Takagi 110U Indoor (T-KJr2U-IN) Installation Manual And Owner's Manual
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Takagi 110U Indoor (T-KJr2U-IN) Installation Manual And Owner's Manual

On-demand water heater
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See also: Installation Instructions & Owner's Manual
On-Demand Water Heater
Installation Manual and Owner's Guide
510U (T-D2U)
models only
Gas Tankless Water Heater
Suitable for potable water heating and space-heating*
* Please refer to local codes for space-heating compliance.
FEATURING
• ENDLESS HOT WATER
• ON-DEMAND USAGE
• COMPACT, SPACE SAVING
• ENERGY CONSERVATION
• COMPUTERIZED SAFETY
• NO PILOT LIGHT
• Satisfies the 2012 SCAQMD Rule
1146.2 for Ultra-Low NOx
Emissions
• EASY-LINK SYSTEM AND
MULTI-UNIT SYSTEM
(510U (T-D2U) models only)
ANSI Z21.10.3 and CSA 4.3
110U Indoor (T-KJr2U-IN)
•
310U Indoor (T-K4U-IN)
•
510U Indoor (T-D2U-IN)
•
WARNING
- Do not store or use gasoline or other
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch, do not
• Immediately call your gas supplier from
TM
• If you cannot reach your gas supplier, call
- Installation and service must be performed
Models
110U Outdoor (T-KJr2U-OS)
•
310U Outdoor (T-K4U-OS)
•
510U Outdoor (T-D2U-OS)
•
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
flammable vapors and liquids in the vicinity
of this or any other appliance.
use any phone in your building.
a neighbor's phone. Follow the gas
supplier's instructions.
the fire department.
by a qualified installer, service agency or the
gas supplier.
If you have any questions, please
call or write to:
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free: 1-877-737-2840

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Summary of Contents for Takagi 110U Indoor (T-KJr2U-IN)

  • Page 1 On-Demand Water Heater Installation Manual and Owner’s Guide ANSI Z21.10.3 and CSA 4.3 Models 110U Indoor (T-KJr2U-IN) 110U Outdoor (T-KJr2U-OS) • • 310U Indoor (T-K4U-IN) 310U Outdoor (T-K4U-OS) • • 510U Outdoor (T-D2U-OS) 510U Indoor (T-D2U-IN) • • 510U (T-D2U) models only If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage,...

  • Page 2: Table Of Contents

    Contents CONTENTS Installation Manual 　SPECIFICATIONS .......................... 4 　INTRODUCTION .......................... 5 　SAFETY GUIDELINES ........................6 　INSTALLATION ..........................7 　　General.............................7 　　Clearances..........................9 　　Included accessories........................9 　　Optional items........................9 　　Warning for installations......................9 　　High-altitude i nstallations......................12 　　Venting i nstructions.......................13 　　Gas supply and gas pipe sizing....................18 　　Water connections........................20 　　Electrical connections......................21 　　Temperature remote controller...................22 　　Easy-link system........................25 　　Multi-unit system........................29 　APPLICATIONS..........................30 　INITIAL OPERATION........................32 Owner's Guide 　OPERATING SAFETY ........................34 　NORMAL OPERATION .......................

  • Page 3: Installation Manual

    Installation Manual Installation Manual CONGRATULATIONS Congratulations and thank you for choosing our tankless water heater. Before use, we recommend that you read through this safety manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. 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.

  • Page 4: Specifications

    Installation Manual Specifications SPECIFICATIONS 110U 110U 310U 310U 510U 510U Model Indoor Outdoor Indoor Outdoor Indoor Outdoor (T-KJr2U-IN) (T-KJr2U-OS) (T-K4U-IN) (T-K4U-OS) (T-D2U-IN) (T-D2U-OS) Natural Gas Input Min.: 15,000 Min.: 15,000 Min.: 15,000 BTU/h (Operating Range) Max.: 140,000 Max.: 190,000 Max.: 199,000 Gas Connection 3/4" NPT Water Connections 3/4" NPT Water Pressure* 15 - 150 (0.1 - 1) (Mpa)

