)
whenthepower
Whentheremote
buttonisturnedon.
-9008172005(TM-RE40)controllerturned
IfthestandbyLEDlightsup,the
ON,standbyLED
remotecontrollerhasbeen
islit.
turnedON.Whentheunithasnot
operatedforfiveminutesormore,
thedisplayturnsofftoconserve
energy.
AnERRORcodeis
displayed.
• Pleaseseep.44-46.
Howaretheunit
numbersassigned?
• ForanEasy-Linksystem,theParentunitisalwayslabeled#1andall
othersubsequentChildunitsarenumberedrandomly.
• TocheckwhichnumbersareassignedtowhichChildunits,pushthe
buttononthecomputerboardofanyChildunitasshownbelow.
Theunitnumberwillbedisplayedontheremotecontroller.(Refer
top.25-28)
Buttontocheckunitnumbers
43
Page
Owner's Guide
Troubleshooting
ERROR CODES
-General• Theunitsareselfdiagnosticforsafetyandconveniencewhentroubleshooting.
• If there is a problem with the installation or the unit, the error code will display on the remote
controller.
• Consultwiththetableonthefollowingpageforthecauseofeacherrorcode.
110U (T-KJr2U) and 310U (T-K4U) models
Error code on the remote
controller 9008172005 (TM-RE40)
510U (T-D2U) models
GreenLED
GreenLED
Error code on the computer board
-Single unit InstallationsExample: If your unit has the “321” error code (which signifies an inlet thermistor failure)
• Remote controller 9008172005 (TM-RE40):“321”willdisplayonthescreeninitsentirety.
• Water heater:ThegreenLEDonthecomputerboardwillbeblinkingtwotimes.
Errorcode
-Easy-Link System(For the 510U (T-D2U) models only)
ErrorcodeswilldisplaydifferentlywithunitsinstalledwithinanEasy-LinkSystem,notonlytoshowwhat
theerrorcodeis,buttoalsoindicatewhichunitwithinthesystemhastheerrorcode.Belowisasample
ofhowthesameerrorcodeisdisplayedinanEasy-LinkSystem.
Example: If Unit #2 has the “321” error code (inlet thermistor failure)
• Remote controller 9008172005 (TM-RE40): “321”and"2"willintermittentlyflashonthedisplay.And
itshowsthatUnit#2hastheerror.
• Parent unit: Theseunitswillnotdisplayanything,
astheerrorcodedoesnotpertain
tothem.
• Unit #2:ThegreenLEDonthecomputerboard
willbeblinkingtwotimes,justlikeinthe
singleunitexample.
• Unit #3 and #4: Theseunitswillnotdisplay
anything,astheerrorcodedoes
notpertaintothem.
Errorcode
Unit#1
PARENT
Unit#2
CHILD
9008172005 (TM-RE40)
44
Page
Unit#
Unit#3
CHILD
Unit#4
CHILD
Owner's Guide
Troubleshooting
-Fault Analysis of Error CodesIf the error code is displayed on the computer board of the water heater or remote controller, please
checkthefollowing.Afterchecking,consult with the manufacturer.
Remote
031
101
111
121
311
321
331
Green
LED
Malfunction
description
Diagnosis
OneTime
IncorrectDIPswitch • ChecktheDIPswitchsettingsonthePCB.(Part#701)
setting
FiveTimes Warningforthe
• Checkthegastypeofthewaterheater.
“991”errorcode • Checkifthereisanyblockageintheintakeairand/
orexhaust.
• If the water heater is installed as a direct-vent
system, check whether there is enough distance
between the intake air terminal and the exhaust
terminal.
• Check the altitude/elevation of area of where the
waterheaterinstalled.
• Checkifthereisgreaseand/ordirtintheburner(Part
#101)andthefanmotor(Part#103),especiallyifthe
water heater has been installed in a contaminated
area.
ThreeTimes Ignitionfailure
• Check if the Hi-limit switch (Part #412) is properly
functioning.
• Checkforconnection/breakageofwires(Part#413,
708, 709, 710, 712), burn marks on the computer
board (Part #701), and/or soot on the flame rod
(Part#108).
• Check if there is a buzzing spark ignition sound
coming from the burner (Part #101) when water
heaterpreparesforcombustion.
• Listenforthedouble“clunk”soundcomingfromgas
valveassembly(Part#102)whenwaterheatergoes
intocombustion.
