Models On-Demand Water Heater Installation Manual and Owner's
Contents
1. Connect to these terminals 510 models Connect to these terminals Properly attach the remote s wires to the remote control ler terminal on the computer board No polarity Do NOT jump or short circuit the wires or computer will be damaged Replace Front Cover securely Wires used for the remote controller connection must be e Minimum 18AWG wire No polarity e Maximum 122m 400 ft long For detailed connection instructions to the remote con troller refer to the instructions that are packaged with the remote controller TK RE02 Front of remote remote Connect other end to these terminals TM RE30 TIME INFO BUZZER 1 L remote remote Connect other end to these terminals 17 Pump Control Mode Only available on the 510 models The 510 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 To control a recircula tion pump connect the pump to the Pump connector in the water heater as shown in the diagram below In an Easy Link system connect the pump ONLY to the PARENT unit The pump is to be connected using suitable relays shown in the diagram2. Fan motor Computer board Flow sensor aN Gas Inlet Hot Water Cold Water Outlet Inlet Thermistor This diagram illustrates tankless water heater design concepts only and does not accurately represent to the water heater s physical description A hot water tap is turned on Water enters the heater The water flow sensor detects the water flow The computer initiates the fan motor and sends a signal to the igniter to create an ignition spark 5 The gas ignites and flames appear within the burner chamber 6 Water circulates through the heat exchanger and then gets hot 7 Using thermistors to measure temperatures throughout the water heater the computer modulates the gas and water valves to ensure proper output water tempera ture ee DD SAFETY GUIDELINES Safety Definitions Indicates an imminently hazardous situa tion which if not avoided will result in death or serious injury DANGER Indicates an imminently hazardous situa tion which if not avoided could result in death or serious injury WARNING Indicates an imminently hazardous situa tion 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 CSA B149 1 Natural Gas and Propane Installation Code 2 Properly ground the unit in accordance with all local cod
3. 38 Fasy linkSystem To PARTS USE 22 a oes hee e 39 General OUTPUT TEMPERATURE CHART 41 Easy Link Connection Procedures 110 Models APPLICATIONS score 20 310 Models Space Heating Applications 20 510 Models RECHICUIQUION s 2 2 2 44 4e cc ser 21 LIMITED WARRANTY 42 Dual purpose Hot Water Heating 21 INITIAL OPERATION coverage eee 22 OPERATING SAFETY 2 6 00 5 056 0b ame ie de k m 23 NORMAL OPERATION 25 General ams one he agape ha as aa Pew Sp aes 25 Temperature Settings 25 Without Remote Controller Dipswitch Settings For Temperature KO CA AP PA AA 26 Freeze protection system 26 Maintenance and service 27 Unit Draining and Filter Cleaning SPECIFICATIONS 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 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 3 4 NPT 3 4 NPT 15 150 psi Inlet Min 5 0 WC Max 10 5 WC Min 8 0 WC Max 14 0 WC Manifold 2 0 WC Pressure IT WC DEn oE 520mm H x 351mm W x 170mm D 520mm H x 351mm W x D216mm D H20 5 x W13 8 x D6 7 H20 5 x W13 8 x D8 5 Elect
4. Unit 1 PARENT TM RE30 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 Red LED TK RE02 TM RE30 Incorrect DIPswitch setting e Check the DIPswitch settings on the PCB Part 701 101 Five Times 10 Warning for the 991 error Check the gas type of the water heat code er Check if there is any blockage in the intake air and or exhaust If the water heater is installed as a direct vent system check whether there is enough distance between the intake air terminal and the exhaust terminal Check the altitude elevation of area of where the water heater installed Check if there is grease and or dirt in the burner Part 101 and the fan motor Part 103 especially if the water heater has been installed in a contaminated area Three Times 11 111 Ignition failure Check if the Hi limit switch Part 412 is properly functioning Check for connection breakage of wires Part 413 708 709 710 712 burn marks on the computer board Part 701 and or soot on the flame rod Part 108 Check if there is a buzzing spark igni tion sound coming from the burner Part 101 when water heater pre pares for combustion Listen for the double clunk sound coming from gas valve assembly Part 102 when water heater goes into combustion Check if there is leaking from he
5. to the following chart e The temperature has been preset at the factory to 50 C 122 F e f temperatures other than the ones listed above are required the remote controller can provide several more temperature options Refer to pg 8 for a list of available temperatures on the remote controller e This water heater is an on demand tankless water heater designed to efficiently supply endless hot water without reference to temperature settings Temperatures available 50 C 55 C 122 F 131 F 60 C 140 F DIPswitch Settings For Temperature 110 amp 310 Computer board 510 Computer board amp Alf E ZAP 7 C E do I TO B if GL Ag DIPswitches DIPswitches Right bank 110 amp 310 Models 50 C 122 F DEFAULT 60 C 140 F 59 131 F 122 F DEFAULT 40 C 45 104 F 113F Switch No 4 Switch No 6 80 C 176 F 70 C 158 F 25 WARNING DO NOT set to 85 C 185 F if you use your water heater in a recirculation system This will cause damage to the heater and void the warranty This temperature setting is only available on the 510 models DO NOT adjust the left bank of DIPswitches For the 510 models Turn off the power supply to the water heater before changing the DIPswitch settings Only change the switches with the dark squares The dark squares indicate which direction the DIPsw
6. and Call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 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 23 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 If owner s manual is missing contact the manufacturer The outlet hot water temperature of the water heater is factory set at 50 C 122 F Use this heater at your own risk The set outlet water temperature can cause severe burns instantly or death from scalds Test the water before bathing or showering Do not leave children or an infirm person in the bath unsupervised Hot Water Heater temperature over 52 C 125 can cause severe burns instantly or death from scalding Children disabled and elderly are at the highest risk of being scalded Fe
7. list Horizontal Installation Diagram Th ET Backflow Preventer Sidewall Vent Terminator Roof TT Backflow Preventer Vertical Condensation Drain 11 Horizontal Installation Diagram With Direct Vent Concentric Horizontal Installation Diagram with direct venting ze Termination ES RAA NG If WN Vertical Condensation Sidewall Vent Terminator ackflow reventer See the picture below for detailed connection instructions to the Direct Vent Conversion Kit Direct vent Concentric Vertical Installation Diagram With direct venting Termination Installation Diagram of Direct Vent Conversion Kit with Roni water heater El Intake port of Direct Vent Conversion Kit Roof Flashing Backflow Preventer Vertical Condensation Drain Plate of Direct Vent Conversion Kit See the picture below for detailed connection instructions to the Direct Vent Conversion Kit Backflow Preventer Recommended for freezing weather conditions 2C 36 F and below Vertical Condensation Drain must be installed accor dance with local codes 12 Vent Termination Clearances M DE il PL vent terminal BO Ar supply inlet CG Area where s not permitted a E RA i PANA ee E EE EEE Kg E nag r A Gas Meter regu lator Direct vent and other Direct Other than than Direct Vent vent Direct Vent A Cl
