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 Indoor (T-KJr2-IN) • 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) If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, WARNING personal injury or death.
Contents CONTENTS Installation Manual SPECIFICATIONS........................................................................................................................... 4 INTRODUCTION........................................................................................................................... 5 SAFETY GUIDELINES..................................................................................................................... 6 INSTALLATION..............................................
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.
Installation Manual Specifications SPECIFICATIONS 110 Indoor Model 110 Outdoor (T-KJr2-IN) (T-KJr2-OS) 310 Indoor (T-K4-IN) 310 Outdoor 510 Indoor 510 Outdoor (T-K4-OS) (T-D2-IN) (T-D2-OS) Natural Gas Input (Operating Range) BTU/h Min.: 19,500 Max.: 140,000 Min.: 11,000 Max.: 190,000 Min.: 11,000 Max.: 199,000 Propane Gas Input (Operating Range) BTU/h Min.: 19,500 Max.: 140,000 Min.: 11,000 Max.: 190,000 Min.: 11,000 Max.
Installation Manual Introduction INTRODUCTION • This manual provides information necessary for the installation, operation, and maintenance of the water heater. • The model description is listed on the rating plate which is attached to the side panel of the water heater. • Please read all installation instructions completely before installing this product. • If you have any problems or questions regarding this equipment, consult the manufacturer or its local representative.
Installation Manual Safety Guidelines SAFETY GUIDELINES SAFETY DEFINITION DANGER WARNING CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury. GENERAL 1.
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. Read the “Safety Guidelines” section. 3.
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. • The manufacturer does not recommend installing the water heater in a pit or location where gas and water can accumulate.
Installation Manual Installation WARNING FOR INSTALLATIONS FOR YOUR SAFETY, READ BEFORE INSTALLATION: Do not install the heater where water, debris or flammable vapors may get into the flue terminal. This may cause damage to the heater and void the warranty. Prohibited Do not have the vent terminal pointing toward any opening into a building. Do not locate your heater in a pit or location where gas and water can accumulate. Prohibited Do not install this water heater under an overhang less than 3 ft.
Installation Manual Installation CLEARANCES Top Back Side Maintain all clearances around the water heater. Front Side Bottom Model Top Bottom Front Back Sides 110 Indoor* (T-KJr2-IN)* 310 Indoor* (T-K4-IN)* 510 Indoor* (T-D2-IN)* 12 in. (305 mm) 12 in. (305 mm) 4 in.** (102 mm) 1 in. (25 mm) 3 in. (76 mm) 110 Outdoor (T-KJr2-OS) 310 Outdoor (T-K4-OS) 510 Outdoor (T-D2-OS) 36 in. (914 mm) 12 in. (305 mm) 24 in. (610 mm) 1 in. (25 mm) 3 in.
Installation Manual Installation 1. 4” Backflow preventer and F-F adaptor: 9007996005 2. Direct-vent conversion kit: 9007667005 (TK-TV10) There are two functions available for this adaptor, which can be connected with the water heater and NovaVent venting line and 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.
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 Altitude 0 to 2,000 ft. (DEFAULT) Switch No. 3 OFF ON OFF Switch No. 4 OFF OFF ON 2,000 to 4,000 ft. 4,000 to 6,000 ft. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ON ON 1 2 3 4 5 6 7 8 ON 510 (T-D2) model (Left bank of dipswitches) Altitude 0 to 2,000 ft. (DEFAULT) Switch No.
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 from carbon monoxide and flue gases poisoning. Improper installation will DANGER void product warranty. When installing the vent system, all applicable national and local codes must be followed.
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). For best results, a vent system should be as short and straight as possible.
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.
Installation Manual Installation -Vent termination clearancesINSIDE CORNER DETAIL V Vent terminal X Air supply inlet V Area where is not permitted G H A D E V B B B C V F V FIXED ED CLOS E BL A OPER V L V ED ABLE FIXLOSED C OPER V B B V I X M V X K J A Gas meter / regulator B A Canada Direct-vent and other than Direct-vent Directvent 1 foot 1 foot 1 foot 3 feet 1 foot 4 feet from below or side opening. 1 foot from above opening.