  • Page 5: Introduction

    Installation Manual Introduction INTRODUCTION • This manual provides information necessary for the installation, operation, and maintenance of the water heater. • The model description is listed on the rating plate which is attached to the side panel of the water heater. • Please read all installation instructions completely before installing this product. • If you have any problems or questions regarding this equipment, consult the manufacturer or its local representative. • This equipment is an on-demand, tankless water heater designed to efficiently supply endless hot water for your needs. • The 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models are only to be installed indoors (direct-vent (double vent) convertible). The 110U Outdoor (T-KJr2U-OS), 310U Outdoor (T-K4U-OS) and 510U Outdoor (T-D2U-OS) models are only to be installed outdoors.

  • Page 6: Safety Guidelines

    Installation Manual Safety Guidelines SAFETY GUIDELINES SAFETY DEFINITION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION GENERAL 1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas Installation Code in Canada. 2. Properly ground the unit in accordance with all local codes or in the absence of local codes, with the National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canadian Electrical Code Part 1 in Canada. 3. Carefully plan where you intend to install the water heater. Please ensure: • Your water heater will have enough combustible air and proper ventilation. • Locate your heater where water leakage will not damage surrounding areas. (Please refer to p. 8.) 4. Check the rating plate for the correct GAS TYPE, GAS PRESSURE, WATER PRESSURE and ELECTRIC RATING.

  • Page 7: Installation

    Installation Manual Installation INSTALLATION GENERAL 1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas Installation Code in Canada. 2. All gas water heaters require careful and correct installation to ensure safe and efficient operation. This manual must be followed exactly. Read the “Safety Guidelines” section. 3. The manifold gas pressure is preset at the factory. It is computer controlled and should not need adjustment. 4. Maintain proper space for servicing. Install the unit so that it can be connected or removed easily. Refer to the "Clearances" section on p. 9 for proper clearances.
  • Page 8 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.

  • Page 9: Clearances

    Installation Manual Installation CLEARANCES Back Side Maintain all clearances around the water heater. Front Side Bottom Model Bottom Front Back Sides 110U Indoor (T-KJr2U-IN)* 12 in. 12 in. 4 in.** 0.5 in. 2 in. 310U Indoor (T-K4U-IN)* (305 mm) (305 mm) (102 mm) (13 mm) (51 mm) 510U Indoor (T-D2U-IN)* 110U Outdoor (T-KJr2U-OS) 36 in. 12 in. 24 in. 0.5 in. 2 in. 310U Outdoor (T-K4U-OS) (914 mm) (305 mm) (610 mm) (13 mm)
  • Page 10 Installation Manual Installation 1. 4” Backflow preventer and F-F adaptor: 2. Direct-vent conversion kit: 9007667005 9007996005 (TK-TV10) There are two functions available for this adaptor, This kit can be used to convert the water which can be connected with the water heater and heater from a single vent system to a direct- NovaVent venting line and prevents the backflow vent (double vent) (or sealed combustion) of air through the exhaust vent. This helps prevent system with a 3 in. (76 mm) intake. Install...
  • Page 11 Installation Manual Installation WARNING FOR INSTALLATIONS FOR YOUR SAFETY, READ BEFORE INSTALLATION: Do not install the heater where water, debris or Do not have the vent terminal pointing toward flammable vapors may get into the flue terminal. any opening into a building. Do not locate your This may cause damage to the heater and void the heater in a pit or location where gas and water warranty. can accumulate. Prohibited Prohibited Do not install this water heater under an Do not install the water heater vent terminator overhang less than 3 ft. (914 mm) from its top within 1 ft. (305 mm) in the USA of any air intake or eaves. The area under an overhang must be or building opening, and within 3 ft. (914 mm)

  • Page 12: High-Altitude Installations

    Installation Manual Installation HIGH-ALTITUDE INSTALLATIONS Check the elevation where your water heater is installed. Set DIPswitches shown in the table below depending on the altitude. Indoor models Altitude 0 (DEFAULT) Up to 2,500 ft Up to 5,000 ft Up to 7,500 ft Over 7,500 ft DIPswitches 1 2 3 4 5 6 7 8 9 10...