8. The hot water is not available when a fix ture is opened The hot water turns cold and stays cold CC m lt C O JE LL O Z D O nad D Cc O LL Oc lt OC LL A gt LL E Fluctuation in hot water temperature Unit does not ignite when water goes through the unit The fan motor is still spinning after opera tion has stopped Unit sounds abnormal e Contact the manufacturer at 1 888 479 8324 while in operation WATER HEATER 28 The time it takes to deliver hot water from the water heater to your fixtures depends on the length of piping between the two The longer the 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 con sider a hot water recirculation system pg 23 Compare the flow and temperature See the charts on pg 43 Check cross plumbing between cold water lines and hot water lines Is the gas supply valve fully open pg 27 Is the gas line sized properly pg 16 Is the gas supply pressure enough pg 17 Is the set temperature set too low pg 27 Make sure the unit has 120 VAC 60 Hz power supply If you are using the remote controller is the power button turned on Is the gas supply valve fully open pg 24 Is the water supply valve fully open pg 24 Is the filter on cold water inlet clean pg 29 Is the hot water fixture sufficiently open
9. l min 4 GPM US through each activated unit in the system 5 o g E JE TD 7p o avi 2 6 O Hot water outlet Unions to fixtures Ball valves Gas supply HOHA Recirculation pump Check valve Air separator Expansion tank Check valve Cold water Y Strainer inlet a Dual purpose Hot Water Heating Domestic and Space Heating Diagramatic layout of Radiant Heating and Domestic Water Heater The recirculation pump is to provide no less than 7 5 l min 2 GPM US and no more than 15 min 4 GPM US through each activated unit in the system An approved Pressure Only Relied odie Valve tie to location approved by local codes and must meet BTU Shut off rating of water heater model used valve 102mm 4 in gas exhaust vent discharge must comply Pressure Check Valve with local and state codes Apply correct thermal gauge ve Can not be common vented expansion tank size with other appliances per application J Tempered water Ot a to house KA a Thermometer Atmospheric AR 2 ne vacuum 2 Thermostatic mixing valve DI breaker 3 G Th i Tu 5 5 5 lt 2 ermometer 5 5 HY 5 e Z 83 q I 6 O gt Water Heating coil Check valves filter used with air handler Q maximum allowable distance of 50 ft Drai Shut off valves rain From water heater and heating panel a EN Check valve plug gt T Unions Pump must be sized prop
10. 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 void product warranty DANGER 10 When installing the vent system all appli cable national and local codes must be followed If you install thimbles fire stops or other protective devices and they pen etrate any combustible or noncombustible construction be sure to follow all applicable national and local codes CAUTION The water heater must be vented in accordance with the section Venting of Equipment of the latest edition of CSA B149 1 Natural Gas and Propane Installation Code as well as applicable local building codes The manufacturer recommends the T Vent line manufac tured 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 Ill Metal Fab Inc and Heat Fab Inc Saf T Vent General rules for venting water heaters are e Place the water heater as close as possible to the vent terminator e The vent collar of the water heater must be fastened directly to an unobstructed vent pipe e Do not weld the vent pipe to the water heater s vent col lar e Do not cut the vent collar of the unit e The vent must be easily removable from the to
11. methods of air removal in a closed loop circulation system see installation manual for details e Electric supply power voltages that fall outside the product s specified range e Damages due to water quality e Introduction of liquids other than potable water or potable water glycol mixtures into the product e Introduction of pool water spa water or any chemically treated water into the product e Introduction of hard water measuring more than 7 grains per gallon 120 ppm for single family domestic applica tions or more than 4 grains per gallon 70 ppm for all other types of applications into the product 43 If you have any questions please call or write to GSW Water Heating 599 Hill Street West Fergus ON Canada N1M 2X1 Toll Free 1 888 479 8324
12. not place the termination directly in front of an opening into a build ing For rooftop terminations termination A In accordance with local codes For multiple unit rooftop terminations whether for stan dard or direct vent installations space all exhaust and intake terminations in accordance with local codes An exhaust termination must be spaced from a wall or surface in accordance with local codes as well In the absence of such a code an exhaust termination must be a horizontal distance of at least 610mm 2 ft away from a wall or surface Gas supply and gas pipe sizing General e Check that the type of gas matches the rating plate first Ensure that any and all gas regula tors 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 vise versa will void all warranty Contact your local distributor to get the correct unit for your gas type The manufacturer is not liable for any property and or personal damage resulting from gas conversions WARNING e The minimum and maximum inlet gas pressures are Gas type Inlet gas pressure Natural Gas Min 5 0 WC Max 10 5 WC Min 8 0 WC Max 14 0 WC e Gas pressure above this specified range for the water heater and or insufficient gas volume will adversely affect performance These pressures are
13. output tem peratures may be limited 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 3 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 below 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 5 Check the inlet gas pressure When the water heater is on maximum burn the manometer should read from 5 0 to 10 5 WC for Natural gas from 8 0 to 14 0 WC for Propane Pressure port Water Connections e 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 This will not properly activate the water heater CAUTION All pipes pipe fittings valves and other components includ ing solderi
14. remove any air pockets Do not use this water heater if any part has been submersed under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts IF YOU SMELL GAS e Do not try to start the water heater e Do not touch any electric switches do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Once the above checks 2 Fully open the manual water control valve on the water supply line have been completed please clean filter of any debris Refer to pg 29 for instructions Open a hot water tap 4 Fully open the manual gas to verify that water is flowing to that tap Then close the hot water tap control valve installed Hz power supply to the water heater enjoy hours of endless hot water yes ta 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 This water heater does not have a pilot lt is equipped with an ignition device that automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the water heater area for evidence of leaking gas Be sure to smell next to the floor because some ga
15. to draw at least 2 8 l min 0 75 GPM US through the water heater pg 27 Is the unit frozen Is there enough gas in the tank cylinder For Propane models Is the flow rate enough to keep the water heater running pg 27 If there is a recirculation system installed does the recirculation line have enough check valves pg 23 Is the gas supply valve fully open pg 24 Is the filter on cold water inlet clean pg 29 Are the fixtures clean of debris and obstructions Check if the flow rate is too low pg 27 Is the filter on cold water inlet clean pg 29 Is the gas line sized properly pg 16 Is the supply gas pressure sufficient pg 17 Check for cross connection between cold water lines and hot water lines Is the flow rate over 2 8 l min 0 75 GPM US pg 27 Check for the filter on cold water inlet pg 29 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 This is normal After operation has stopped the fan motor keeps running from 15 to 70 seconds in order to re ignite quickly as well as purge all the exhaust gas out of the flue b PROBLEM SOLUTIONS Remote controller e Make sure the unit is supplied with power does not display any Make sure the connection to the unit is correct pg 19 thing when the power button is turned on TM RESO only NN When ON If the green
