Takagi T-KJr2U-IN Installation Manual And Owner's Manual
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Takagi T-KJr2U-IN Installation Manual And Owner's Manual

Takagi 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 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...

  • Page 2: Table Of 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 C onnections......................21 　　Temperature Remote Controller...................22 　　Easy-link S ystem........................25 　　Multi-Unit System........................29 　APPLICATIONS..........................30 　INITIAL OPERATION........................32 Owner's Guide OPERATING SAFETY ........................

  • Page 3: Installation Manual

    Installation Manual Contents 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)

  • Page 5: Introduction

    • Please read all installation instructions completely before installing this product. • If you have any problems or questions regarding this equipment, consult with 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 to be installed indoor (direct-vent convertible). The 110U Outdoor (T-KJr2U-OS), 310U Outdoor (T-K4U-OS) and 510U Outdoor (T-D2U-OS) models are to be only installed outdoor. • The principle behind tankless water heaters is simple: Exhaust vent collar Burners Heat exchanger...

  • 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 Canada 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

    7. Do not install the unit where the exhaust vent is pointing into any opening in a building or where the noise may disturb your neighbors. Make sure the vent termination meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building (refer to p. 14). 8. Particles from flour, aerosols, and other contaminants may clog the air vent or reduce the functions of the rotating fan and cause improper burning of the gas. Regularly ensure that the area around the unit is dust- or debris-free; regular maintenance is recommended for these types of environment. 9. If you will be installing the water heater in a contaminated area with a high level of dust, sand, flour, aerosols or other contaminants/chemicals, they can become airborne and enter and build up within the fan and burner causing damage to the water heater. 10. For the 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models: • These units may be converted to a direct-vent (sealed combustion) appliance by installing a direct-vent conversion kit Part No. 9007667005 (TK-TV10) which will bring in all required combustible air from outside the building. When installing the direct-vent conversion kit, please follow all instructions included with the kit. • If the water heater is used as a direct-vent appliance, the unit requires a 3 in. (76 mm) combustible air supply pipe. The intake pipe must be sealed airtight. Air supply pipe can be made of ABS, PVC, galvanized steel, corrugated aluminum, corrugated stainless steel or Category III stainless steel. • Terminating the venting through a sidewall is recommended for the direct-vent system. • Running the exhaust vent and the intake pipe parallel is recommended.
  • 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 Black 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)
  • Page 10 Installation Manual Installation 1. Backflow Preventer: 9007678005 (TK-BF01) 2. Direct-Vent Conversion Kit: 9007667005 (TK-TV10) The Backflow preventer prevents the backflow of air through the exhaust vent. This helps prevent This kit can be used to convert the water harmful exhaust gases from entering the home, as heater from a standard vent system to a direct- well as helping to prevent the unit from freezing in vent (or sealed combustion) system. Install areas where cold air can be blown or drawn into this conversion kit in accordance with the the exhaust system. Install this vent damper in...
  • Page 11 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 with in 3 ft. (914 mm) open to three sides. (Outdoor models only) in Canada of any air intake or building opening.

  • 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 1 2 3 4 5 6 7 8 9 10...

  • Page 13: Venting Instructions

    CAUTION applicable national and local codes. The water heater must be vented in accordance with the section “Venting of Equipment" of the latest edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 7 of the CAN/CSA B149.1 Natural Gas 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. (FasNSeal), Flex-L Inc., Z-Flex Inc. (Z-Vent III), Metal-Fab Inc., and Heat-Fab Inc. (Saf-T Vent). General rules for venting water heaters are: • Place the water heater as close as possible to the vent terminator. • The vent collar of the water heater must be fastened directly to an unobstructed vent pipe.
  • Page 14 45 ft. (13.7 m) 40 ft. (12.2 m) 25 ft. (7.6 m) Excludes elbow termination, rain caps, or the 4 in. (102 mm) PVC Concentric Termination -DIPswitch settings for Direct Vent models- Set DIPswitches shown in the table below depending on the vent length. 110U Direct vent (T-KJr2U-IN) 510U Direct vent (T-D2U-IN) Vent length 310 Direct vent (T-K4U-IN) (Upper bank of DIPswitches) ON 1 2 3 4 5 6 7 8 9 10...
  • 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 Diagram Horizontal Installation Diagram Rain Cap Wall Roof Flashing Roof Backflow Preventer* Sidewall Vent Terminator Backflow Preventer* Vertical Condensation Drain** Vertical Condensation Drain** Horizontal Installation Diagram...

  • 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 1 ft. (610 mm) (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.

  • 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 supply gas line. 2. Remove the screw for the pressure port located on the gas inlet of the water heater shown in the diagram 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: Electrical Connections

    Installation Manual Installation -Pressure relief valve- The water heater has a high-temperature shut off 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 code. • 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. • Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in. (150 mm) from the floor. This discharge tube must allow free and complete drainage without any restrictions.

  • 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. (122m) <Mounting and Wiring the Remote Controller> 1.  Take off the “Back plate” from the remote controller with a flat head screwdriver. (Fig.
  • Page 23 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. 6. Connect the "Remote controller cable" to the remote controller terminal on the computer board. See p.22 for details. 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 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 18AWG wire (No polarity) • Maximum 400 ft. (122m) 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) models. You can manifold from 2 to 4 units without the need for a multi-system controller. A 4-unit system has full automatic modulation between 15,000 BTU/h and 796,000 BTU/h. Easy-Link connection with other 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 upper bank of DIPswitches to the ON position. See the computer board diagram as shown in the next page. 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...
  • Page 28 Installati on Manual Installati on CASE 3: Wrong connections between the "CHILD-1" unit and the "CHLD-2" unit • If you connect the “PARENT” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit, the “CHILD-2” 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

    MULTI-UNIT SYSTEM Multiple 510U (T-D2U) models can be combined for a Multi-Unit system, along with the multi unit controller (Parts 9007675005 (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 9007675005 (T-D2U) (TM-MC02) Hot Out Cold IN An individual cut-off switch is recommended for each unit in a multi-unit system for the purpose of maintenance.

