Takagi T-KJr2-IN Installation Manual And Owner's Manual
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Takagi T-KJr2-IN Installation Manual And Owner's Manual

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See also: Installation Instructions & Owner's Manual
On-Demand Water Heater
Installation Manual and Owner's Guide
510 (T-D2) models
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
EASY-LINK SYSTEM
510 (T-D2) models only
ANSI Z21.10.3 and CSA 4.3
・110 Indoor (T-KJr2-IN) ・110 Outdoor (T-KJr2-OS)
・310 Indoor (T-K4-IN)
・510 Indoor (T-D2-IN)
only
Models
・310 Outdoor (T-K4-OS)
・510 Outdoor (T-D2-OS)
If the information in these
instructions is not followed
exactly, a fire or explosion
WARNING
may result causing
property damage, personal injury or death.
-Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
-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.
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
call or write to:
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free: 1- 877-737-2840
Follow
the
gas

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  • Page 1 On-Demand Water Heater Installation Manual and Owner’s Guide ANSI Z21.10.3 and CSA 4.3 Models ・110 Indoor (T-KJr2-IN) ・110 Outdoor (T-KJr2-OS) ・310 Indoor (T-K4-IN) ・310 Outdoor (T-K4-OS) ・510 Indoor (T-D2-IN) ・510 Outdoor (T-D2-OS) 510 (T-D2) models only If the information in these...

  • Page 2: Table Of Contents

    Contents CONTENTS Installation Manual SPECIFICATIONS…………………………………………………………………………………………..………………………... INTRODUCTION…………………………………………………………………………………………………..…………………. SAFETY GUIDELINES…………….………………………………………………………………………………………..……….. INSTALLATION………………………………………………………………………………………………..…………………..…. General………………………………………………………………………………………………………………………..…..… Clearances…………………………………………………………………………………………………………………………… Included Accessories…………….………………………………………………………………………………………..….. Optional Items…………………………………………………………………………………………………………………….. High-Altitude Installations……………………………………………………………………………………………………. Venting Instructions…………………………………………………………………………………………………………….. Gas Supply and Gas Pipe Sizing………..................… Water Connections……………..…………………………………………………………………………………………….… Electrical Connections……………………………………………………………………..……………………………..Remote Controller Connections……..………………………………………………………………………………….… Pump Control Connections…………………………………………..………..………..…………………………………… Easy-Link System...…………………………..…………………………………………………………………………..…..APPLICATIONS...……………………………………………………………………………………………………………………… INITIAL OPERATION..………………………………………………………………………………………………………….…… Owner’s Guide OPERATING SAFETY…………………………………………………………………………………………………………………...

  • Page 3: Specifications

    Specifications SPECIFICATIONS Outdoor Indoor Outdoor Model Indoor Outdoor Indoor (T-KJr2-IN) (T-KJr2-OS) (T-K4-IN) (T-K4-OS) (T-D2-IN) (T-D2-OS) Natural Gas Input Min: 19,500 Btu/h Min: 11,000 Btu/h Min: 11,000 Btu/h (Operating Range) Max: 140,000 Btu/h Max: 190,000 Btu/h Max: 199,000 Btu/h Propane Input...

  • Page 4: Introduction

    This equipment is an on-demand, tankless water heater designed to efficiently supply endless hot water for your needs. The 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models are to be only installed indoor (direct-vent convertible). The 110 Outdoor (T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS) models are to be only installed outdoor.

  • Page 5: Safety Guidelines

    Safety Guidelines SAFETY GUIDELINES SAFETY DEFINITIONS 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 6: Installation

    10. For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models: These units may be converted to a direct-vent (sealed combustion) appliance by installing a direct-vent conversion kit Part No.
  • Page 7 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 8: Clearances

    Installation CLEARANCES Maintain all clearances around the water heater. Back Side Side Front Bottom Model Bottom Front Back Sides 110 Indoor* (T-KJr2-IN)* 12” 12” 24” 1” 2 “ 110 Outdoor (T-KJr2-OS) 36” 12” 24” 1” 2 “ Model Bottom Front...