16. valve Part Easy Link System only 402 for connection breakage of wires Part 718 locked motor drive due to scale buildup and or water leakage Six Times Four Times One Time 701 Computer board Fault Check for connection breakage of wires Part 714 and or burn marks on the computer board Part 701 Check the power supply of the water heater 721 False Flame Detection Check if condensate drain is installed on the vent collar of the water heater Check if there is leaking from heat exchanger Part 401 741 Miscommunication between Check the model type of the remote water heater and remote controller Controller Inspect the connections between the water heater and remote controller Check the power supply of the water heater 101 Miscommunication in Easy Check if the connections between the Link system parent unit and the child units are cor rect Refer to pg 20 22 Six Times N A N A CO 2 Malfunction Malfunction description Diagnosis Red LED TM RE30 Imperfect combustion Check the gas type of the water heat er Inspect the environment around the water heater Determine how long the unit has been installed Check the altitude elevation of the area of where the water heater installed Check if there is any blockage in the intake air and or exhaust If the water heater is installed as a direct vent system check whether there is enough distance between the intake air terminal and the exh
17. 100 F 39 C 102 40 C 104 P 41 C 106 F 42 C 108 F 43 C 109 F 44 C 111 F 45 C 113 46 C 115 F 47 C 117 F 50 C 122 F 55 C 131 F 60 C 140 F 70 C 158 and 75 C 167 F See the troubleshooting section for information on possible error codes 2 Temperature Remote Controller TM RE30 4 Direct Vent Conversion Kit TK TV10 5 Pipe Covers TK PCO1 and TK PCJr2 The Temperature Remote Controller has two functions lt allows the output temperature from the water heater to be adjusted within the range of 37 C to 85 C 99 F to 185 and it also works as a diagnostic tool that will give a concise error code whenever there is a problem with the unit The temperature options are 75 99 F 38 C 100 39 C 102 40 C 104 F 41 106 42 C 108 43 1109P 111 45 1139P 46 C 115 F 47 C 117 F 50 122 F 55 C 131 F 60 140 F 65 C 149 F 70 C 158 F 75 C 167 F 80 C 176 F and 85 C 185 F See the troubleshooting section for information on possible error codes The Backflow preventer 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 Install this vent damper in accor dance with the installation instructions and any applicable codes This kit can
18. 510 EK441 Gas valve wire for 110 amp 310 EKK3K Gas valve wire for 510 EKK10 Flame rod wire for 110 EK431 Flame rod wire for 310 EKK3L Flame rod wire for 510 EKK11 EH IG wire for 110 amp 310 EKK3R EH IG wire for 510 EKKOZ 708 709 710 711 EKN74 712 High voltage igniter cable EKK2M 713 Freeze protection thermostat for EKJ59 110 310 amp 510 714 Proportional gas valve wire for EKK58 110 amp 310 Proportional gas valve wire for EKK12 510 Pump and multi cable for 510 EKK36 Thermistors wire for 510 EKK1Z RS VG wire for 510 EKK35 Water valves wire for 510 EKK33 D O item Description Part Computer board cover for 110 amp EKK49 310 Computer board cover for 510 EKK1M OUTPUT TEMPERATURE CHART Chart is based on properly sizes gas line 110 Models Output Temperature vs GPM Max 6 6 GPM with Various Inlet Water Temperature gt j z INd5 19 EM 10H ed a Lo a NG 310 Models Output Temperature vs GPM Max 8 0 GPM with Various Inlet Water Temperature 5 o IN e 40F e S50F ii 60F 70F d 2 191emM 10H Indino 105 115 125 150 165 28 26 28 35 31 70F 80 80 78 69 62 57 52 48 44 39 35 510 Models Output Temperature vs GPM Max 10 0 GPM with Various Inlet Water Temperature 4 40 F m 50F 6560 F 70 F a naaa rele 4 eee as Tels Li Li Li Li ises
19. J64 EKJ66 EX00M EKK5H EWO0OO EWOO1 EW002 EW003 EW004 EWOO5 EX014 EWOOB EW008 EWOOH EWO24 EKK31 EW006 EWOOA EWOO9 WOOD ECOOX EM167 EK417 EKH5W EK429 m EKH6T EK421 EKK5K EX02E EKK25 EX00V EKKOG EKK2X 06 107 08 0 1 1 1 109 1 0 111 112 113 114 115 116 117 118 119 120 121 150 151 154 401 2 4 4 404 5 6 f 4 4 4 408 0 0 0 0 0 0 0 0 409 410 411 412 413 Description Burner window Rod holder gasket Combustion chamber tube for 310 84 510 Pressure port for 310 8 510 Flow adjustment valve Flow sen sor for 110 amp 310 Flow adjustment valve Flow sen sor for 510 Inlet thermistor for 510 EKK2V EKK2W EX00R EKKOE EX00S EKKOF EX00U EKK32 EKN61 EK430 EK412 EKK2Y EKK2K EK416 TU001 EKK2D EKK2N EKKIE EKK2Z EKK1B EKK4H EK436 EZP18 EK042 EKK56 EK418 EK406 TU002 EK427 EK438 EKKOU EKK1U EKK2B EKK2C EKK4J EKK38 ERK55 EKK1A EKK1V EKK2E EKK2T EM212 EKN34 EK333 CO CO Hem Description Part EKO31 452 EKK26 EKO29 EZM04 EZMO6 EZM14 EZM15 EZM16 Fastener 4 11 for 510 EKH30 EKK24 461 Fastener 16A EM192 Fastener 16 25A for 510 EKK39 EKNSO 701 EK420 EK414 EK439 702 EKHO9 703 EK428 704 EKKSN EKK3C 705 Transformer wire for 110 EK408 Transformer wire for 310 amp 510 EK440 706 EKKAV 707 Switch wire for 110 EK407 Switch wire for 310 amp
20. LED lights up the remote controller has i been turned ON When the unit has not operated for five minutes or more the display turns off to con serve energy GET T Z O oo co CN O O ul o Ox SE rs LLI as gt H How are the unit num For an Easy Link system the Parent Sa a bers assigned unit is always labeled 1 and all other subsequent Child units are numbered randomly To check which numbers are assigned to which Child units push the button on the computer board of any Child unit as shown below The unit number will be displayed on the 7 Seg LED Refer to pg 20 22 EASY LINK SYSTEM 29 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 control ler installed it will either display a numerical error code on the 7 Seg LED on the computer board Only for the 510 models display a blinking red LED for the 110 amp 310 models or the error code will display on the remote controller if it is installed Consult with the table on the following page for the cause of each error code 110 amp 310 Red LED Error code on the Error code on the computer board TK RE02 510 Error code on the computer board Error Code the TM RE30 Single Unit Installations Example If your unit displays the 321 error code which
21. On Demand Water Heater Installation Manual and Owner s Guide Models 110 310 510 If the information in these instructions is not followed exactly a fire or explosion may result causing property dam WARNING age personal injury or death Do not store or use gasoline or other flam mable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e 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 suppli er s instructions e f you cannot reach your gas supplier call the fire department Installation and service must be performed by Gas Tankless Water Heater a qualified installer service agency or the gas Suitable for potable water heating and space heating supplier Please refer to local codes for space heating compliance PES ER If you have any questions ON DEMAND USAGE please call or write to e COMPACT SPACE SAVING GSW Water Heating ENERGY CONSERVATION COMPUTERIZED SAFETY 999 Hill Street West NO PILOT LIGHT Fergus ON Canada N1M 2X1 EASY LINK SYSTEM Toll Free 1 888 479 8324 510 models only 320576 000 REV 00 10 11 Table of Contents SPECIFICATIONS 3 TROUBLESHOOTING 28 INTRODUCTION anejos opaco na 4 Conca lso reload pts ne 28 SAFETY GUIDELINE
