Takagi 110 Indoor (T-KJr2-IN) Installation Manual And Owner's Manual
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Takagi 110 Indoor (T-KJr2-IN) Installation Manual And Owner's Manual

On-demand water heater
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On-Demand Water Heater
Installation Manual and Owner's Guide
ANSI Z21.10.3 and CSA 4.3
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) model only)
510 (T-D2)
model only
110 Indoor (T-KJr2-IN)
•
310 Indoor (T-K4-IN)
•
510 Indoor (T-D2-IN)
•
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
• Immediately call your gas supplier from
TM
• If you cannot reach your gas supplier, call
- Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
If you have any questions, please
Models
110 Outdoor (T-KJr2-OS)
•
310 Outdoor (T-K4-OS)
•
510 Outdoor (T-D2-OS)
•
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
use any phone in your building.
a neighbor's phone. Follow the gas
supplier's instructions.
the fire department.
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 110 Indoor (T-KJr2-IN)

  • Page 1 On-Demand Water Heater Installation Manual and Owner’s Guide 510 (T-D2) model only ANSI Z21.10.3 and CSA 4.3 Models 110 Outdoor (T-KJr2-OS) 110 Indoor (T-KJr2-IN) • • 310 Indoor (T-K4-IN) 310 Outdoor (T-K4-OS) • • 510 Indoor (T-D2-IN) 510 Outdoor (T-D2-OS) • • 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 　　Warning for installations......................9 　　Clearances..........................10 　　Included accessories......................10 　　Optional items........................10 　　High-altitude installations......................12 　　Venting instructions.......................13 　　Gas supply and gas pipe sizing....................18 　　Water connections........................20 　　Electrical connections......................21 　　Remote controller connections....................22 　　Pump control connections....................23 　　Easy-Link System........................24...

  • 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.

  • Page 4: Specifications

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

  • 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.

  • 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

    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, Propane 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.
  • 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: 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 heater in a pit or location where gas and water warranty.

  • Page 10: Clearances

    Installation Manual Installation CLEARANCES Back Side Maintain all clearances around Front Side the water heater. Bottom Model Bottom Front Back Sides 110 Indoor* (T-KJr2-IN)* 12 in. 12 in. 4 in.** 1 in. 3 in. 310 Indoor* (T-K4-IN)* (305 mm) (305 mm) (102 mm) (25 mm) (76 mm)
  • Page 11 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)

  • 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. 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. (DEFAULT) Switch No.

  • Page 13: Venting Instructions

    Installation Manual Installation VENTING INSTRUCTIONS -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.

  • Page 14: Exhaust Venting

    Installation Manual 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 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 15 Installation Manual Installation Venting Illustrations- For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN), and 510 Indoor (T-D2-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 Hanger...

  • 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...
  • 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 (610 mm) min. 1 ft. (305 mm) 1 ft. (305mm) away from another exhaust termination. min. An exhaust termination must also be at least 2 ft.

  • 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 110 (T-KJr2) model, 190 Cubic ft./hr for the 310 (T-K4) model, and 199 Cubic ft./hr for the 510 (T-D2) model.

  • 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.

  • Page 21: Electrical Connections

    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.

  • Page 22: Remote Controller Connections

    Installation Manual 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. Wires used for the remote controller connection must be: • Minimum 20 AWG wire (No polarity) • 9007666005 (TK-RE02) for 110 (T-KJr2) &...

  • Page 23: Pump Control Connections

    Installation Manual Installation PUMP CONTROL CONNECTIONS Available on the 510 (T-D2) model only The 510 (T-D2) model water heater 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, such as a relay.

  • Page 24: Easy-Link System

    Installation Manual Installation EASY-LINK SYSTEM (Available on the 510 (T-D2) model only) -General- The 510 (T-D2) 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. • The Easy-Link System allows up to 4 units to manifold together.
  • Page 25 Installation Manual Installation 5. 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 using the supplied linking cable. 6. Between the “CHILD-1” and the “CHILD-2” units: Connect the “2”...
  • Page 26 Installation Manual Installation • A remote controller is not required for an Easy-Link System, however, it does NOTICE provide for more temperature options and ease of maintenance. • 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.