  • Page 13: Venting Instructions

    Installation Manual Installation VENTING INSTRUCTIONS For indoor models -General- • Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death. • Improper installation can cause nausea or asphyxiation, severe injury or death DANGER from carbon monoxide and flue gases poisoning. Improper installation will void product warranty. When installing the vent system, all applicable national and local codes must be followed. If you install thimbles, fire stops or other protective devices and they penetrate any combustible or noncombustible construction, be sure to follow all CAUTION applicable national and local codes.
  • Page 14 Installation Manual Installation -Vent length and No. of Elbows- This is a Category III appliance and must be vented accordingly. The vent system must be sealed airtight. All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive tape having a minimum temperature rating of 350 °F (177 °C). For best results, a vent system should be as short and straight as possible. • This water heater is a Category III appliance and must be vented accordingly with any 4 in. (102 mm) vent approved for use with Category III or Special BH type gas vent. • Follow the vent pipe manufacturer’s instructions when installing the vent pipe. • Do not common vent this appliance with any other vented appliance. (Do not terminate vent into a chimney. If the vent must go through the chimney, the vent must run all the way through the chimney with Category III approved or Special BH vent pipe.) • When the horizontal vent run exceeds 5 ft. (1.5 m), support the vent run at 3 ft. (0.9 m) intervals...
  • Page 15 Installation Manual Installation Venting Illustrations- For the 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models For details of the optional items, refer to the Installation manual for each Optional item. Vertical Installation Horizontal Installation Rain cap Wall Roof flashing Roof Backflow preventer* Sidewall vent termination Backflow preventer* Vertical condensation drain** Vertical condensation drain** Horizontal Installation Vertical Installation (With direct-venting) (With direct-venting) Wall Rain cap...

  • Page 16: Vent Termination Clearances

    Installation Manual Installation -Vent termination clearances- INSIDE CORNER DETAIL Vent terminal Air supply inlet Area where is not permitted Gas meter / regulator Canada U.S.A Direct-vent and other Direct- Other than than Direct-vent vent Direct-vent Clearance above grade, veranda, porch, deck, or 1 foot 1 foot 1 foot balcony 4 feet from below or B Clearance to window or door that may be opened 3 feet 1 foot side opening. 1 foot from above opening. C Clearance to permanently closed window Vertical clearance to ventilated soffit located above the vent terminator within a horizontal distance of 2 feet (61cm) from the center line of the terminator E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner Clearance to each side of center line extended 3 feet...
  • Page 17 Installation Manual Installation -For sidewall terminations- For multiple sidewall exhaust terminations (e.g. multi- 2 ft. unit systems), an exhaust termination must be at least 1 (610 mm) min 1 ft. (305 mm) ft. (305mm) away from another exhaust termination. An exhaust termination must also be at least 2 ft. (610 mm) away from an inside corner. (If the adjacent wall is less than 1 ft. (305 mm) min 2 ft. (610 mm) of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall.) Exhaust...

  • Page 18: Gas Supply And Gas Pipe Sizing

    Installation Manual Installation GAS SUPPLY AND GAS PIPE SIZING -General- • 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.
  • Page 19 Installation Manual Installation -Natural Gas Supply Piping- Maximum delivery capacity of cubic feet of gas per hour of IPS pipe carrying Natural Gas with 0.60 specific gravity based on pressure drop of 0.5" 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 Length...

  • Page 20: Water Connections

    Installation Manual Installation -Measuring inlet gas pressure- 1. Turn off all electric power to the water heater if service is to be performed. 2. Turn the manual gas valve located on the outside of the unit clockwise to the off position. The water heater cannot perform properly without sufficient inlet gas pressure. Below are instructions on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL. 1. Shut off the manual gas valve on the gas supply line. 2. Remove the screw for the pressure port located on the gas inlet of the water heater shown in the diagram on the right. 3. Connect the manometer to the pressure port. 4. Re-open the manual gas valve. Check to see that there are no gas leaks. Open some of the fixtures that use the highest flow rate to turn on the water heater.