22. S sirio danken gan de de 4 Error COURS 8 a Se oa a imdi 30 Safety Definitions ts verso tesis ies eed ONG 4 Single Unit Installations General nA KGG e iie e a 4 Easy Link System INSTALLATION iie aaa 5 Fault Analysis Of Error Codes 31 General A D me DA te 5 COMPONENTS DIAGRAM 34 Clearances 7 Case Assembly 34 Included Accessories 7 110 Optional HMS irk a se eee sean 7 310 amp 510 High altitude Installations 10 Burner Assembly 35 Venting Instructions 10 110 General 310 amp 510 Exhaust venting Computer Board Assembly 37 Venting Illustrations 110 amp 310 Vent Termination Clearances Water Way Assembly 37 Gas supply and gas pipe sizing 15 110 General Computer Board Assembly 37 Gas Connections 510 Measuring Inlet Gas Pressure Water Way Assembly 37 Water Connections 15 310 Pressure Relief Valve Water Way Assembly 38 Electrical Connections 16 510 Remote Controller Connections 17 Water outlet section 38 Pump Control Mode 18 Waterinletsection
23. at exchanger Part 401 Three Times 12 121 Loss of flame Check if the Hi limit switch Part 412 is properly functioning Check for connection breakage of wires Part 413 708 709 710 712 burn marks on the computer board Part 701 and or soot on the flame rod Part 108 Check if there is leaking from heat exchanger Part 401 Two Times 31 311 Output thermistor failure e Check for connection breakage of 32 321 Inlet thermistor failure wires and or debris on thermistor Part Mixing thermistor failure ee Two Times 39 391 Air fuel Ratio Rod failure e Check for connection breakage of wires Part 709 and or soot on the AFR rod Part 108 31 110 amp 310 50 gt Malfunction description Diagnosis Red LED TK RE02 TM RE30 N A Flow Sensor Failure Easy Check for connection breakage of Link System only wires and or debris on the flow sensor impeller Part 402 717 510 Abnormal Gas Solenoid Valve Check for connection breakage of wires Part 708 and or burn marks on the computer board Part 701 N A Abnormal Main Gas Valve Check for connection breakage of wires Part 708 and or burn marks on the computer board Part 701 611 Fan Motor Fault Check for connection breakage of wires dust buildup in the fan motor Part 103 and or burn marks on the computer board Part 701 Check for frozen corrosion of connec tors Part 103 N A 651 Flow Adjustment Valve Fault Inspect the flow adjustment
24. aust terminal Check if there is grease and or dirt in the burner Part 101 and the fan motor Part 104 especially if the water heater has been installed in a contaminated area 33 COMPONENTS DIAGRAM Case Assembly 310 amp 510 34 Burner Assembly 110 Burner assembly r Assembly 35 310 8 510 Burner assembly Fan motor section AAA A ASA AA Le gt D D mao D gt gt D gt amm al 36 Computer Board Assembly Computer Board Assembly 2 lt YANN az Yes DM AE BALLS Se TE ver P 24 P 44 e AE NN Sr NV f ST a S LAA Water Way Assembly Water Way Assembly Y Y 3 Water outlet section Water Way Assembly m LO Water inlet section 38 D i z JJ Mm Mm Mi 910 Junction box inner plate 7 Back guard panel for 110 Back guard panel for 310 4 510 Hex head screw M4x12 w Washer 60 Pan screw M xt0 FEZN 66 Nylon amp 101 Burner assembly for 110 ku Burner assembly for 310 8 510 102 Manifold with gas valve assembly LP for 110 Manifold with gas valve assembly LP for 310 amp 510 Manifold with gas valve assembly NA for 110 Manifold with gas valve assembly NA for 310 amp 510 103 Fan motor for 110 kd Fan motor for 310 amp 510 104 510 EK415 EK402 EK419 EK403 EK434 EK401 EKJ09 EK
25. be used to convert the water heater from a standard vent system to a direct vent or sealed combustion system Install this conversion kit in accordance with the installation instructions and any applicable codes The pipe cover protects the plumbing pipes to the water heater from unex pected adjustments This pipe cover is fixed to the bottom of the water heater which hides the plumbing and improves the visual aspects of the whole installation for the water heater 6 Recess box TK RB02 The Recess box will allow for clean installations The water heater fits inside the recess box which hides and protects the whole water heater and plumb ing The Recess box will fit in between most wall studs 7 T Vent Wall Thimble with Termination TK KPWL4 and TK KPWH4 These terminations are used when venting out through the wall and are com patible with the T Vent pipe system These terminations are special stainless steel vents for gas appliances and are UL listed as Category Il Ill and IV There are two types of terminations the Louver termination and the Hood termination For different wall thicknesses there are two ranges of lengths available refer to the venting brochure for details Install these vent termi nations in accordance with their installation instructions and any applicable local codes Louver Termination Hood Termination TK KPWL4 TK KPWH4 8 Direct Vent Concentric Termination TK KPCT43 Used when terminat
26. below Please make sure the relays are properly rated for the recir culation pump Using the water heater s internal thermistors as a tempera ture control the recirculation pump will only turn on when recirculation is needed In an Easy Link system the pump must be connected to the Pump connector in the PARENT unit only If the pump is connected to any of the CHILD units the CAUTION pump will not work Connect to this Pump connector These components are NOT included with the water heater and are external to the unit They must be acquired separately Power supply for relay Power supply E S O for pump 2 120 VAC 35 O 220 VAC etc o oc Therma 120 VAC relay 220 VAC etc for relay N 7 woo gt Easy link System Only available on the 510 models General The 510 water heaters can be connected with other heaters of the same model with communication cables to work as a multiple unit manifold system The Easy Link system allows up to 4 units to manifold together 18 e Acommunication cable gray color comes with each 510 model 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 11 000 BTU h and 796 000 BTU h Hot Out The Easy Link system is limited up to 4 units If you connect more than 4 units only the first 4 units will w
27. correct settings and or connections CASE 1 e Unless you change DIPswitch No 1 of the PARENT unit to the ON position the system will not work as an Easy Link system The units will operate as individual units PARENT CHILD 1 unit unit Connectors Connectors Wrong setting Right bank of Dipswitches oh 192 3 4 5 6 wl MBHBHE Communication cable Right bank of Dipswitches 123456 AHAHA Wrong DIPswitch setting on the PARENT unit Prohibited CASE 2 e f you connect the 1 or 2 connector of the PARENT unit to the PARENT or 1 connector of the CHILD 1 unit the system will not work as an Easy link system The units will operate as individual units PARENT CHILD 1 unit unit Connectors Wrong connection P a f Right bank of Right bank o ak NE i ah connection o on Ba lalalalala o WHHHHE Communication cable Y OR PARENT CHILD 1 unit unit Wrong connection Right bank of Dipswitches 123456 BAHARA Communication cable Y Right bank of Dipswitches 123456 BAHARA Wrong connection Wrong connections between the PARENT unit and the CHILD 1 unit Prohibited 19 CASE 3 e f you connect the PARENT connector of the CHILD APPLICATIONS 1 unit to the 1 connector of the CHILD 2 unit the Space Heating Applications CHILD 2 unit will operate as an indiv
28. csas s lelele Idd 13 M 10H nd no 4 i When the set temperature is 55 C a gt or higher maximum flow rate is limited to 8 0 GPM 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 transfer able 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 DAMAGE PERSONAL DAMAGES LOSS OF USE OR INCONVENIENCE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU 2 Warranty for 510 models Application HX Parts Labor Years _ No Recirculation 12 On Demand Recirculation Single Family OTE Control Domestic Hot Water w Standard Pump Control Control Recirculation Timer e TET No No Pump Control 24 h