  • Page 27: Remote Controller

    Installation Manual Installation 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.

  • Page 28: 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 29: 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 Mass. code. All water piping should be insulated in accordance with 780 CMR (Massachusetts energy code) 4-inch gas exhaust vent (Discharge must Cold water supply Automatic tempering device comply with local and...

  • Page 30: 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.

  • Page 31: 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.

  • Page 32: 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.
  • Page 33 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.

  • Page 34: Normal Operation

    Owner's Guide Normal Operation NORMAL OPERATION GENERAL • Hot water temperature above 125 °F (52 °C) can cause severe burns instantly or death from scalding. • The outlet hot water temperature of the water heater is factory set at 122 °F (50 °C). WARNING • Feel the water temperature before bathing or showering.
  • Page 35 Owner's Guide Normal Operation b) 510 (T-D2) model: 9007603005 (TM-RE30) <Set temperature> 9007603005 (TM-RE30) 1. Turn on the 120VAC power supply to the water heater. 2. Press the "ON/OFF" button on the remote to turn “HOT” “TIME” the remote controller on. It shows the time and set temperature on the display as shown to the “COLD”...
  • Page 36 Owner's Guide Normal Operation How to change to the High temperature mode 1. Turn off power to the remote controller by pressing the “ON/OFF” button. (Lamp is OFF to indicate that power is off.) 2. Simultaneously press and hold both the “HOT” and “COLD” buttons for at least 5 seconds. And then make sure “1”...
  • Page 37 • Features available only on 9007603005 (TM-RE30) <Set the time> 1. Press the "TIME" button, then press the "HOT" or the "COLD" button to set the clock time. 2. Press the "TIME" button again to save and exit. NOTE: If you want to hide the clock time, press and hold the "TIME" button for 3 seconds or longer. <Energy saving mode >...

  • Page 38: Temperature Settings On The Pcb

    Owner's Guide Normal Operation TEMPERATURE SETTINGS ON THE PCB -WITHOUT REMOTE CONTROLLER- Depending on the model, there are 4 or 8 temperatures that you can select from by changing the DIPswitch settings on the computer board without the remote controller. See the table below. 110 (T-KJr2) and 310 (T-K4) models Temperatures settings 122 °F (50 °C)

  • Page 39: Flow

    Owner's Guide Normal Operation FLOW Household Flow Rates • The flow rate through the water heater is limited to a Appliance/Use Flow rate GPM maximum of 6.6 GPM for the 110 (T-KJr2) model, 8.0 GPM Lavatory Faucet for the 310 (T-K4) model, and 10.0 GPM for the 510 (T-D2) model.

  • Page 40: 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.

  • Page 41: Troubleshooting

    Owner's Guide Troubleshooting TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS WATER CONNECTIONS 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.
  • Page 42 Owner's Guide Troubleshooting PROBLEM SOLUTIONS Unit does not ignite • Is the flow rate over 0.5 GPM? (p. 34) when water goes • Check for the filter on cold water inlet. (p. 40) 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.

  • Page 43: Error Codes

    Owner's Guide Troubleshooting ERROR CODES -General- • The water heaters have self-diagnostic function for safety and convenience when troubleshooting. • If there is a problem with the installation or the unit, the 510 (T-D2) model will display a numerical error code on the 7-Seg LED on the computer board, and the 110 (T-KJr2) and 310 (T-K4) models will display a blinking red LED on the computer board.
  • Page 44 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. 110 (T-KJr2) and 310 (T-K4) (T-D2) Malfunction Diagnosis...
  • Page 45 Owner's Guide Troubleshooting 110 (T-KJr2) and 310 (T-K4) (T-D2) Malfunction Diagnosis Remote description Remote 7 Seg LED Air-fuel ratio • Check for connection/breakage of wires (Part #709) and/ rod failure or soot on the AFR rod (Part #108). Times Flow sensor • Check for connection/breakage of wires and/or debris on failure (Easy-Link the flow sensor impeller (Part #402, 717).