  • Page 9: Optional Items

    Installation OPTIONAL ITEMS 110 Indoor 110 Outdoor 310 Indoor 310 Outdoor 510 Indoor 510 Outdoor Model (T-KJr2-IN) (T-KJr2-OS) (T-K4-IN) (T-K4-OS) (T-D2-IN) (T-D2-OS) 9007666005 ✔ ✔ ✔ ✔ (TK-RE02) 9007603005 ✔ ✔ (TM-RE30) 9007678005 ✔ ✔ ✔ (TK-BF01) 9007667005 ✔ ✔...
  • Page 10 Installation 5. Pipe Covers: 9007670005 (TK-PC01) and 6. Recess box: 9007674005 (TK-RB02) 9007671005 (TK-PCJr2) The Recess box will allow for The pipe cover protects “clean” installations. The water plumbing pipes to the water heater heater fits inside the recess box, from unexpected adjustments.

  • Page 11: High-Altitude Installations

    Installation HIGH-ALTITUDE INSTALLATIONS Check the elevation where your water heater is installed. Set dipswitches shown in the table below depending on the altitude. 110 (T-KJr2) and 310 (T-K4) models 0 to 2,000 ft Altitude 2,000 to 4,000 ft 4,000 to 6,000 ft Over 6,000 ft (DEFAULT) Switch No.3...

  • Page 12: Venting Instructions

    CAN/CSA B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local building codes. The manufacturer recommends the “T-Vent” line manufactured by TAKAGI (Refer to “T-Vent” brochure for details). However, the following are also UL listed manufacturers: ProTech Systems Inc.

  • Page 13: Exhaust Venting

    Installation -Exhaust venting- For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models This is a Category III appliance and must be vented accordingly. The vent system must be sealed air tight. 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.
  • Page 14 Installation Horizontal Installation Diagram Vertical Installation Diagram (With direct-venting) (With direct-venting) Rain Cap Wall Roof Roof Flashing Sidewall Vent Terminator Backflow Fire stop Preventer * Vertical Condensation Drain** Backflow Preventer * Vertical Condensation See the picture below for detailed connection Drain** instructions to the Direct-Vent Conversion Kit.

  • Page 15: Vent Termination Clearances

    Installation -Vent termination clearances- Canada U.S.A Direct vent and other than Direct Direct vent Other than Direct Vent Vent Clearance above grade, veranda, porch, deck, 1 foot 1 foot 1 foot or balcony. 4 feet from below or side Clearance to window or door that may be 3 feet 1 foot opening.
  • Page 16 Installation Please follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the following clearances can be used as guidelines. Local codes supersede these guidelines. CAUTION For sidewall terminations 2ft. 3ft. 1ft. 2ft.

  • Page 17: Gas Supply And Gas Pipe Sizing

    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 WARNING inlet pressure may cause serious accidents.
  • Page 18 Installation -Natural Gas Supply Piping- Maximum Delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe Carrying Natural Gas of 0.60 Specific Gravity Based on Pressure Drop of 0.5” WC Based on Energy Content of 1,000 BTU/Cubic Ft.: The water heater requires 140 Cubic Ft./hr for the 110 (T-KJr2) models, 190 Cubic Ft./hr for the 310 (T-K4) models, and 199 Cubic Ft./hr for the 510 (T-D2) models.
  • Page 19 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 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.

  • Page 20: Water Connections

    Installation WATER CONNECTIONS Do not use this water heater if any part has been submersed under water. Immediately call a licensed professional to inspect the water heater to replace any damaged parts. Do not reverse the hot outlet and cold inlet connections to the water heater. CAUTION This will not properly activate the water heater.

  • Page 21: Electrical Connections

    Installation ELECTRICAL CONNECTIONS Follow the electrical code requirements of the local authority having jurisdiction. 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 WARNING CSA C22.1 Canadian Electrical Code, Part 1, in Canada.