29. e Running the exhaust vent and the intake pipe paral lel is recommended e Terminating the exhaust and intake on the same wall surface is recommended Terminating in the same pressure zone allows for pressure balancing which prevents nuisance shutdowns WARNING Installation and service must be per formed by a qualified installer for example a licensed plumber or gas fitter otherwise the warranty will be void The installer licensed professional is responsible for the correct installa tion of the water heater and for com pliance with all national state provin cial and local codes The manufacturer does not recom mend installing the water heater in a pit or location where gas and water can accumulate Do not have the vent terminal pointing toward any operating window door or opening into a building Do not install next to any source of air borne debris such as a clothes dryer that can cause debris to be trapped inside the combustion chamber unless the system is direct vented The manufacturer does not recom mend installing the water heater in an attic due to safety issues If you install the water heater in an attic e Make sure the unit will have enough combustion air and proper ventila tion Keep the area around the water heater clean When dust collects on the flame sensor the water heater will shut down on an error code If the above conditions cannot be met use the direct vent convers
30. each water heater in the Easy Link system in accordance with the table below Unit 1 Child units Unit 2 3 and 4 EM A 510 Computer board Easy Link system Online LED Left bank of D DIPswitches Y 7 Seg LED Right bank of DIPswitches Easy Link connectors are next to the computer board To change the DIPswitch settings for the Easy Link system locate the bank of DIPswitches to the right of the 7 seg LED Do not adjust the left bank of DIPswitches HL AN x B Basic diagram of connections between the Easy Link System units PARENT CHILD 1 CHILD 2 CHILD 3 unit unit unit unit Connectors Connectors Connectors Connectors Right bank of Dipswitches 1423456 HR Communication cable Right bank of Dipswitches 123456 MBBBBE Right bank of Dipswitches 123456 ve MBBBBA Right bank of Dipswitches 123456 MBBBBA The dark squares indicate the direction the DIPswitches should be set to CAUTION Note e A remote controller is not required for the Easy Link system e lf running the Easy Link system without a remote control ler please make sure the temperature settings on ALL the units are set to the same settings Otherwise the units will not operate properly e lf 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 in
31. earance above grade veranda porch deck or balcony 4 feet from below or Clearance to window or door that may be opened side opening 1 foot from above opening 7 reg E CA aa AG Nin t L g O 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 ME es fro Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above gt 3 feet meter regulator assembly Clearance to service regulator vent outlet cor 4 feet from below or Clearance to non mechanical air supply inlet to building or Ka MAAN 3 feet 1 foot side opening 1 foot the combustion air inlet to any other application from above opening Clearance to mechanical air supply inlet Clearance above paved sidewalk or paved driveway 7 feet x 7 feet located on public property Clearance under veranda porch deck or balcony A G E F Li J ES For clearances not specified in CSA B149 1 Natural Gas and Propane Installation Code please use clearances in accordance with local installation codes and the requirement of the gas supplier Please follow all local and national codes in regards to proper termination clearances In the absence of such codes the follow ing clearances can be used as gu
32. ed Service Representative A list of authorized Service Representatives is available upon request 42 e 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 SOME STATES DO NO ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU 5 THIS WARRANTY WILL NOT COVER THE FOLLOWING e Any product that is not installed by a licensed plumber gas installer or contractor Damages due to accidents abuse misuse improper installation misapplication or incorrect
33. eeze protection system Any water pipes hot or cold located outside the unit will not be protected Properly protect CAUTION and insulate these pipes from freezing Maintenance and service Turn off the electrical power supply and close the manual gas shutoff valve WARNING and the manual water control valve before Servicing WARNING e Clean the cold water inlet filter Refer to diagram on the right e Be sure that all openings for combustion and ventilation air are not blocked e 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 e Keep the area around the water heater clear Remove any combustible materials gasoline or any flammable vapors and liquids e n 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 e lf 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 e Visual check of burner flames see below through the burner window in the burner assembly located at the middle of the water heater Blue flame Satisfactory Flame blowing up P Red or Yellow flame Unsatisfactory Unsati
34. el water temperature before bathing or showering Temperature limiting valves are avail able Ask a professional person 24 NORMAL OPERATION General Hot Water temperatures over 52 C 125 F can cause severe burns instant ly or death from scalding The outlet hot water temperature of the water heater is factory set at 50 C Ge Gi Feel the water temperature before bath ing or showering Note e Flow rate to activate the water heater 2 8 l min 0 75 gal lon US per minute e Flow rate to keep the water heater running 1 5 l min 0 4 gallon US per minute 1 Open a hot 2 Mix cold water 3 Close the hot with the hot to get water tap the correct tem perature water If a remote controller installed turn the remote controller ON by pressing the power ON OFF button on the remote controller and then set the temperature by pressing the HOT COLD buttons before opening a hot water tap The temperature is displayed when the remote controller is turned ON Temperature Settings 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 Model 45 C 19 40 C 104 F 45 C 113 F 50 122 F 55C 131 F a 60 C 140 F 70 C 158 F 80 C 176 F 85 C 185 F For detailed DIPswitch settings for each temperature refer
35. erly with each application Pump shall T handle gas run 60 seconds every 6 hours shut off valve 5 Note e Priority Control Devices such as a flow switch an Aquastat or other electronic controller can be used to prioritize the domestic water system over the heating system e Follow all local codes e This illustration is a concept design only There are a wide variety of variations to the application of controls and equip ment presented Designers must add all necessary safety and auxiliary equipment to conform to code requirements and design practice For more details contact the manufacturer 21 INITIAL OPERATION WARNING 22 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 lf 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 pg 17 Do not try to light the burner manually It is equipped with an electronic ignition device which automatically lights the burner Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater Purge the GAS and WATER LINES to
