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On-Demand Water Heater
Installation Manual and Owner's Guide
ANSI Z21.10.3 ・ CSA 4.3
110U Indoor (AT-KJr3U-IN)
•
310U Indoor (AT-K5U-IN)
•
510U Indoor (AT-D3U-IN)
•
Gas Tankless Water Heater
Suitable for combination 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
• Complies with SCAQMD Rule
1146.2 for NOx emissions require-
ment of 14 ng/J or 20 ppm
• FIELD GAS CONVERTIBLE
• EASY-LINK SYSTEM AND
MULTI-UNIT SYSTEM
(510U (AT-D3U-IN/OS) only)
510U (AT-D3U-IN/OS)
only
Models
110U Outdoor (AT-KJr3U-OS)
•
310U Outdoor (AT-K5U-OS)
•
510U Outdoor (AT-D3U-OS)
•
Series 200
WARNING
- Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch, do not
TM
use any phone in your building.
• Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
If you have any questions, please
500 Tennessee Waltz Parkway
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
call or write to:
Ashland City, TN 37015
Toll Free: 1-877-737-2840
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Summary of Contents for Takagi AT-KJr3U-IN
- Page 1 On-Demand Water Heater Installation Manual and Owner’s Guide 510U (AT-D3U-IN/OS) ANSI Z21.10.3 ・ CSA 4.3 only Models 110U Outdoor (AT-KJr3U-OS) 110U Indoor (AT-KJr3U-IN) • • 310U Outdoor (AT-K5U-OS) 310U Indoor (AT-K5U-IN) • • 510U Outdoor (AT-D3U-OS) 510U Indoor (AT-D3U-IN) •...
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Page 2: Table Of Contents
Contents CONTENTS Owner's Guide Installation Manual OPERATING SAFETY ........39 SPECIFICATIONS ..........4 INTRODUCTION ..........5 NORMAL OPERATION ........41 SAFETY GUIDELINES........6 BUILT-IN CONTROLLER SAFETY DEFINITION ........6 AND REMOTE CONTROLLER ....41 GENERAL ............6 GENERAL ............41 INSTALLATION ..........7 TEMPERATURE SETTINGS ......42 GENERAL ............7 TEMPERATURE SETTINGS ON THE PCB ..44 CLEARANCES ..........9 FLOW ............ -
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 installation manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor. -
Page 4: Specifications
Installation Manual Specifications SPECIFICATIONS 110U 110U 310U 310U 510U 510U Indoor Outdoor Indoor Outdoor Indoor Outdoor Model (AT-KJr3U- (AT-KJr3U- (AT-K5U- (AT-K5U- (AT-D3U- (AT-D3U- 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"... -
Page 5: Introduction
• This appliance is an on-demand, tankless water heater. It is designed to efficiently supply endless hot water for your needs. • The 110U Indoor (AT-KJr3U-IN), 310U Indoor (AT-K5U-IN) and 510U Indoor (AT-D3U-IN) models are only to be installed indoors. The 110U Outdoor (AT-KJr3U-OS), 310U Outdoor (AT-K5U-OS) and 510U Outdoor (AT-D3U-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. -
Page 7: Installation
Direct Venting is recommended. 9. For 110U Indoor (AT-KJr3U-IN), 310U Indoor (AT-K5U-IN) and 510U Indoor (AT-D3U-IN) models: • If the water heater is used as a direct-vent appliance, the unit requires a 3 in. (76 mm) combustible air supply pipe. - 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. • The installer (licensed professional) is responsible for the correct installation of WARNING the water heater and for compliance with all national, state / provincial, and local codes.
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Page 9: Clearances
Side Maintain all clearances around the water heater. Front Side Bottom Model Bottom Front Back Sides 110U Indoor (AT-KJr3U-IN)* 12 in. 12 in. 4 in.** 1.0 in. 3 in. 310U Indoor (AT-K5U-IN)* (305 mm) (305 mm) (102 mm) (25 mm) - Page 10 Installation Manual Installation 1. 4” Backflow preventer and Female-female adaptor It prevents the backflow of air through the exhaust vent. This helps prevent harmful exhaust gases from entering the home, as well as helping to prevent the unit from freezing in areas where cold air can be blown or drawn into the exhaust system.