• Checkifthereisleakingfromheatexchanger.(Part
#401)
ThreeTimes Lossofflame
• Check if the Hi-limit switch (Part #412) is properly
functioning.
• Checkforconnection/breakageofwires(Part#413,
708, 709, 710, 712), burn marks on the computer
board (Part #701), and/or soot on the flame rod
(Part#108).
• Checkifthereisleakingfromheatexchanger.(Part
#401)
TwoTimes OutletandMixing
thermistorfailure
TwoTimes Inletthermistor
• Check for connection/breakage of wires and/or
failure
debrisonthermistor.(Part#407,408,411,715)
TwoTimes Heatexchanger
thermistorfailure
(510U(T-D2U))
modelsonly)
45
Page
Owner's Guide
Troubleshooting
Remote
Green
LED
Malfunction
description
Diagnosis
391
TwoTimes
441
TwoTimes
510
SixTimes
551
SixTimes
611
FourTimes
651
FourTimes
661
FourTimes
701
711
721
OneTime
SixTimes
FalseFlame
Detection
741
N/A
761
N/A
991
FiveTimes
Miscommunication
betweenwater
heaterandremote
controller
Miscommunication
inEasy-Linksystem
Imperfect
combustion
Air-fuelRatioRod • Checkforconnection/breakageofwires(Part#709)
failure
and/orsootontheAFRrod.(Part#108)
FlowSensorFailure • Check for connection/breakage of wires and/or
(Easy-LinkSystem
debrisontheflowsensorimpeller.(Part#402)
only)
AbnormalGas
• Checkforconnection/breakageofwires(Part#708)
SolenoidValve
and/or burn marks on the computer board (Part
#701).
AbnormalMainGas • Checkforconnection/breakageofwires(Part#708)
Valve
and/or burn marks on the computer board (Part
#701).
FanMotorFault
• Checkforconnection/breakageofwires,dustbuildup
inthefanmotor(Part#103)and/orburnmarkson
thecomputerboard(Part#701).
• Checkforfrozen/corrosionofconnectors(Part#103).
FlowAdjustment • Inspect the flow adjustment valve (Part #402), for
ValveFault(Easyconnection/breakage of wires, locked motor drive
LinkSystemonly)
duetoscalebuildup,and/orwaterleakage.
BypassvalveFault • Inspectthebypassvalve(Part#403),forconnection/
(510U(T-D2U))
breakage of wires, locked motor drive due to scale
modelsonly)
buildup,and/orwaterleakage.
Computerboard
• Checkforconnection/breakageofwires(Part#714).
Fault
• For indoor models, check if condensate drain is
installedontheventcollarofthewaterheater.
• Check if there is leaking from heat exchanger (Part
#401).
• Checkthemodeltypeoftheremotecontroller.
• Inspect the connections between the water heater
andremotecontroller.
• Checkthepowersupplyofthewaterheater.
• Check if the connections between the parent unit
andthechildunitsarecorrect.Refertopg.25-28.
• Checkthegastypeofthewaterheater.
• Inspect the environment around the water heater.
Determinehowlongtheunithasbeeninstalled.
• Check the altitude/elevation of the area of where
thewaterheaterinstalled.
• Checkifthereisanyblockageintheintakeairand/
orexhaust.
• Ifthewaterheaterisinstalledasadirect-ventsystem,
checkwhetherthereisenoughdistancebetweenthe
intakeairterminalandtheexhaustterminal.
• Checkifthereisgreaseand/ordirtintheburner(Part
#101)andthefanmotor(Part#104),especiallyifthe
water heater has been installed in a contaminated
area.