  • Page 30: Applications

    Installation Manual Installation APPLICATIONS -Space-Heating Applications- • In order to purge air in water pipes within a closed-loop system, an air vent and air separator should be installed in the system. Required circulation flow rates are labeled next to each application diagram. These flow rate WARNING requirements must be followed.

  • Page 31: 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) 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 Shut-off 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 Installation 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.

  • Page 33: 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 date of your unit written on the rating plate of the water heater. Page...

  • 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.
  • 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 the picture to the right. (EX.: 120 °F) (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) Press the "HOT" button or the "COLD" button to set 140 °F. Simultaneously press and hold the "HOT" and "INFO"...

  • 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 Fist of all, inlet water temperature will be displayed on the remote controller by pressing the "INFO" button. Inlet water temperature Outlet water temperature will be displayed on the remote controller by pressing the "INFO" button. Outlet water temperature And then, water flow will be displayed on the remote controller by pressing the "INFO" button. Water flow 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 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

    Outdoor 4.3 (16.3) FREEZE PROTECTION SYSTEM • This unit comes equipped with heating blocks to protect it against damages associated with freezing. • For this freeze protection system to operate there has to be electrical power to the unit. Damage to the heat exchanger caused by freezing temperatures due to power loss is not covered under the warranty. In cases where power losses can occur, consider the use of a backup power supply. • The freeze protection system will activate when the surrounding and/or outside temperatures drop below 36.5 °F (2.5 °C). • For the 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models: • In any areas subject to freezing temperatures, the manufacturer highly recommends an indoor installation with an indoor model. In such an installation, freezing issues can only occur if cold air enters through the venting into the heat exchanger, whether by negative pressures within the installation location or by strong outside winds. • The manufacturer also highly recommends the use of a back flow vent damper to minimize the amount of cold air entering through the exhaust venting when the water heater is off. • It is the installer’s responsibility to be aware of freezing issues and take all preventative measures. The manufacturer will not be responsible for any damage to the heat exchanger as a result of freezing. • If you will not be using your heater for a long period of time: 1. Completely drain the unit of water. Refer to p. 41...

  • Page 41: Maintenance And Service

    Owner's Guide Normal Operation MAINTENENCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. WARNINRG • 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. • 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

    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 the fixtures. distance or the bigger the pipes, the longer it will take to get hot water. • If you would like to receive hot water to your fixtures quicker, you may want to consider a hot water recirculation system. (p. 29) The water is not hot • Compare the flow and temperature. See the charts on p. 54. enough. • Check cross plumbing between cold water lines and hot water lines. • Is the gas supply valve fully open? (p. 32) • Is the gas line sized properly? (p. 19) • Is the gas supply pressure enough? (p. 20) • Is the set temperature set too low? (p. 36-37) The water is too hot.
  • Page 43 Owner's Guide Normal Operation PROBLEM SOLUTIONS Unit does not ignite • Is the flow rate over 0.5 GPM (1.9 L/min)? (p. 37) 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 1-888-479-8324. 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. 22) 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 LED...

  • Page 44: Error Codes

    Owner's Guide Troubleshooting ERROR CODES -General- • The units are self diagnostic for safety and convenience when trouble shooting. • If there is a problem with the installation or the unit, the error code will display on the remote controller. • Consult with the table on the following page for the cause 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...
  • 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 Gas • Check for connection/breakage of wires (Part #708) Solenoid Valve and/or burn marks on the computer board (Part #701). Six Times Abnormal Main Gas • Check for connection/breakage of wires (Part #708)

  • Page 47: Components Diagram

    Owner's Guide Troubleshooting COMPONENTS DIAGRAM Case assembly Outdoor models Indoor models Temperature remote controller Page...
  • Page 48 Owner's Guide Troubleshooting 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

    Components Diagram 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...
  • Page 52 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 Heat exchanger assembly for 110U and 310U Indoor 319143-459 EK119 (T-KJr2U-IN and T-K4U-IN) for 110U and 310U Outdoor 319143-460 EK121 (T-KJr2U-OS and T-K4U-OS) for 510U Indoor (T-D2U-IN) 319143-461 EKD62 for 510U Outdoor (T-D2U-OS) 319143-462 EK122 Flow adjustment valve / Flow sensor 319143-463 EK129 Bypass valve for 510U (T-D2U) models 319143-464 EKD58 Water inlet 319143-193 EKK1U...
  • 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 319143-128 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 sizes 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. 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. ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND, IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT, BREACH OF WARRANTY, TORT LIABILITY (INCLUDING NEGLIGENCE), STRICT LIABILITY, INDEMNITY OR OTHERWISE WILL BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY...
  • Page 56 Owner's Guide 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. • All warranty claims and warranty service must be authorized and approved by the manufacturer.     (4) Includes dual-purpose applications (combination heating and domestic). 3. Repair, Replacement or Refund: 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. 4. Limitation on Duration of Implied Warranties: ANY IMPLIED WARRANTIES ARISING UNDER STATE LAW, INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, SHALL IN NO EVENT EXTEND PAST THE EXPIRATION OF ANY WARRANTY PERIOD HEREUNDER.

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