  • Page 46: Components Diagram

    Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly 110 Indoor (T-KJr2-IN) 110 Outdoor (T-KJr2-OS) 310 and 510 Indoor 310 and 510 Outdoor (T-K4-IN and T-D2-IN) (T-K4-OS and T-D2-OS) Temperature remote controller 110 (T-KJr2) and 510 (T-D2) model 310 (T-K4) models Page...
  • Page 47 Owner's Guide Components Diagram Burner assembly 110 (T-KJr2) model Burner assembly Manifold Assembly 110 Indoor (T-KJr2-IN) only Page...
  • Page 48 Owner's Guide Components Diagram Burner assembly 310 (T-K4) and 510 (T-D2) models Burner assembly 310 (T-K4) model Power control section 510 (T-D2) model 310 Indoor (T-K4-IN) 510 Indoor (T-D2-IN) Manifold Fan motor section for indoor models Assembly 310 Outdoor (T-K4-OS) 510 Outdoor (T-D2-OS) Fan motor section for outdoor models Page...
  • Page 49 Owner's Guide Components Diagram Computer board assembly 110 (T-KJr2) and 510 (T-D2) model 310 (T-K4) models 402 402 714 719 408 Water Way assembly 110 (T-KJr2) model 310 (T-K4) model 510 (T-D2) model Bypass section Water outlet section Water inlet section Exhaust section (Outdoor model) Page...

  • Page 50: Parts List

    Owner's Guide Parts List PARTS LIST Part # Item # Description 110, 310 and T-KJr2, T-K4 and 510 models T-D2 models Case assembly for 110 Indoor (T-KJr2-IN) 319143-159 EK415 for 110 Outdoor (T-KJr2-OS) 319143-172 EK432 for 310 and 510 Indoor (T-K4-IN and T-D2-IN) 319143-151 EK402 for 310 and 510 Outdoor (T-K4-OS and T-D2-OS)
  • Page 51 Owner's Guide Parts List Part # Item # Description 110, 310 and T-KJr2, T-K4 and 510 models T-D2 models Flame rod for 110 (T-KJr2) model 319143-339 EX00R Flame rod for 310 (T-K4) and 510 (T-D2) models 319143-035 EKK0E Igniter rod for 110 (T-KJr2) model 319143-373 EX00S Igniter rod for 310 (T-K4) and 510 (T-D2) models...
  • Page 52 Owner's Guide Parts List Part # Item # Description 110, 310 and T-KJr2, T-K4 and 510 models T-D2 models Overheat-cut-off fuse 319143-149 EK333 Heater 319143-200 EKK2R Inlet heater 319143-078 EKK2P Pipe heater fixing plate 319143-088 EKK27 Heater fixing plate 16 319143-125 EK031 Fuse fixing plate 18...
  • Page 53 Owner's Guide Parts List Part # Item # Description 110, 310 and T-KJr2, T-K4 and 510 models T-D2 models Pump and multi cable for 510 (T-D2) model 319143-204 EKK36 Thermistors wire for 510 (T-D2) model 319143-195 EKK1Z RS-VG wire for 510 (T-D2) model 319143-203 EKK35 Water valves wire for 510 (T-D2) model...

  • Page 54: Output Temperature Chart

    Owner's Guide Output Temperature Chart OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line 110 (T-KJr2) model Output temperatue vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature Set Temp. 310 (T-K4) model Output temperatue vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature Set Temp 510 (T-D2) model 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.
  • 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.

This manual is also suitable for:

310 indoor (t-k4-in)510 indoor (t-d2-in)110 outdoor (t-kjr2-os)310 outdoor (t-k4-os)510 outdoor (t-d2-os)

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