  • Page 22: Remote Controller Connections

    Installation REMOTE CONTROLLER CONNECTIONS <How to connect the remote controller to the water heater> Disconnect power supply from the water heater. Take off the water heater’s front cover. Locate the remote controller terminal, pictured below (located around the lower right-hand side of the computer board).

  • Page 23: Pump Control Connections

    Installation PUMP CONTROL CONNECTIONS Available on the 510 (T-D2) models only The 510 (T-D2) models water heaters can be used to control a recirculation pump. Proper pump control helps to preserve the life of the system and saves energy as well. The water heater pump control port is a “normally open dry contact”, and therefore needs additional components to properly control a recirculation pump.

  • Page 24: Easy-Link System

    Installation EASY-LINK SYSTEM Available on the 510 (T-D2) models only -General- can be connected with other heaters of the same model 510 (T-D2) models water heaters 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 510 (T-D2) models.

  • Page 25: Computer Board

    Installation 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.
  • Page 26 Installation A remote controller is not required for the Easy-Link system. NOTICE If running the Easy-Link system without a remote controller, please make sure the temperature settings on ALL the units are set to the same settings. Otherwise, the units will not operate properly. 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.
  • Page 27 Installation CASE 3: 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 C o n n e c to r s...

  • Page 28: Applications

    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 to the system. Required circulation flow rates are labeled next to each application diagram. These flow rate requirements must be followed.

  • Page 29: Dual-Purpose Hot Water Heating

    Relief Valve, Tie to Location Local Codes and Must Meet BTU Cold Inlet approved by Local Codes and Rating of water heater Model Used Must Meet BTU Rating of Takagi Check Valve Will Model Used Have 1/8" Hole in Apply Correct 4"...

  • Page 30: Initial Operation

    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.

  • Page 31: Operating Safety

    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.
  • Page 32 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.

  • Page 33: Normal Operation

    Normal Operation NORMAL OPERATION GENERAL Hot Water temperatures over 125 F (52°C) can cause severe burns instantly or death from scalding. The outlet hot water temperature of the water heater is factory WARNING set at 122°F (50°C). Feel the water temperature before bathing or showering. Flow rate to activate the water heater : 0.5 gallons per minute at the NOTICE...
  • Page 34 Normal Operation -Dipswitch settings for each temperature on the computer board- 110 (T-KJr2) and 310 (T-K4) models Temperature Settings 122 F 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 113 F 131 F...

  • Page 35: Flow

    The freeze protection system will activate when the surrounding and/or outside temperatures drop below 36.5°F (2.5°C). For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models: In any areas subject to freezing temperatures, the manufacturer highly recommends an indoor installation with an indoor model.

  • Page 36: Maintenance And Service

    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 diagram below) 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.

  • Page 37: Troubleshooting

    Troubleshooting TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS It takes long time to get The time it takes to deliver hot water from the water heater to hot water at the your fixtures depends on the length of piping between the two. fixtures. The longer the distance or the bigger the pipes, the longer it will take to get hot water.
  • Page 38 Troubleshooting PROBLEM SOLUTIONS Unit does not ignite when Is the flow rate over 0.5 GPM? (p. 33) water goes through the unit. Check for the filter on cold water inlet. (p. 36) 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.

  • Page 39: Error Codes

    Troubleshooting ERROR CODES The units are self diagnostic for safety and convenience when trouble shooting. If there is a problem with the installation or the unit, depending on the model or if there is a remote controller installed, it will either display a numerical error code on the 7-Seg LED on the computer board (for the 510 (T-D2) models only), display a blinking red LED (for the 110 (T-KJr2) and 310 (T-K4) models), or the error code will display on the remote controller if it is installed.
  • Page 40 Troubleshooting -FAULT ANALYSIS OF ERROR CODES- If the error code displayed on the computer board of the Water heater or remote controller, please check the following. After checking, Consult with the manufacturer. 110 (T-KJr2) and 310 (T-K4) (T-D2) Malfunction Diagnosis description Remote Remote Incorrect...
  • Page 41 Troubleshooting 110 (T-KJr2) and 310 (T-K4) Malfunction (T-D2) Diagnosis description Remote Remote Flow Sensor Check for connection/breakage of wires and/or debris Failure (Easy-Link on the flow sensor impeller. (Part #402, 717) System only) Abnormal Gas Check for connection/breakage of wires (Part #708) Solenoid Valve and/or burn marks on the computer board (Part Times...