36. es or in the absence of local codes with CSA C22 1 Canada Electrical Code Part 1 3 Carefully plan where you intend to install the water heater Please ensure e 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 pg 6 4 Check the rating plate for the correct GAS TYPE GAS PRESSURE WATER PRESSURE and ELECTRIC RATING If this unit does not match your requirements do not install Consult with the manufacturer 5 lf any problem should occur turn off all hot water taps and turn off the gas Then call a trained technician or the Gas Company or the manufacturer WARNING Water temperatures over 52 C 125 can cause severe burns instantly or death from scalding The water tem perature is set at 50 C 122 from the factory to minimize any scalding risk Before bathing or showering always check the water temperature Do not store or use gasoline or other flammables vapors or liquids in the vicinity of this appliance Do not reverse the water and or gas connections as this will damage the gas valves and can cause severe injury or death Follow the diagram on pg 17 when installing your water heater Do not use this appliance if any part has been in contact with or been immersed in water Immediately call a licensed plumber a licensed gas fitter or a pro fessional service technician to inspect and or se
37. idelines CAUTION For sidewall terminations t 3 xhaus i E rmination corner multiple sidewall exhaust terminations e g multi unit systems an exhaust termination must be at least 305mm 1 ft away from another exhaust termination An exhaust ter mination must also be at least 610mm 2 ft away from an inside corner if the adjacent wall is less than 610mm 2 ft of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall Air supply inlet For direct vent sidewall ter minations that use two sep arate penetrations for the intake and exhaust distance the intake and exhaust ter minations at least 915mm 3 ft away from each other no matter the orientation 14 Local codes supersede these guidelines corner For multiple unit direct sidewall terminations that combine the intake and exhaust into a single penetration space each direct vent termination at least 305mm 1 ft away from each other no matter the orientation A direct vent termination must also be at least 610mm 2 ft away from an inside corner if the adjacent wall is less than 610mm 2 ft of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall Exhaust termination Exhaust and or direct vent sidewall terminations should be at least 610mm 2 ft away from an opposite sur face wall Do
38. idual unit and will not be part of the Easy Link system PARENT CHILD 1 CHILD 2 unit unit unit N Wrong connection P Right bank of 7 Dipswitches 123456 HAHAHA Right bank of Dipswitches 1423456 RENE Communication cable Right banko Dipswitches 123456 Wrong connections between the CHILD 1 unit and the CHILD 2 unit Prohibited Connecting two PARENT connectors together from two separate units may dam age the computer board The communi cation cable has a female end and a male end so it s impossible to have a PARENT to PARENT connection with the commu nication cable Do not splice or modify connectors WARNING WARNING CASE 4 e fa remote controller optional is used it has to be con nected to the PARENT unit If the remote controller is connected to a CHILD unit it will only control that particular individual CHILD unit and will not control the Easy Link system as a whole PARENT CHILD 1 Remote controller unit unit 4 Right bank of Dipswitches 123456 AHAHA Communication Wrong connection Remote controller connected to incorrect unit Prohibited 20 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 fol lowed To
39. ing direct vent sealed combustion systems with direct vent models that require a 76mm 3 in intake and a 102mm 4 in exhaust This concentric termination provides the convenience of only having to make one penetration through a sidewall instead of two separate penetrations for the intake and exhaust piping The termination includes a bird screen restricting small animals pests and foreign objects from entering into the vent system This sidewall termination is available in three different sizes to cover all ranges of wall thicknesses Part Covering wall thickness 249 330mm 9 8 13 0 in High altitude Installations Check the elevation where your water heater is installed Set DIPswitches shown in the table below depending on the altitude 110 amp 310 Models 0 to 2 000 ft DEFAULT 2 000 to 4 000 to 6 000 ft Consult our Technical Services at 1 888 HUF 479 8324 Consult our Technical Services at 1 888 479 8324 The dark squares indicate the eran he DIPswitches should be set to 110 amp 310 Computer board 510 Computer board LAE T amp VN 4 T e i AY L S gre gt al L POS NM ZA e EN DIPswitches Mela ele E E E DIPswitches Left bank DO NOT adjust any DIPswitches on the right bank for the 510 models WARNING Venting Instructions General e Improper venting of this appliance can result in excessive
40. ion kit TK TV10 Place the unit for easy access for service and maintenance A drain pan or other means of pro tection against water damage is required to be installed under the water heater in case of leaks CAUTION The warranty will not cover damage caused by water quality e Only potable water or potable water glycol mixtures can be used with this water heater Do not introduce pool or spa water or any chemically treated water into the water heater Water hardness levels must not exceed 7 grains per gallon 120 ppm for single family domestic applications or more than 4 grains per gallon 70 ppm for all other types of applications Water hard ness leads to scale formation and may affect damage the water heater Hard water scaling must be avoided or controlled by proper water treat ment Water pH levels must be between 6 5 and 8 5 e Well water must be treated Do not install the unit where water debris or flammable vapors may get into the flue terminal The manufacturer recommends using the direct vent kit when the water heater is installed in a beauty salon Some chemicals used in a beauty salon may affect the flame sensor Water heat er may not work properly Although the water heater is designed to operate with minimal sound the manu facturer does not recommend install ing the unit on a wall adjacent to a bedroom or a room that is intended for quiet study or meditation etc Locate your heater close to a d
41. itch should be set to Flow The flow rate through the water heater is limited to a maximum of 25 l min 6 6 GPM US for the 110 30 3 min 8 0 GPM US for the 310 and 37 8 l min 10 0 GPM US for the 510 The temperature setting along with the supply tempera ture of the water will determine the flow rate output of the unit Please refer to the temperature vs gallons per minute charts on pg 43 to determine the likely flow rates based on your local ground water temperature and your desired outlet water temperature Household Flow Rates Appli U Flow Rate lance Use pels M GP Lavatory Faucet Bath Tub 15 2 37 8 4 0 10 0 Kitchen Sink US 1 0 2 0 1 5 1 5 4 0 Washing machine Taken from UPC 2006 26 Based on the CAN CSA P 7 test method for measuring energy loss of gas fired instantaneous water heaters the water heater is rated for litres per hour I hr US gallons per hour GPH or litres per minute l min US gallons per minute GPM for Natural Gas and Propane when raising the water temperature by 43C 77F from 14 C to 57 C 58 F to 135 F See the following chart O Unit of Measure hr min GPH US GPM US hr min GPH US GPM US hr min GPH US GPM US Refer to the table on the left for typical household plumb ing fixture flow rates to determine what the water heater can do in a household application Freeze protection sy