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Page 11: Warning For Installations
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 water heater in a pit or location where gas and warranty. -
Page 12: High-Altitude Installations
No. 3 : OFF No. 4 : OFF No. 4 : ON No. 4 : ON NOTE: The dark squares indicate the correct DIP switch positions. 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) 510U (AT-D3U-IN/OS) Computer board Computer board Lower bank of DIP switches... -
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 from carbon monoxide and flue gases poisoning. - Page 14 • A condensate collector is required for horizontal and/or vertical vent runs exceeding 5 ft. of equivalent length (not including sidewall terminatons). • A backflow preventor should be installed in the exhaust when the heater is installed in climates subject to freezing temperatures. General rules for vent terminations: •...
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Page 15: Combustion Air Supply
-Combustion Air Supply- • This gas water heater requires an adequate source of clean air for combustion and ventilation. Without sufficient air, your water heater may not operate properly and may emit excessive and abnormal amounts of carbon monoxide WARNING which may result in carbon monoxide poisoning or death. - Page 16 Calculate the air volume of the room Air requirements depend on the size of the room. Room Volume (ft. ) = Floor Area (ft. ) X Ceiling Height (ft.) If there are large objects in the room (e.g., refrigerator, furnace, car), subtract their volume from the vol- ume of the room to get a better estimate of the air available.
- Page 17 Calculate minimum size of vent openings and ducts The vent cross-sectional area needed to provide the free area depends on the covering on the vent openings. Typical vents use louvers or grilles to protect the opening. The louver or grill itself blocks some of the free area, so the open- ing may need to be larger to meet the minimum free area requirements.
- Page 18 Combustion Air Supply Options Gable vent to outdoors Install above insulation 12” maximum Outlet air to Confined attic 1 in Space 4,000 btu/h Two permanent Openings Confined Alternate 1 in Space Inlet air from Air Inlet the crawl space 4,000 btu/h 12”...
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Page 19: Vent Length And No. Of Elbows
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). -
Page 20: Dip Switch Settings For Vent Length
• Vent kit of 9008900005 (page 22) • Outdoor Installation (page 22) Single Pipe with Room-Air Intake DIP switch settings for single pipe with room-air intake 110U Indoor (AT-KJr3U-IN) 510U Indoor (AT-D3U-IN) Vent length 310U Indoor (AT-K5U-IN) (Upper bank of DIP switches) No. - Page 21 Installation Manual Installation Two-Pipe, Direct-Vent Installation Examples DIP switch settings for direct vent installation 110U Indoor (AT-KJr3U-IN) 510U Indoor (AT-D3U-IN) Vent length 310U Indoor (AT-K5U-IN) (Upper bank of DIP switches) No. 3 : O N No. 6 : O N...
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Page 22: Outdoor Installation
Installation Manual Installation Horizontal Installation with the 9008900005 vent kit For the Direct vent kit of 9008900005, set the following DIP switch settings. 110U Indoor (AT-KJr3U-IN) 510U Indoor (AT-D3U-IN) Vent length 310U Indoor (AT-K5U-IN) (Upper bank of DIP switches) No. 6 : O N No. -
Page 23: Clearances For Sidewall Terminations
Installation Manual Installation -Clearances for sidewall terminations- For direct-vent sidewall terminations that use two separate penetrations for the intake and exhaust, comply with the minimum clearances shown in the diagrams below. Exhaust Exhaust Intake Intake <Case 1> 0.4 ft. (130 mm) min. -
Page 24: Clearances For Multiple Sidewall Terminations
Installation Manual Installation -Clearances for multiple sidewall terminations- For multiple sidewall exhaust terminations (e.g. multi- unit systems), an exhaust termination must be at least 1 ft. (305mm) away from another exhaust termination. An 1ft. (305 mm) exhaust termination must also be at least 2 ft. (610 mm) min. -
Page 25: 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 bal- 1 foot 1 foot 1 foot... -
Page 26: Gas Supply And Gas Pipe Sizing
Installation Manual Installation GAS SUPPLY AND GAS PIPE SIZING -General- • Do not use this water heater with any gas other than the one listed on the rating plate unless the water heater has been properly converted. • Ensure that any and all gas regulators used are operating properly and providing gas pressures within the specified range shown below. -
Page 27: Natural Gas Supply Piping
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, 190 Cubic ft./hr for 310U, and 199 Cubic ft./hr for the 510U model. -
Page 28: Measuring Inlet Gas Pressure
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 to the OFF position. WARNING The water heater cannot perform properly without sufficient inlet gas pressure. -
Page 29: 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. •... -
Page 30: Temperature Remote Controller
Installation Manual Installation TEMPERATURE REMOTE CONTROLLER -Included Accessories-Outdoor models only- 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 9009069005 (TM-RE42) It is also an optional accessory as a second remote for the indoor models. The optional remote con- troller doesn't come with the remote cable. - Page 31 (No polarity) * Do NOT jump or short-circuit the wires, or the computer will be damaged. 6. Replace the water heater's front cover securely. Fig. E-2 Fig. E-1 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) 510U (AT-D3U-IN/OS) 9009069005 (TM-RE42) 9009069005...