  • Page 21: Pressure Relief Valve

    Installation Manual Installation -Pressure relief valve- The water heater has a high-temperature shutoff switch built in as a standard safety feature (called a Hi-Limit switch) therefore a “pressure only” relief valve is required. • This unit does not come with an approved pressure relief valve. • An approved pressure relief valve must be installed on the hot water outlet. • The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow local codes. • The discharge capacity must be at least 140,000 BTU/h for the 110U (T-KJr2U) models, 190,000 BTU/h for the 310U (T-K4U) models, and 199,000 BTU/h for the 510U (T-D2U) models. • The pressure relief valve needs to be rated for a maximum of 150 psi (1 MPa). • The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment.

  • Page 22: Temperature Remote Controller

    Installation Manual Installation TEMPERATURE REMOTE CONTROLLER -INCLUDED ACCESSORIES- Check that these items below are included with the remote controller. Temperature Screws Manual Remote controller cable remote controller Qty: 1 Qty: 2 Qty: 1 Qty: 1 -INSTALLATION- • This remote controller is NOT waterproof Do not install in high temperature environments, steamy conditions (such as a bath room), outdoors, in direct sunlight, or within the reach of children. CAUTION Make sure the remote controller does not come into contact with water or oil. • Do not place the remote control wiring close to other wires from other products. • Do not extend the remote control wiring more than 400 ft. (122 m.) <Mounting and wiring the remote controller> 1.  Take off the “Back plate” from the remote controller with a flat head screwdriver. (Fig.
  • Page 23 Installati on Manual Installati on 3.  Tighten the two "Fork terminals" beneath the two "Remote controller terminal" screws on the back of the main body. (Fig. C-1) 4. Cut out the inlet for the remote controller cable from the bottom of the main body. (Fig. C-2) 5.  Place the “Main body” back on the "Back plate", with the "Remote controller cable" running out of the bottom inlet. Fig. C-1 Remote controller terminals Fig. C-2 Inlet for the remote Two fork terminals controller cable Cut out Remote controller cable <How to connect the remote controller to the water heater> 1.  Disconnect power supply from the water heater.
  • Page 24 Installation Manual Installation 5.  Pull the remote’s wires through the hole at the bottom of the water heater’s casing. 6.  Properly attach the remote’s wires to the remote controller terminal on the computer board (No polarity).  * Do NOT jump or short-circuit the wires, or computer will be damaged. 7.  Replace Front Cover securely. 8.  Wires used for the remote controller connection must be: • Minimum 20 gauge wire (No polarity) • Maximum 400 ft. (122 m) long 510U (T-D2U) models 9008172005 (TM-RE40) Connect other end to these terminals Front of remote Page...