46
Page
Owner's Guide
Troubleshooting
COMPONENTS DIAGRAM
Case assembly
Outdoor models
Indoor models
0 52
0 0 3
0 52
0 0 4
0 0 7
0 0 1
0 0 1
7 0 4
0 0 6
0 0 2
0 0 5
7 0 2
7 1 7
0 51
0 52
0 0 2
7 0 4
0 50
Temperature remote controller
7 2 1
47
Page
Owner's Guide
Troubleshooting
Computer board assembly
110U (T-KJr2U) and
310U (T-K4U) models
7 1 0
7 0 1
510U (T-D2U) models
7 1 0
7 0 5
7 0 8
7 0 1
7 0 5
7 0 9
7 0 8
4 0 8
4 0 7
1 0 3
7 1 4
7 0 9
4 0 3
1 0 3
4 0 2
4 0 2
4 0 2
7 1 5
4 0 2
7 1 4
7 0 7
0 6 1
7 1 5
7 0 7
7 1 6
7 1 6
Surge box assembly
1 2 1
0 53
7 0 3
7 0 5
7 0 4
7 0 6
7 0 5
48
Page
Owner's Guide
Components Diagram
Burner assembly
Burnerassembly
1 0 1
1 1 6
1 2 3
0 6 2
1 0 8
7 2 0
1 1 0
0 6 0
1 0 9
0 53
1 0 5
0 6 0
7 0 9
4 0 1
1 1 7
1 0 7 1 0 6
1 0 3
1 0 4
7 1 8
1 1 1
1 2 2
0 53
7 1 2
0 56
1 1 5
0 6 0
0 52
1 1 4
7 1 3
0 54
1 1 3
0 6 0
1 1 2
7 1 4
1 0 2
1 1 6
7 0 8
0 53
Manifold
Assembly
0 55
1 2 0
0 57
1 51
1 1 8
7 0 7
7 1 0
7 1 1
1 1 7
1 53
1 1 9
0 55
7 1 8
7 1 2
1 50
4 0 1
0 53
1 54
0 53
4 0 1
0 52
0 6 2
1 52
7 1 9
0 6 3
Exhaust section (Outdoor models)
49
Page
Owner's Guide
Components Diagram
Water Way assembly
4 6 3
Bypass section
(510U (T-D2U)models)
4 1 3
4 53
4 0 3
4 52
4 58
4 56
4 6 0
A
4 6 2
4 0 1
B
4 1 2
510U (T-D2U)
models
4 59
0 58
A
4 54
4 1 1
B
4 51
D
4 1 4
To Water
inlet section
4 51
To Water
outlet section
C
4 56
4 54
4 0 8
4 6 0
D
4 6 0
4 55
4 0 2
4 6 1
4 58
4 0 9
4 50
4 1 4
C
4 56
4 1 4
4 0 4
0 52
4 1 0
0 59
4 0 6
Water outlet section
4 57
4 54
4 0 7
4 0 5
Water inlet section
50
Page
4 1 5
Owner's Guide
Components Diagram
PARTS LIST
Item #
001
002
003
004
005
006
007
050
051
052
053
054
055
056
057
058
059
060
061
062
063
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
Part #
Description
CaseassemblyforIndoormodels
forOutdoormodels
Frontcoverfor110Uand310UIndoor(T-KJr2U-INandT-K4U-IN)
for110Uand310UOutdoor(T-KJr2U-OSandT-K4U-OS)
for510UIndoor(T-D2U-IN)
for510UOutdoor(T-D2U-OS)
AirblockageplateforIndoormodels
Bracket
Junctionbox
Powersuuplycodeassembly
Backguardpanel
ScrewM4×12(W/Washer)
ScrewM4×10(W/Washer)
ScrewM4×10(Coated)
ScrewM4x10
HexheadscrewM4×12(W/Washer)
HexheadscrewM4x8
ScrewM3x10
TaptightscrewM4x12FEZN
ScrewM4x10
ScrewM4x6
ScrewM4x12
ScrewM3x6
ScrewM4x8
Wireclamp60
Burnerandmixingchamberassembly
ManifoldwithgasvalveassemblyNA
FanmotorforIndoormodels
FanmotorforOutdoormodels
Burnerfixingplateassembly
Burnerandmixingchambersubassembly
Burnerwindow
Rodholdergasket
FlamerodwithAFRfunction
Igniterrod
Rodholder
Rodcap
Burnerdamper
ManifoldgasketA
ManifoldgasketB
Fixingplate
Pressureport
Combustionchambertube
Gasinlet
Gasinletring
51
Page
110U, 310U and T-KJr2U, T-K4U
510U models and T-D2U models
319143-428
EK103
319143-429
EK111
319143-430
EK110
319143-431
EK123
319143-432
EKD59
319143-433
EKD63
319143-150
EK401
319143-184
EKJ09
319143-014
EKJ64
319143-437
EKK4D
319143-221
EKK5H
319143-025
EW000
319143-325
EW001
319143-026
EW002
319143-060
EW003
EW004
319143-326
EW005
319143-063
EW008
319143-327
EKK31
319143-201
319143-087
EW00A
319143-328
EW009
319143-438
EKK37
319143-439
EW016
EK155
319143-440
EM167
319143-048
319143-441
EK120
319143-442
EK118
319143-443
EK109
319143-043
EKK25
319143-444