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Page 32: Easy-Link System
Installation Manual Installation EASY-LINK SYSTEM Available on the 510U (AT-D3U-IN/OS) model only -General- The 510U (AT-D3U-IN/OS) model water heaters can be connected with other allowable heaters (see the table below) with communication cables to work as a multiple-unit manifold system. •... - Page 33 Installation Manual Installation 7. 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. 8. Verify that all cables are connected like the diagram (B). 9. Turn on power to the “PARENT” unit. Next, turn on “CHILD-1”.
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Page 34: Multi-Unit System
Installation Manual Installation MULTI-UNIT SYSTEM Multiple 510U (AT-D3U-IN/OS) models can be combined for a Multi-Unit System, along with the multi-unit controller (Part 9008300005 (TM-MC02)). Each multi-unit controller can control from 2 to 20 units for commercial or residential applications. For a 20-unit system, the computer can modulate from 15,000 BTU/h to 3.98 million BTU/h. -
Page 35: Applications
Applications APPLICATIONS SPACE-HEATING APPLICATIONS • This water heater is suitable for combination water (potable) heating and space heating and not suitable for space heating applications only. • 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. -
Page 36: Dual-Purpose Hot Water Heating
Installation Manual Installation DUAL-PURPOSE HOT WATER HEATING (Domestic and Space Heating): Diagrammatic layout of radiant heating and domestic water heater per Massachusetts code. All water piping should be insulated in accordance with 780 CMR 3" intake and 4" vent (Massachusetts energy code) (Discharge must comply with local and Cold water supply... -
Page 37: Initial Operation
Installation Manual Initial operation INITIAL OPERATION FOR YOUR SAFETY, READ BEFORE OPERATING • Check the GAS and WATER CONNECTIONS for leaks before firing the 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. -
Page 38: 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 owner's guide carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor. -
Page 39: 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 appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. - Page 40 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. Do not install water heater where flammable products will be stored or used unless the main burner is at least 18”...
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Page 41: Normal Operation
Owner's Guide Normal Operation NORMAL OPERATION BUILT-IN CONTROLLER and REMOTE CONTROLLER The illustrations below show examples of the displays of the controller. The exact display may differ from examples. Built-in controller Remote controller Display for Temperature "INFO" Button When the STAND BY LED is ON, the hot water temperature will be Each time the button is pressed, displayed. -
Page 42: Temperature Settings
160 °F (70 °C). -Temperature table of controller- Following are the temperature set points that are available with your built-in controller or remote controller: a) For 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) °F 100 105 110 115 120* 125 130 135 140 °C b) For 510U (AT-D3U-IN/OS) °F... - Page 43 Owner's Guide Normal Operation -Additional features- Information mode You can get some information about the water heater's condition by pressing the "INFO" button. For more information, follow the procedures below: Screen on the controller INFO Operation Button Built-in controller Remote controller Inlet water temperature will be displayed on 1st.