  • Page 25: Easy-Link System

    Installation Manual Installation EASY-LINK SYSTEM (Available on the 510U (T-D2U) models only) -General- The 510U (T-D2U) models water heaters can be connected with other allowable heaters (see the table below) with communication cables to work as a multiple-unit manifold system. • The Easy-Link system allows up to 4 units to manifold together. • A communication cable (gray color) comes with each 510U (T-D2U) model. You can manifold from 2 to 4 units without the need for a multi-unit controller. A 4-unit system has full automatic modulation between 15,000 BTU/h and 796,000 BTU/h. Easy-Link connection with allowable heaters T-K3 T-K3-Pro 510 models (T-D2-IN / T-D2-OS) 510U models (T-D2U-IN / T-D2U-OS) Gas In Hot Out Cold In • The Easy-Link system is limited up to 4 units. If you connect more than 4 units, only the first 4 units will work as a part of the Easy-Link system. The other additional units will not work.
  • Page 26 Installation Manual Installation 2. Select one unit to be the “PARENT” unit. 3. “PARENT” unit: Locate the two banks of DIPswitches at the bottom left of the computer board of the unit that you select to be the “PARENT” unit. Change DIPswitch No. 1 on the lower bank of DIPswitches to the ON position. See the computer board diagram below. Do not change any DIPswitches on any of the “CHILD” units. 4. Between the “PARENT” and the “CHILD-1” units: Connect the “PARENT” connector of the “PARENT” unit to the “1” connector of the “CHILD-1” unit. 5. Between the “CHILD-1” and the “CHILD-2” units: Connect the “2” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit. 6. Between the “CHILD-2” and the “CHILD-3” units: Connect the “2” connector of the “CHILD-2” unit to the “1” connector of the “CHILD-3” unit. 7. Make sure the remote controller display the unit #. The numbering system automatically allocates the unit # to each water heater in the Easy-Link system, in accordance with the table below. Type of unit Unit # of easy-link Parent Child...
  • Page 27 Installation Manual Installation • A remote controller is required for the Easy-Link system for ease of usage and NOTICE maintenance. • If a remote controller is used, the temperature on all the units in the system will automatically be set to the same temperature that is set on the remote. (C) Examples of incorrect settings and /or connections CASE 1: Wrong DIPswitch setting on the "PARENT" unit • Unless you change DIPswitch No. 1 of the “PARENT” unit to the “ON” PARENT unit CHILD-1 unit position, the system will not work as an Easy-Link system. The units will operate as individual units. Wrong Setting Lower bank of Lower bank of DIPswitches DIPswitches Communica on cable...
  • Page 28 Installati on Manual Installati on CASE 3: Wrong connections between the "CHILD-1" unit and the "CHILD-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” unit will operate as an individual unit, and will not be part of the Easy-Link system. PARENT unit CHILD-1 unit CHILD-2 unit Connectors Connectors Connectors...

  • Page 29: Multi-Unit System

    Installation Manual Installation MULTI-UNIT SYSTEM Multiple 510U (T-D2U) models can be combined for a multi-unit system, along with the multi- unit controller (Parts 9008300005 (TM-MC02)) and remote controller (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 between the usages of 15,000 BTU/h to 4.0 Million BTU/h. 510U 9008300005 (T-D2U) (TM-MC02) Hot Out...

  • Page 30: Applications

    Installation Manual Applications 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 WARNING requirements must be followed.

  • Page 31: Dual-Purpose Hot Water Heating

    Installation Manual Applications -Dual-purpose hot water heating- (Domestic and Space Heating): Diagrammatic layout of radiant heating and domestic water heater per mass. code. All water piping should be insulated in accordance with 780 CMR (Massachusetts energy code) Cold water supply Automatic tempering device must be installed below the top of the water heater 4" gas exhaust vent Check valve will have as per manufacturer’s (Discharge must 1/8" hole drilling in recommendations Apply correct thermal comply with local and clapper optional expansion tank-size Shutoff state codes.) Can not per application valve be common vented Pressure with other appliances Tempered water to gauge plumbing fixtures. Must Piping loop meet temperature between water requirements of 248 CMR...

  • Page 32: Initial Operation

    Installation Manual Initial operation INITIAL OPERATION FOR YOUR SAFETY, READ BEFORE OPERATING • Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time. • Open the main gas supply valve to the unit using only your hand to avoid any spark. Never use tools. If the knob will not turn by hand, do not try to force it; call a qualified service technician. Forced repair may result in a fire or explosion due to gas leaks. • Be sure to check for the presence of leaking gas toward the bottom of the unit because some gases are heavier than air and may settle towards the floor. • Check the GAS PRESSURE. Refer to p. 20. • Do not try to light the burner manually. It is equipped with an electronic ignition device which automatically lights the burner. • Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater.

  • Page 33: Owner's Guide

    Owner's Guide Owner's Guide CONGRATULATIONS Congratulations and thank you for choosing our tankless water heater. Before use, we recommend that you read through this safety manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. 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.