Installation Manual Installation -For sidewall terminations2 ft. 1 ft. (305 mm) (610 mm) min. min. 1 ft. (305 mm) min. Exhaust termination Inside corner 2 ft. 1 ft. (305 mm) (610 mm) min. min. 1 ft. (305 mm) min. Combined intake and exhaust termination Exhaust termination 3 ft. (915 mm) min. Inside corner For multiple sidewall exhaust terminations (e.g. multiunit systems), an exhaust termination must be at least 1 ft. (305mm) away from another exhaust termination.
Installation Manual Installation GAS SUPPLY AND GAS PIPE SIZING -General- CAUTION • 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. • Conversion of this unit from natural gas to propane or vice versa will void all warranty. Contact your local distributor to get the correct unit for your gas type.
Installation Manual Installation -Natural Gas Supply PipingMaximum 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.
Installation Manual Installation -Measuring inlet gas pressure1. Turn off all electric power to the water heater if service is to be performed. 2. Turn the manual gas valve located on the outside of the unit clockwise to the off position. The water heater cannot perform properly without sufficient inlet gas pressure. Below are instructions on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL. 1. Shut off the manual gas valve on the gas supply line. 2.
Installation Manual Installation -Pressure relief valveThe water heater has a high-temperature shutoff switch built in as a standard safety feature (called a Hi-Limit switch) therefore a “pressure only” relief valve is required. • This unit does not come with an approved pressure relief valve. • An approved pressure relief valve must be installed on the hot water outlet. • The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow local codes.
Installation Manual Installation REMOTE CONTROLLER CONNECTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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) & 310 (T-K4) models Maximum 150 ft. long 9007603005 (TM-RE30) for 510 (T-D2) model Maximum 400 ft.
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.
Installation Manual Installation EASY-LINK SYSTEM (Available on the 510 (T-D2) model only) -GeneralThe 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. • A communication cable (gray color) comes with each 510 (T-D2) model. You can manifold from 2 to 4 units without the need for a multi-unit controller.
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” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit. 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.
Installation Manual Installation NOTICE • A remote controller is not required for an Easy-Link System, however, it does 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.
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.
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 requirements must be followed.
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) Atmospheric vacuum breaker Thermostatic mixing valve Heating Coil (used with air-handler) Check valves 50’-0” maximum distance from water heater to fan coil.
Installation Manual Initial operation INITIAL OPERATION FOR YOUR SAFETY, READ BEFORE OPERATING • Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time. • Open the main gas supply valve to the unit using only your hand to avoid any spark. Never use tools. If the knob will not turn by hand, do not try to force it; call a qualified service technician. Forced repair may result in a fire or explosion due to gas leaks.
Owner's Guide Owner's Guide CONGRATULATIONS Congratulations and thank you for choosing our tankless water heater. Before use, we recommend that you read through this safety manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. If you lose the manual, contact the manufacturer or your local distributor. When you call, please tell us the product name and the serial number of your unit written on the rating plate of the water heater.
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.
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: 1. Far away from heater 2. In approved containers 3. Tightly closed 4. Out of children's reach Vapors: 1. Cannot be seen 2. Vapors are heavier than air 3. Go a long way on the floor 4.
Owner's Guide Normal Operation NORMAL OPERATION GENERAL • • WARNING NOTICE • 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). Feel the water temperature before bathing or showering. HOT • Flow rate to activate the water heater: 0.5 gallon per minute at the default set temperature. • Flow rate to keep the water heater running: 0.4 gallon per minute. 1.
Owner's Guide Normal Operation b) 510 (T-D2) model: 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 “TIME” the remote controller on. It shows the time and set temperature on the display as shown to the right. “INFO” 3. Press the "HOT" button or the "COLD" button to set the temperature. You can set the temperature from 100 °F (37 °C) “BUZZER” to 122 °F (50 °C).