EK144
319143-445
EK147
319143-033
EKK2V
319143-446
EK107
319143-447
EK125
319143-448
EK124
319143-449
EK126
319143-450
EK136
319143-451
EK116
319143-452
EK108
319143-045
EKK2K
319143-453
EK140
319143-042
EKK2D
319143-454
EM482
319143-455
EK117
319143-342
EX00D
Owner's Guide
Parts List
Item #
120
121
122
123
150
151
152
153
154
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
450
451
452
453
454
455
456
457
458
459
460
461
462
463
Part #
Description
Igniterplate
Surgeboxplate
Gasket
Gasket
O-ringP18NBR(Black)
O-ringP20NBR(Black)
SiliconringforOutdoormodels
RainprotectionplateinExhaustchamberforOutdoormodels
ExhaustportforOutdoormodels
Heatexchangerassemblyfor110Uand310UIndoor
(T-KJr2U-INandT-K4U-IN)
for110Uand310UOutdoor
(T-KJr2U-OSandT-K4U-OS)
for510UIndoor(T-D2U-IN)
for510UOutdoor(T-D2U-OS)
Flowadjustmentvalve/Flowsensor
Bypassvalvefor510U(T-D2U)models
Waterinlet
Inletdrainplug
Inletwaterfilter
Inletthermistorfor110U(T-KJr2U)and310U(T-K4U)models
Inletthermistorfor510U(T-D2U)models
Outletthermistorfor110U(T-KJr2U)and310U(T-K4U)models
Outletthermistorfor510U(T-D2U)models
Wateroutlet
Outletdrainplug
Heatexchangerthermistorfor510U(T-D2U)models
Hi-Limitswitchfor110U(T-KJr2U)and310U(T-K4U)models
Hi-Limitswitchfor510U(T-D2U)models
Overheat-cut-offfuse
Pipeheater
Inletheater
Pipeheaterfixingplate
Heaterfixingplate16
Fusefixingplate18
Fusefixingplate14
O-ringP4FKM
O-ringP6FKM
O-ringP14FKM
O-ringP15FKM
O-ringP16FKM
Fastener“4-11”for510U(T-D2U)models
Fastener“14-22”
Fastener“16A”
Fastener“16-25A”for510U(T-D2U)models
SiliconringforIndoormodels
52
Page
110U, 310U and T-KJr2U, T-K4U
510U models and T-D2U models
319143-051
EKK1B
319143-176
EK436
319143-456
EK127
319143-457
EK145
319143-350
EZP18
319143-057
EK042
319143-206
EKK3G
319143-458
EK134
319143-219
EKK56
319143-459
EK119
319143-460
EK121
319143-461
319143-462
319143-463
319143-464
319143-193
319143-197
319143-198
319143-214
319143-465
319143-218
319143-190
319143-466
319143-199
319143-096
319143-228
319143-095
319143-149
319143-467
319143-468
319143-088
319143-125
319143-066
319143-146
319143-082
319143-080
319143-100
319143-091
319143-083
319143-097
319143-105
319143-226
319143-205
319143-065
EKD62
EK122
EK129
EKD58
EKK1U
EKK2B
EKK2C
EKK4J
EK137
EKK55
EKK1A
EK104
EKK2E
EKK2T
EM212
EKN34
EK333
EK130
EK105
EKK27
EK031
EKK26
EK029
EZM04
EZM06
EZM14
EZM15
EZM16
EKH30
EKK24
EM192
EKK39
EKN50
Owner's Guide
Parts List
Item #
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
Part #
Description
110U, 310U and T-KJr2U, T-K4U
510U models and T-D2U models
Computerboardfor110U(T-KJr2U)models
319143-469
EKJ6V
for310U(T-K4U)models
319143-470
EK106
for510U(T-D2U)models
319143-471
EK149
RubbergrommetforIndoormodels
319143-426
EK148
Surgebox
319143-128
EK280
120VACwireforIndoormodels
319143-427
EK146
forOutdoormodels
319143-138
EKK3C
Switchwire
319143-472
EK115
120VACPowerON-OFFswitch
319143-141
EKK4V
EK138
Remotecontrollerwirefor110U(T-KJr2U)and310U(T-K4U)models
319143-473
319143-474
EKD61
for510U(T-D2U)models
319143-475
EK114
Gasvalvewire
Flamerodwirefor110U(T-KJr2U)and310U(T-K4U)models
319143-476
EK150
Flamerodwirefor510U(T-D2U)models
319143-477
EKD64
EH-IGwire
319143-478
EK113
EK153