  • Page 34: Operating Safety

    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 property damage, personal injury or loss of life. A. This water heater does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the water heater area for evidence of leaking gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS. • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. C. Use only your hand to turn the gas valve knob. Never use tools. If the knob will not turn by hand, don't try to repair it. Call a qualified service technician. Forced or attempted repair may result in a fire or explosion. D. Do not use this water heater if any part has been under water. Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above or in the Owner's Manual. 2. Turn off all electric power to the water heater.
  • Page 35 Owner's Guide Operating Safety DANGER Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater. Keep flammable products: Vapors: 1. Far away from heater 1. Cannot be seen 2. In approved containers 2. Vapors are heavier than air 3. Tightly closed 3. Go a long way on the floor 4. Out of children's reach 4. Can be carried from other rooms to the main burner by air currents WARNING: Do not install water heater where flammable products will be stored. Read and follow water heater warnings and instructions.

  • Page 36: Normal Operation

    Owner's Guide Normal Operation NORMAL OPERATION REMOTE CONTROLLER The illustration below shows an example of the display. The exact display may differ from examples. Display for Temperature "INFO" Button When the STAND BY LED is ON, the Each time the button is pressed, hot water temperature will be the operation mode is selected displayed. in the sequence of the following. Inlet water Outlet water Water "COLD" Button temperature temperature flow "HOT" Button Press the "HOT" button or the IN USE LED (Green) "COLD" button to set the hot The lamp lights during combustion. water temperature. "ON/OFF" Button STAND BY LED (Orange) Press this button to The indicator is ON to show that...

  • Page 37: Temperature Settings

    Owner's Guide Normal Operation TEMPERATURE SETTINGS -Set temperature- Operation Screen Turn on the 120 VAC power supply to the unit (the water heater or the multi-unit controller). Press the "ON/OFF" button on the remote in order to turn the remote controller on. When ON, the STAND BY LED is lit. It shows the set temperature on its display as shown in the (EX.: 120 °F) picture on the right. (EX.: 120 °F) Press the "HOT" button or the "COLD" button to set the temperature setting of the unit. (Increasing temperature, example 140 °F to 145 °F) -510U (T-D2U) models only- Press the "HOT" 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. The display will...

  • Page 38: Additional Features

    Owner's Guide Normal Operation ADDITIONAL FEATURES -Information mode- You can get some information about the water heater condition by pressing the "INFO" button. For more information, follow the procedures below: Operation Screen First of all, inlet water temperature will be displayed on Inlet water temperature the remote controller by pressing the "INFO" button. Outlet water temperature will be displayed on the Outlet water temperature remote controller by pressing the "INFO" button. And then, water flow will be displayed on the remote Water flow controller by pressing the "INFO" button. Press the "INFO" button to finish information mode.

  • Page 39: Without Remote Controller

    Owner's Guide Normal Operation TEMPERATURE SETTINGS ON THE PCB (WITHOUT REMOTE CONTROLLER) There are 2 preset temperatures (120 °F (49 °C) and 140 °F (60 °C)) that you can select from by changing the DIPswitch settings on the computer board without the remote controller. See the table below. When the remote controller is in normal operation, the set temperature of the remote controller is given priority over the set temperature of the DIPswitch settings. • The temperature has been preset at the factory to 120 °F (49 °C). 110U (T-KJr2U) and 310U (T-K4U) models Computer board 120 °F (49 °C) 140 °F (60 °C) DEFAULT ON 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 No. 9 : OFF No. 9 : ON...

  • Page 40: Flow

    Owner's Guide Normal Operation FLOW Household Flow Rates • The flow rate through the water heater is limited to a maximum of 6.6 GPM (25 L/min) for the 110U Flow rate Appliance/Use (T-KJr2U) models, 8.0 GPM (30 L/min) for the 310U GPM (US) L/min (T-K4U) models, and 10.0 GPM (38 L/min) for the Lavatory Faucet 510U (T-D2U) models. Bath Tub 4.0 – 10.0 15.2 - 37.8 • The temperature setting, along with the supply Shower temperature of the water will determine the flow rate output of the unit.