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” (or “0”) is displayed on remote controller. I N OUT FLOW L/ M G / M I N OUT FLOW L/M G/M “1” is displayed for single unit. “0” is displayed for Easy-Link System. 3. Press the “TIME” button.
• Features available only on 9007603005 (TM-RE30) 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. The remote controller has an energy saving mode.
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.
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 1.0 for the 310 (T-K4) model, and 10.0 GPM for the 510 (T-D2) Lavatory Faucet model. Bath Tub 4.0 – 10.0 • The temperature setting, along with the supply temperature Shower 2.0 of the water will determine the flow rate output of the unit. Kitchen Sink 1.5 • Please refer to the temperature vs.
Owner's Guide Normal Operation MAINTENANCE AND SERVICE WARNING Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. • • • • • Clean the cold-water inlet filter. (Refer to Unit draining and filter cleaning section in this page.) Be sure that all openings for combustion and ventilation air are not blocked. The venting system should be checked annually for any leaks, corrosion, blockages or damage.
Owner's Guide Troubleshooting TROUBLESHOOTING PROBLEM GENERAL SOLUTIONS WATER CONNECTIONS TEMPERATURE and AMOUNT OF HOT WATER It takes long time to • The time it takes to deliver hot water from the water heater to your get hot water at the fixtures depends on the length of piping between the two. The longer fixtures. the distance or the bigger the pipes, the longer it will take to get hot water.
Owner's Guide Troubleshooting EASY-LINK SYSTEM 510 (T-D2) model only Remote controller WATER HEATER PROBLEM SOLUTIONS Unit does not ignite when water goes through the unit. • • • • • • Is the flow rate over 0.5 GPM? (p. 34) Check for the filter on cold water inlet. (p. 40) 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.
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. If a remote controller is installed, the error codes will be displayed on the remote controller.
Owner's Guide Troubleshooting -Fault Analysis of Error CodesIf 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) 510 (T-D2) Malfunction description Diagnosis Red Remote Remote LED 7 Seg LED One Time 03 031 Incorrect Five Times 10 101 Three Times 11 111 Three Times 12 121 Two Times 31 311 • Check the DIPswitch settings on the PCB (Part #701).
Owner's Guide Troubleshooting 110 (T-KJr2) and 510 310 (T-K4) (T-D2) Red Remote Remote LED 7 Seg LED Two 39 391 Times N/A N/A 441 Six Times 51 510 Six Times 55 N/A Four Times 61 611 N/A N/A 651 One Time 70 701 Six Times 72 721 N/A 74 741 N/A N/A 761 Five Times 99 991 Malfunction description Air-fuel ratio rod failure Flow sensor failure (Easy-Link System only) Abnormal gas solenoid valve Abnormal main gas valve Diagnosis • Check for connection/breakage of wires (Part #709) and/ o
Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly 110 Indoor (T-KJr2-IN) 003 110 Outdoor (T-KJr2-OS) 052 052 052 004 007 052 004 007 053 001 702 702 052 052 721 002 002 720 051 066 704 310 and 510 Indoor (T-K4-IN and T-D2-IN) 704 006 053 005 052 310 and 510 Outdoor (T-K4-OS and T-D2-OS) 052 052 052 004 007 052 004 007 001 052 002 056 050 050 003 001 001 053 702 702 052 721 002 720 051 066 056 704 050 050 052 Temperature remote controller 11
Owner's Guide Components Diagram Burner assembly 110 (T-KJr2) model Burner assembly 101 110 108 107 106 105 065 709 104 109 111 401 712 059 053 052 706 053 121 704 053 703 059 112 705 103 053 113 114 708 150 701 Manifold Assembly 053 053 102 061 119 151 711 055 053 118 062 712 714 058 115 110 Indoor (T-KJr2-IN) only 067 120 053 713 052 055 47 Page