42. measured when the water heater is in full operation e Inlet gas pressure must not exceed the above maximum values gas pressure above the specified range will cause dangerous operating conditions and damage to the unit e Until testing of the main gas line supply pressure is com pleted ensure the gas line to the water heater is discon nected to avoid any damage to the water heater Gas Connections 1 Install a manual gas shut off valve between the water heater and the gas supply line 2 When the gas connections are completed it is necessary to perform a gas leak test see below either by applying soapy water to all gas fittings and observing for bubbles or by using a gas leak detection device The water heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa The water heater must be isolated from the gas sup ply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 5kPa 3 Always purge the gas line of any debris and or water before connecting to the gas inlet Note Size the gas pipe appropriately to supply the neces sary volume of gas required for the water heater using CSA B149 1 Natural Gas and Propane Installation Code or local codes Otherwise flow capabilities and
43. ng materials must be suitable for potable water systems 1 A manual shut off valve must be installed on the cold water inlet to the water heater between the main water supply line and the water heater 15 2 In addition a manual shut off valve is also recommended on the hot water outlet of the unit If the water heater is installed within or subjected to a closed loop water sys tem a thermal expansion tank must be installed 3 Before installing the water heater flush the water line to remove all debris and after installation is complete purge the air from the line Failure to do so may cause damage to the heater 4 There is a wire mesh filter within the cold inlet to trap debris from entering your heater This will need to be cleaned periodically to maintain optimum flow AU As close as possible 0 O Pressure Relief Valve Hot outlet Cold intlet Gas intlet 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 e This unit does not come with an approved pressure relief valve e An approved pressure relief valve must be installed on the hot water outlet e The pressure relief valve must conform to ANSI 221 22 or CAN 1 4 4 and installation must follow local code e The discharge capacity must be at least 140 000 BTU h for
44. on meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building refer to pg 13 8 Particles from flour aerosols and other contaminants may clog the air vent or reduce the functions of the rotat ing 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 f 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 air borne and enter and build up within the fan and burner causing damage to the water heater 10 For the 110 310 amp 510 models e These units may be converted to a direct vent sealed combustion appliance by installing a direct vent conversion kit Part No 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 e If the water heater is used as a direct vent appliance the unit requires a 76mm 3 in combustible air sup ply 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 e Terminating the venting through a sidewall is recom mended for the direct vent system
45. ork as a part of the Easy Link system The other addi tional units will not work All units within an Easy Link System must be of the same exact model CAUTION Different models cannot com bine together to form an Easy Link System Easy Link Connection Procedures 1 Verify the set temperatures of all units within the system Every single water heater must be set to the same set temperature Select one unit to be the PARENT unit PARENT unit Locate the two banks of DIPswitches to the right of the 7 seg LED on the computer board of the unit that you select to be the PARENT unit Change DIPswitch No 1 on the right 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 7 seg LED of all the units computer boards display the unit The numbering system auto matically allocates the unit to
46. p of the water heater for normal service and inspection of the unit The water heater vent must not be connected to any other gas appliance or vent stack e Avoid using an oversized vent pipe or using extremely long runs of the pipe e For rooftop venting a rain cap or other form of termina tion that prevents rain water from entering into the water heater must be installed e Do not common vent or connect any vent from other appliances to the water heater vent General rules for vent terminations e Avoid locating the water heater vent terminator near any air intake devices These fans can pick up the exhaust flue products from the water heater and return them to the building This can create a health hazard e Locate the vent terminator so that it cannot be blocked by any debris at any time Most codes require that the ter minator be at least 305mm 12 in above grade but the installer may determine if it should be higher depending on the job site condition and applicable codes e A proper sidewall terminator is recommended when the water heater is vented through a sidewall e Regarding the clearances from the exhaust terminator to the air inlet or opening refer to the next few pages Exhaust venting For the 110 310 amp 510 models This is a Category Ill appliance and must be vented accord ingly The vent system must be sealed air tight All seams and joints without gaskets must be sealed with high heat resistant
47. r Control 24 hr Recirculation DOO On Demand Recirculation cd Demand Recirculation Commercial Or Multi a Fr Family Domestic Hot Water w Standard Pump Control Control Recirculation Timer Only No Pump Control 24 hr All Types Warranty for 110 amp 310 models Application Labor Years No Recirculation 12 5 On Demand Recirculation Single Family Aguastat Control Domestic Hot Water w Standard Pump Control Recirculation Timer hee ee No No Pump Control 24 hr _ Control 24 hr Recirculation Timer Only No Pump Control 24 hr All Types f All Types DOO On Demand Recirculation DOO On Demand Recirculation Recirculation Multi Family Domestic Aquastat Control 10 Hot Water w Standard PumpControl __ 1 Heat exchanger 2 An on demand recirculation system is a system that utilizes either a push button or other type of manual activation as opposed to automatic activation with a temperature sensor or timer to activate the circulation pump An on demand recirculation system can use either the existing cold water line as the return line or have its own dedicated return line 3 Limited Labor Coverage The manufacturer will provide for reasonable labor charges associated with warranty repairs or replacements with in one 1 year from the date of purchase The manufacturer will only pay directly to the service provider e Warranty service must be performed by an authoriz
48. r pip ing 2 The water heater requires 120 VAC 60 Hz electrical power supply that is properly grounded e A proper disconnect i e on off switch power plug etc controlling the main power to the water heater must be provided for service reasons Must comply with local codes e Connect the power supply to the water heater exact ly as shown in the wiring diagram 3 A green screw is provided in the junction box to ground the connection Can be hardwired or wired to a plug in The use of a surge protector is recommended in order to protect the unit from power surges O1 BR Connect Power supply 120 VAC 60 Hz Ground View of electrical connections of water heater Bottom view of water heater Remote Controller Connections To connect the remote controller to the water heater 1 2 3 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 com puter boara Open the plastic cover of the remote controller and then attach the two fork terminals to connector base of the backside the remote controller with two screws Make sure the terminals are firmly fixed Pull the remote s wires through the hole at the bottom of the water heater s casing 110 amp 310 models Y w H 0 NG NO 7 Q o ik A o 9 He OOLOY