Igniter
319143-479
EK154
Highvoltageignitercable
319143-480
319143-185
EKJ59
Freezeprotectionthermostat
Proportionalgasvalvewire
319143-481
EK112
EKD60
24Vcablesfor510U(T-D2U)models
319143-482
EKK1M
Computerboardcover
319143-191
319143-425
EW022
CablestrapforIndoormodels
319143-483
EK151
Cable
Remotefixingplatefor510(T-D2U)models
319143-484
EK152
Flowadjustmentplate
EK156
Temperatureremotecontroller
319143-485
ER014
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Owner's Guide
Output Temperature Chart
OUTPUT TEMPERATURE CHART
Chartisbasedonproperlysizesgasline
Output Hot Water GPM
110U (T-KJr2U) models
Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature
310U (T-K4U) models
Output Hot Water GPM
Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature
Output Hot Water GPM
510U (T-D2U) models
Output Temperature vs. GPM (Max. 10.0 GPM) with Various Inlet Water Temperature
*Whenthesettemperatureis131°F(55 °C)orhigher,maximumflowrateislimitedto8.0GPM.
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Owner's Guide
Warranty
LIMITED WARRANTY
1. Generaltermsoflimitedwarranty:
Thislimitedwarrantygivesyouspecificlegalrights,andyou mayalsohaveotherrightswhichvaryfromStateto
State.Themanufacturerwillhonorthewarrantytotheoriginalretailbuyerattheoriginallocationonly,anditis
nottransferable.
THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER
NORMAL USAGE FOR THE PRODUCT’S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED
IN THE FOLLOWING TABLES. ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS
LIMITED WARRANTY AND, IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT, BREACH OF
WARRANTY, TORT LIABILITY (INCLUDING NEGLIGENCE), STRICT LIABILITY, INDEMNITY OR OTHERWISE WILL
BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY
DAMAGE, PERSONAL DAMAGES, LOSS OF USE, OR INCONVENIENCE. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU.
2. Warrantyformodels: 510U (T-D2U) models
Application
SingleFamily
DomesticHot
Water
Commercialor
Multi-Family
DomesticHot
Water
Heating(4)
NoRecirculation
On-DemandRecirculation(2)
AquastatControl
PumpControl
w/Standard
TimerOnly
Recirculation
NoPumpControl(24hr.)
NoRecirculation
On-DemandRecirculation(2)
AquastatControl
PumpControl
w/Standard
Recirculation
TimerOnly
NoPumpControl(24hr.)
AllTypes
HX(1)
12
5
Parts
5
1(3)
3
3
5
5
1(3)
3
3
5
5
1(3)
HX(1)
Parts
[Unit:Year]
Labor
12
5
3
3
1
1
3
3
Warrantyformodels: 110U (T-KJr2U) and 310U (T-K4U) models
Application
SingleFamily
DomesticHot
Water
Multi-Family
DomesticHot
Water
Heating(4)
Commercial
NoRecirculation
On-DemandRecirculation(2)
AquastatControl
PumpControl
w/Standard
TimerOnly
Recirculation
NoPumpControl(24hr.)
NoRecirculation
On-DemandRecirculation(2)
AquastatControl
PumpControl
w/Standard
Recirculation
TimerOnly
NoPumpControl(24hr.)
AllTypes
AllTypes
[Unit:Year]
Labor
1(3)
1(3)
1
1
1
1
1
1
1(3)
1(3)
(1)Heatexchanger
(2)Anon-demandrecirculationsystemisasystemthatutilizeseitherapush-buttonorothertypeof
manualactivation(asopposedtoautomaticactivationwithatemperaturesensorortimer)to
activatethecirculationpump.Anon-demandrecirculationsystemcanuseeithertheexistingcold
waterlineasthereturnlineorhaveitsowndedicatedreturnline.