Owner's Guide Components Diagram Burner assembly 310 (T-K4) and 510 (T-D2) models Burner assembly 101 107 105 108 065 709 106 104 109 110 111 401 712 053 Power control section 053 704 310 (T-K4) model 121 706 703 A 052 053 116 117 705 053 510 (T-D2) model 053 053 704 103 121 703 706 054 112 A 115 113 705 053 701 057 058 114 708 150 A Manifold Assembly 053 067 120 053 712 055 062 066 711 053 714 310 Indoor (T-K4-IN) 510 Indoor (T-D2-IN) Fan motor section for in
Owner's Guide Components Diagram Computer board assembly 110 (T-KJr2) and 310 (T-K4) models 710 510 (T-D2) model 103 701 701 717 708 718 707 103 710 709 402 402 714 719 408 709 407 707 708 716 715 719 Water Way assembly 110 (T-KJr2) model 310 (T-K4) model 463 463 463 453 413 452 510 (T-D2) model 450 414 452 450 450 414 063 412 412 063 453 413 452 063 401 453 413 414 412 401 401 B 451 414 414 C 414 B B C C 451 458 451 462 459 403 454 411 Bypass sect
Owner's Guide Parts List PARTS LIST Item # 001 002 003 004 005 006 007 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065 066 067 101 102 103 Part # Description Case assembly for 110 Indoor (T-KJr2-IN) for 110 Outdoor (T-KJr2-OS) for 310 and 510 Indoor (T-K4-IN and T-D2-IN) for 310 and 510 Outdoor (T-K4-OS and T-D2-OS) Front cover for 110 Indoor (T-KJr2-IN) for 110 Outdoor (T-KJr2-OS) for 310 Indoor (T-K4-IN) for 310 Outdoor (T-K4-OS) for 510 Indoor (T-D2-IN) for 510 Outdoor (T-D2-OS) Air
Owner's Guide Parts List Item # 108 109 110 111 112 113 114 115 116 117 118 119 120 121 150 151 152 153 154 401 402 403 404 405 406 407 408 409 410 411 412 Part # Description 110, 310 and 510 models 319143-339 319143-035 319143-373 319143-037 319143-340 319143-036 319143-038 319143-170 9009012005 9009014005 319143-044 319143-045 319143-160 319143-367 319143-042 319143-041 319143-344 T-KJr2, T-K4 and T-D2 models 319143-050 319143-049 319143-051 319143-213 319143-176 319143-350 319143-057 319143-370 31
Owner's Guide Parts List Item # 413 414 415 450 451 452 453 454 455 456 457 458 459 460 461 462 463 701 702 703 704 705 706 707 708 709 710 711 712 713 714 Part # Description Overheat-cut-off fuse Heater Inlet heater Pipe heater fixing plate Heater fixing plate 16 Fuse fixing plate 18 Fuse fixing plate 14 O-ring P4 FKM O-ring P6 FKM O-ring P14 FKM O-ring P15 FKM O-ring P16 FKM Fastener “4-11” for 510 (T-D2) model Fastener “14-22” Fastener “16A” Fastener “16-25A” for 510 (T-D2) model Silicon ring Compu
Owner's Guide Parts List Item # 715 716 717 718 719 720 721 722 Part # Description Pump and multi cable for 510 (T-D2) model Thermistors wire for 510 (T-D2) model RS-VG wire for 510 (T-D2) model Water valves wire for 510 (T-D2) model Computer board cover for 110 (T-KJr2) and 310 (T-K4) models Computer board cover for 510 (T-D2) model Rubber grommet for Indoor models Cable strap for Indoor models Temperature remote controller for 110 (T-KJr2) and 310 (T-K4) models Temperature remote controller for 510 (T-D
Owner's Guide Output Temperature Chart OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line Output Hot Water GPM 110 (T-KJr2) model Output temperatue vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature Incoming Temp. Set Temp. 310 (T-K4) model Output Hot Water GPM Output temperatue vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature Incoming Temp. Set Temp Output Hot Water GPM 510 (T-D2) model Output temperature vs. GPM (Max. 10.
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.
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.