  • Page 41: Maintenance And Service

    Owner's Guide Normal Operation MAINTENANCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. WARNING • Clean the cold-water inlet filter. (Refer to Unit draining and filter cleaning section in this page.) • Be sure that all openings for combustion and ventilation air are not blocked. • The venting system should be checked annually for any leaks, corrosion, blockages or damage. • The burner should be checked annually for dust, lint, grease or dirt. • Keep the area around the water heater clear. Remove any combustible materials, gasoline or any flammable vapors and liquids. • In accordance with all local codes and common safety practices, water discharged from the pressure relief valve can cause severe burns instantly from scalding. DO NOT touch the pressure relief valve. • If the relief valve discharges periodically, it may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation.

  • Page 42: Troubleshooting

    Owner's Guide Troubleshooting TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS It takes long time to • The time it takes to deliver hot water from the water heater to your get hot water at the fixtures depends on the length of piping between the two. The longer fixtures. the distance or the bigger the pipes, the longer it will take to get hot water.
  • Page 43 Owner's Guide Troubleshooting PROBLEM SOLUTIONS Unit does not ignite • Is the flow rate over 0.5 GPM (1.9 L/min)? (p. 36) when water goes • Check for the filter on cold water inlet. (p. 41) through the unit. • Check for reverse connection and cross connection. • If you use the remote controller, is the power button turned on? • Check if the inlet temperature is too high. The fan motor is • This is normal. After operation has stopped, the fan motor keeps still spinning after running from 15 to 70 seconds in order to re-ignite quickly, as well operation has stopped. as purge all the exhaust gas out of the flue. Unit sounds abnormal • Contact the manufacturer at 1-877-737-2840. while in operation Remote controller does • Make sure the unit is supplied with power. not display anything • Make sure the connection to the unit is correct. (p. 23-24) when the power When the remote button is turned on. -9008172005 (TM-RE40)- controller turned If the STAND BY LED lights up, the ON, STAND BY remote controller has been...

  • Page 44: Error Codes

    Owner's Guide Troubleshooting ERROR CODES -General- • The units are self-diagnostic for safety and convenience when troubleshooting. • If there is a problem with the installation or the unit, the error code will be displayed on the remote controller. • Consult with the table on the following pages for the description of each error code. 110U (T-KJr2U) and 310U (T-K4U) models 510U (T-D2U) models Error code on the remote controller 9008172005 (TM-RE40) Green LED Green LED Error code on the computer board -Single unit Installations- Example: If your unit has the “321”...
  • Page 45 Owner's Guide Troubleshooting -Fault Analysis of Error Codes- If the error code is displayed on the computer board of the water heater or remote controller, please check the following. After checking, consult with the manufacturer. Green Malfunction Remote Diagnosis description One Time Incorrect DIPswitch • Check the DIPswitch settings on the PCB (Part #701). setting Five Times Warning for the • Check the gas type of the water heater.
  • Page 46 Owner's Guide Troubleshooting Green Malfunction Remote Diagnosis description Two Times Air-fuel ratio rod • Check for connection/breakage of wires (Part #709) failure and/or soot on the AFR rod (Part #108). Two Times Flow sensor failure • Check for connection/breakage of wires and/or (Easy-Link System debris on the flow sensor impeller (Part #402). only) Six Times Abnormal main gas • Check for connection/breakage of wires (Part #708) solenoid valve and/or burn marks on the computer board (Part #701). Six Times Abnormal gas • Check for connection/breakage of wires (Part #708)

  • Page 47: Components Diagram

    Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly Outdoor models Indoor models Temperature remote controller Page...
  • Page 48 Owner's Guide Components Diagram Computer board assembly 110U (T-KJr2U) and 310U (T-K4U) models 510U (T-D2U) models Surge box assembly Page...
  • Page 49 Owner's Guide Components Diagram Burner assembly Burner assembly 107 106 Manifold assembly Exhaust section (Outdoor models) Page...
  • Page 50 Owner's Guide Components Diagram Water Way assembly Bypass section (510U (T-D2U)models) 510U (T-D2U) models To Water inlet section To Water outlet section Water outlet section Water inlet section Page...