  • Page 42: Components Diagram

    Components Diagram COMPONENTS DIAGRAM Case assembly 110 Indoor (T-KJr2-IN) 110 Outdoor (T-KJr2-OS) 0 5 2 0 0 3 0 5 2 0 5 2 0 0 4 0 0 4 0 0 7 0 0 7 0 5 3 0 5 2...

  • Page 43: Burner Assembly

    7 1 3 0 5 3 1 1 5 1 0 2 110 Indoor (T-KJr2-IN) only O n l y T - K J r 2 - I N 0 6 1 0 5 3 0 6 7 1 1 9...
  • Page 44 Components Diagram 310 (T-K4) models and 510 (T-D2) models Burner assembly 1 0 1 1 0 1 1 0 7 1 0 6 1 0 5 1 0 8 0 6 5 1 0 4 7 0 9 7 0 9 1 0 9 1 1 0 1 1 1...

  • Page 45: Water Way Assembly

    Components Diagram Computer 110 (T-KJr2) and 510 (T-D2) models 310 (T-K4) models board 7 1 0 7 01 Assembly 1 0 3 7 01 7 0 7 7 0 8 7 1 7 7 1 8 7 1 0 1 03 7 0 7 7 0 9 7 0 8...

  • Page 46: Output Temperature Chart

    310 Outdoor (T-K4-OS) 319143-371 EK409 for 510 Indoor (T-D2-IN) 319143-174 EK434 for 510 Outdoor (T-D2-OS) 319143-175 EK435 Air blockage plate for 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) 319143-150 EK401 and 510 Indoor (T-D2-IN) Bracket 319143-184 EKJ09 Junction box 319143-014...
  • Page 47 Rain protection plate in Exhaust chamber for 110 Outdoor 319143-216 EKK53 (T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS) Exhaust port 319143-219 EKK56 Heat exchanger assembly for 110 Indoor (T-KJr2-IN) 319143-162 EK418 for 110 Outdoor (T-KJr2-OS) 319143-166 EK426 for 310 Indoor (T-K4-IN)
  • Page 48 310 (T-K4) models 319143-208 EKK3L for 510 (T-D2) models 319143-189 EKK11 EH-IG wire for 110 Indoor (T-KJr2-IN) and 310 Indoor (T-K4-IN) 319143-209 EKK3R EH-IG wire with freeze protection thermostat for 110 Outdoor 319143-210 EKK40 (T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS)

  • Page 49: Output Temperature Chart

    Part# Item# Description 110, 310, T-KJr2, T-K4, 510 models T-D2 models Freeze protection thermostat for 110 Indoor (T-KJr2-IN), 319143-185 EKJ59 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) Proportional gas valve wire for 110 (T-KJr2) and 310 (T-K4) models 319143-220 EKK58...
  • Page 50 Output Temperature Chart 310 (T-K4) models Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature 10.0 40 F 50 F 60 F 70 F 40 F 50 F 60 F 70 F 510 (T-D2) models Output Temperature vs. GPM (Max. 10.0 GPM) with Various Inlet Water Temperature 12.0 40 F 50 F...

  • Page 51: Limited Warranty

    Warranty LIMITED WARRANTY 1. General terms of limited warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from State to State. The manufacturer will honor the warranty to the original retail buyer at the original location only, and it is not transferable. 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.
  • Page 52 Warranty (3) Limited Labor Coverage The manufacturer will provide for reasonable labor charges associated with warranty repairs or replacements within one (1) year from the date of purchase. The manufacturer will only pay directly to the service provider. Warranty service must be performed by an authorized Service Representative. A list of authorized Service Representatives is available upon request.

This manual is also suitable for:

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