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Page 44: Temperature Settings On The Pcb
NOTE: The tables above show the correct DIP switch position for each temperature setting. (Each black square represents a switch.) For the 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U- IN/OS), only adjust DIP switch No. 9. For the 510U (AT-D3U-IN/OS), only adjust DIP switch No. -
Page 45: 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 model, 8.0 GPM (30 L/min) for the 310U model, GPM (US) L/min and 10.0 GPM (38 L/min) for the 510U model. -
Page 46: 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" on this page.) •... -
Page 47: Troubleshooting
Owner's Guide Troubleshooting TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS It takes a 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. - Page 48 Owner's Guide Troubleshooting PROBLEM SOLUTIONS Unit does not ignite • Is the flow rate over 0.5 GPM (1.9 L/min)? (p. 41) when water goes • Check the filter on the cold water inlet. (p. 46) through the unit. • Check for reverse connection and cross connection. •...
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Page 49: Error Codes
Owner's Guide Troubleshooting ERROR CODES -General- • The units have self-diagnostic functions 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 built-in controller or remote controller. •... - Page 50 -For the 510U (AT-D3U-IN/OS) model in an Easy-Link System- Error codes will be displayed differently with units installed within an Easy-Link System, not only to show what the error code is, but to also indicate which unit within the system has the error code. Below is a sample of how the error code of "321"...
- Page 51 Owner's Guide Troubleshooting -Fault Analysis of Error Codes- If the error code is displayed on the computer board of the water heater or the controller, please check the following. After checking, consult with the manufacturer. Green Malfunction Remote Diagnosis description One Flash Incorrect DIP switch •...
- Page 52 Owner's Guide Troubleshooting Green Malfunction Remote Diagnosis description Six Flashes Abnormal main gas • Check for connection/breakage of wires (Part #708) and/ solenoid valve or burn marks on the computer board (Part #701). Six Flashes Abnormal gas • Check for connection/breakage of wires (Part #714) and/ solenoid valve or burn marks on the computer board (Part #701).
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Page 53: Components Diagram
Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly Built-in temperature controller Page... - Page 54 Owner's Guide Components Diagram Computer board assembly 110U (AT-KJr3U-IN/OS) and 510U (AT-D3U-IN/OS) 310U (AT-K5U-IN/OS) Surge box assembly Page...
- Page 55 Owner's Guide Components Diagram Burner assembly Burner assembly Manifold assembly 510U (AT-D3U-IN/OS) Exhaust section (Outdoor model) LP Conversion Kit Page...
- Page 56 Owner's Guide Components Diagram Water Way assembly To Water inlet section Bypass section 510U (AT-D3U-IN/OS) To Water outlet section 110U 310U (AT-KJr3U AT-K5U-IN/OS) 459 454 To Water inlet section 510U (AT-D3U-IN/OS) To Water outlet section 510U (AT-D3U-IN/OS) Water outlet section Water inlet section Page...
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Page 57: Parts List
Owner's Guide Parts List PARTS LIST Part # AT-KJr3U-IN/OS, Item # Description 110U, 310U and AT-K5U-IN/OS and 510U models AT-D3U-IN/OS Case assembly for Indoor models EK596 for Outdoor models EK597 Front cover for Indoor models EK598 for Outdoor models EK599... - Page 58 Water inlet 319143-193 EKK1U Inlet drain plug 319143-197 EKK2B Inlet water filter 319143-198 EKK2C Inlet thermistor for 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) 319143-214 EKK4J Inlet thermistor for 510U (AT-D3U-IN/OS) 319143-572 EK573 Outlet thermistor for 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) 319143-529 EK207...
- Page 59 319143-427 EK146 for Outdoor models 319143-138 EKK3C Switch wire EK614 120 VAC Power ON-OFF switch EK590 Remote controller wire for 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) 319143-490 EK189 for 510U (AT-D3U-IN/OS) 319143-491 EK165 Gas valve wire EK585 Flame rod wire EK586...
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Page 60: Output Temperature Chart
Owner's Guide Output Temperature Chart OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line 110U (AT-KJr3U-IN/OS) Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature Set Temp. (°F) 310U (AT-K5U-IN/OS) Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature Set Temp. -
Page 61: Limited Warranty
(3) In all applications, the total of length of operation time must be less than 3,000 hours for the 110U (AT-KJr3U-IN/OS) and 310U (AT-K5U-IN/OS) models, and less than 9,000 hours for the 510U (AT-D3U-IN/OS) model. (4) Includes dual-purpose applications (combination heating and domestic) 3. - Page 62 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.
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