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Owner's Guide
Warranty
(3)LimitedLaborCoverage
•Themanufacturerwillprovideforreasonablelaborchargesassociatedwithwarrantyrepairs
orreplacementswithinone(1)yearfromthedateofpurchase.Themanufacturerwillonlypay
directlytotheserviceprovider.
•WarrantyservicemustbeperformedbyanauthorizedServiceRepresentative.Alistofauthorized
ServiceRepresentativesisavailableuponrequest.
•Allwarrantyclaimsandwarrantyservicemustbeauthorizedandapprovedbythemanufacturer.
(4)Includesdual-purposeapplications(combinationheatinganddomestic).
3. Repair,ReplacementorRefund:
ThemanufactureroritsauthorizedServiceRepresentativewill,atitssolediscretion,repairorreplaceanyfailed
or defective mechanical or electrical parts, or components thereof, or, if the manufacturer or its authorized
ServiceRepresentativecannotreplacesaidparts,andrepairisnotcommerciallypracticable,themanufactureror
itsauthorizedServiceRepresentativewillrefundthepurchaseprice.ThemanufactureroritsauthorizedService
Representativemay,atitssolediscretion,usenew,refurbishedorreconditionedparts.
4. LimitationonDurationofImpliedWarranties:
ANY IMPLIED WARRANTIES ARISING UNDER STATE LAW, INCLUDING THE IMPLIED WARRANTIES OF FITNESS
FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, SHALL IN NO EVENT EXTEND PAST THE EXPIRATION OF
ANY WARRANTY PERIOD HEREUNDER. SOME STATES DO NO ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
5. THIS WARRANTY WILL NOT COVER THE FOLLOWING:
• Anyproductthatisnotinstalledbyalicensedplumber,gasinstaller,orcontractor.
• Damagesduetoaccidents,abuse,misuse,improperinstallation,misapplication,orincorrectsizing.
• Damagesduetofires,flooding,freezing,electricalsurges,oranyActsofGod.
• Damagesduetounauthorizedalterations,attachments,and/orrepairs.
• Damagesduetoalackofmaintenance(e.g.waterfilter,watertreatmentsystem,ventblockage,etc.)
• Anyproductinstalledinanimproperenvironment(e.g.corrosive,dusty,chemicallycontaminated,
excessivelint,etc.).
• Freezedamagethatoccurswithouttakingproperpreventivemeasuresasdescribedintheinstallation
manual.
• Condensatedamageduetoimproperlyinstalledorlackofacondensatetrap(drain).
• Anyproductnotinstalledincompliancewithallapplicablelocal&provincialcodes,ordinances,and
goodtradepractices.
• Anyproductsoldtoorinstalledinareasoutsideofthefiftystates(andtheDistrictofColumbia)of
theUnitedStatesofAmericaandCanada.
• Anyproductinstalledinapplicationsthatcausethewaterheatertoactivatemorethan300timesper
day(thisaveragestoanactivationevery5minutesina24-hourperiod).
• Anyfailuresthatarenotduetodefectsinmaterialsorworkmanship(mechanicaland/orelectricalparts).
• Damagesduetoimproperinstallation:
• Gas:incorrectgaspipesizing,incorrectgasmetersizing,incorrectgastype,and/orgaspressures
thatfalloutsidetheproduct’sspecifiedrange.
• Water:incorrectwaterpipesizing,waterpressuresthatfalloutsidetheproduct’sspecifiedrange,
recirculationflowratesthatfalloutsidetheproduct’sspecifiedrange(airremoval),and/orlackof
propermethodsofairremovalinaclosed-loop,circulationsystem(seeinstallationmanualfor
details).
• Electric:supplypowervoltagesthatfalloutsidetheproduct’sspecifiedrange.
• Damagesduetowaterquality:
• Introductionofliquidsotherthanpotablewaterorpotablewater/glycolmixturesintotheproduct.
• Introductionofpoolwater,spawater,oranychemicallytreatedwaterintotheproduct.
• Introductionofhardwatermeasuringmorethan7grainspergallon(120ppm)forsinglefamily
domesticapplicationsormorethan4grainspergallon(70ppm)forallothertypesofapplications
intotheproduct.
• Introductionofuntreatedorpoorlytreatedwellwaterintotheproduct.
• IntroductionofwaterwithpHlevelslessthan6.5andgreaterthan8.5intotheproduct.
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