  • Page 51: Parts List

    Owner's Guide Parts List PARTS LIST Part # Item # Description 110U, 310U and T-KJr2U, T-K4U 510U models and T-D2U models Case assembly for Indoor models 319143-428 EK103 for Outdoor models 319143-429 EK111 Front cover for 110U and 310U Indoor (T-KJr2U-IN and T-K4U-IN) 319143-430 EK110 for 110U and 310U Outdoor (T-KJr2U-OS and T-K4U-OS) 319143-431 EK123 for 510U Indoor (T-D2U-IN) 319143-432 EKD59 for 510U Outdoor (T-D2U-OS) 319143-433 EKD63 Air blockage plate for Indoor models 319143-150 EK401 Bracket...
  • Page 52 Owner's Guide Parts List Part # Item # Description 110U, 310U and T-KJr2U, T-K4U 510U models and T-D2U models Surge box plate 319143-176 EK436 Gasket 319143-456 EK127 Gasket 319143-457 EK145 O-ring P18 NBR (Black) 319143-350 EZP18 O-ring P20 NBR (Black) 319143-057 EK042 Silicon ring for Outdoor models 319143-206 EKK3G Rain protection plate in Exhaust chamber for Outdoor models 319143-458 EK134 Exhaust port for Outdoor models 319143-219 EKK56...
  • Page 53 Owner's Guide Parts List Part # Item # Description 110U, 310U and T-KJr2U, T-K4U 510U models and T-D2U models Computer board for 110U (T-KJr2U) models 319143-469 EKJ6V for 310U (T-K4U) models 319143-470 EK106 for 510U (T-D2U) models 319143-471 EK149 Rubber grommet for Indoor models 319143-426 EK148 Surge box 320273-128 EK280 120 VAC wire for Indoor models 319143-427 EK146 for Outdoor models 319143-138 EKK3C Switch wire 319143-472 EK115...

  • Page 54: Output Temperature Chart

    Owner's Guide Output Temperature Chart OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line 110U (T-KJr2U) models Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature 310U (T-K4U) models Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature 510U (T-D2U) models Output Temperature vs.

  • Page 55: Limited Warranty

    Owner's Guide Warranty LIMITED WARRANTY 1. The manufacturer warrants this product against defects in materials or workmanship as described in this document if installed within the United States or Canada. The manufacturer or its authorized Service Representative will, at its sole discretion, repair or replace any failed or defective mechanical or electrical parts, or components thereof, or, if the manufacturer or its authorized Service Representative cannot replace said parts, and repair is not commercially practicable, the manufacturer or its authorized Service Representative will refund the purchase price. The manufacturer or its authorized Service Representative may, at its sole discretion, use new, refurbished or reconditioned parts.
  • Page 56 Owner's Guide Warranty •  Freeze damage that occurs without taking proper preventive measures as described in the installation manual. •  Condensate damage due to improperly installed or lack of a condensate trap (drain). •  Any product not installed in compliance with all applicable local & provincial codes, ordinances, and good trade practices. •  Any product sold to or installed in areas outside of the fifty states (and the District of Columbia) of the United States of America and Canada. •  Any product installed in applications that cause the water heater to activate more than 300 times per day. (This averages to an activation every 5 minutes in a 24-hour period.) •  Any failures that are not due to defects in materials or workmanship (mechanical and/or electrical parts). •  Damages due to improper installation: • Gas: incorrect gas pipe sizing, incorrect gas meter sizing, incorrect gas type, and/or gas pressures that fall outside the product’s specified range. • Water: incorrect water pipe sizing, water pressures that fall outside the product’s specified range, recirculation flow rates that fall outside the product’s specified range (air removal), and/or lack of proper methods of air removal in a closed-loop, circulation system. (See installation manual for details.) • Electric: supply power voltages that fall outside the product’s specified range. •  Damages due to water quality: • Introduction of liquids other than potable water or potable water / glycol mixtures into the product. • Introduction of pool water, spa water, or any chemically treated water into the product. • Introduction of hard water measuring more than 7 grains per gallon (120 ppm) for single family domestic applications or more than 4 grains per gallon (70 ppm) for all other types of applications into the product. • Introduction of untreated or poorly treated well water into the product. • Introduction of water with pH levels less than 6.5 and greater than 8.5 into the product. 60Z101-2 Page...

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