49. rain where water leakage will not do damage to surrounding areas As with any water heating appliance the potential for leak age at some time in the life of the prod uct does exist The manufacturer will not be responsible for any water damage that may occur If you install a drain pan under the unit ensure that it will not restrict the combustion air flow Clearances Optional ltems Model wo 310 so gt Treo x x mrs ara AA to x x x eo x more x Bottom Maintain all clearances around the water heater Top Bottom Front Back Sides _ 110 305mm 305mm 610mm 25mm 51mm 12 in 12in 24 in 1 in 2 in 310 305mm 305mm 610mm 25mm 51mm 12 in 12in 24 in 1 in 2 in 510 305mm 305mm 610mm 25mm 51mm 12 in 12in 24 in 1 in 2 in Included Accessories Check that these items below are included with the water heater Installation Manual amp Owner s Guide Product Registration Card Communication Cable 510 models only 1 Temperature Remote Controller TK RE02 The Temperature Remote Controller has two functions lt allows the output temperature from the water heater to be adjusted within the range of 37 C to 75 C 99 F to 167 F and it also works as a diagnostic tool that will give a concise error code whenever there is a problem with the unit The tem perature options are 75 C 99 F 38 C
50. ric Ignition Supply 120 VAC 60 Hz 751 W 0 51 576 W OTSA 898 W 07SA Standby 6 2 W 0 05A 6 2 W 0 05A 6 2 W 0 05A o Freeze Protection 111 W 0 93A 111 W 0 93A 111 W 0 93A 40 psi or above is recommended for maximum flow The Manifold Pressure is the factory setting and generally should not need adjustment NOTE e Check the rating plate to ensure this product matches your specifications The manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Electric onsumption INTRODUCTION e This manual provides information necessary for the installation operation and maintenance of the water heater e The model description is listed on the rating plate which is attached to the front panel of the water heater e Please read all installation instructions completely before installing this product e f you have any problems or questions regarding this equipment consult with the manufacturer or its local representative e This equipment is an on demand tankless water heater designed to efficiently supply endless hot water for your needs e The 110 310 amp 510 models are to be installed indoors only direct vent convertible The principle behind tankless water heaters is simple Exhaust vent collar my Heat o UV exchanger EI i Flow adjustment valve
51. rvice the unit if necessary Do not disconnect the electrical supply if the ambient temperature will drop below freezing The Freeze Prevention System only works if the unit has electrical power The warranty will not be covered if the heat exchanger is damaged due to freezing Refer to the section on the Freeze Prevention System on pg 28 for more information INSTALLATION General 1 Follow all local codes or in the absence of local codes follow the most recent edition of CSA B149 1 Natural Gas and Propane Installation Code All gas water heaters require careful and correct installa tion to ensure safe and efficient operation This manual must be followed exactly Read the Safety Guidelines section The manifold gas pressure is preset at the factory It is computer controlled and should not need adjustment Maintain proper space for servicing Install the unit so that it can be connected or removed easily Refer to the Clearances section on pg 7 for proper clearances The water heater must be installed in a location where the proper amount of combustible air will be available to it at all times without obstructions The electrical connection requires a means of discon nection to terminate power to the water heater for ser vicing and safety purposes 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 terminati
52. s is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Use only your hand to turn the gas valve knob Never use tools If the knob will not turn by hand don t try to repair it Call a qualified service technician Forced or attempted repair may result in a fire of explosion Do not use this water heater if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts OPERATING INSTRUCTIONS STOP Read the safety information above or in the Owners Manual Turn off all electric power to the water heater Do not attempt to light the burner by hand Turn the manual gas valve located on the outside of the unit clockwise to the off position Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step Turn the manual gas valve located on the outside of the unit counter clockwise to the ON position Turn on all electrical power to the water heater If the water heater will not operate follow the instructions to Turn Off Gas to water heater
53. sfactory The manufacturer recommends having the unit checked once a year or as necessary by a licensed technician If repairs are needed any repairs should be done by a licensed technician 9 Securely screw the drain Unit Draining and Filter Cleaning Drain Plug with Filter Large Drain Plug Simli O LE Vial Gas Valve Water Valve 1 Close the manual gas shut off valve 2 Turn off power to the unit and wait a couple of seconds Turn on again 3 Wait 30 seconds and then turn off power to the unit yet again 4 Close the water shut off valve 5 Open all hot water taps in the house When the residual water flow has ceased close all hot water taps 6 Have a bucket or pan to catch the water from the unit s drain plugs Unscrew the two drain plugs Large and small to drain all the water out of the unit 7 Wait a few minutes to ensure all water has completely drained from unit 8 Clean the filter Check the water filter located within the cold inlet With a tiny brush i ATP ER clean the water filter of any Sine e TOE debris which may have accu EG a mulated and reinsert the filter AP back into the cold water inlet FE N 3 plugs back into place Hand tighten only 21 TROUBLESHOOTING General KU PROBLEM SOLUTIONS It takes long time to get hot water at the fixtures The water is not hot enough The water is too hot
54. signifies an inlet thermistor failure 30 110 amp 310 models The red LED on the computer board will be blinking two times If the TK RE02 is installed 32 will display on the screen in its entirety 510 models The 7 seg LED on the computer board will display 3 2 1 in that order one digit at a time and continually repeat If the TM RE30 is installed 321 will display on the screen in its entirety Easy Link System For the 510 models only Error codes will display differently with units installed within an Easy Link System not only to show what the error code is but to also indicate which unit within the system has the error code Below is a sample of how the same error code is displayed in an Easy Link System Example If Unit 2 has the 321 error code inlet thermistor failure Parent unit It will display 3 2 1 0 2 one digit at a time on the 7 Seg LED The first 3 numbers indicate the error code The last two numbers indicate that Unit 2 has the error code Unit 2 It will display 3 2 1 on the 7 Seg LED just like in the Single Unit example Unit 3 amp 4 These units will not display anything as the error code does not pertain to them TM RE30 It will display 232 on its screen The first 2 indicates that Unit 2 has the error The 32 indicates the first two digits of the 321 error code nn A A
55. silicone sealant or UL listed aluminum adhe sive tape having a minimum temperature rating of 177 C 350 F For best results a vent system should be as short and straight as possible e This water heater is a Category Ill appliance and must be vented accordingly with any 102mm 4 in vent approved for use with Category Ill or Special BH type gas vent e Follow the vent pipe manufacturer s instructions when installing the vent pipe e Do not common vent this appliance with any other vented appliance Do not terminate vent into a chimney If the vent must go through the chimney the vent must run all the way through the chimney with Category lll approved or Special BH vent pipe e When the horizontal vent run exceeds 1 5m 5 ft sup port the vent run at 0 9m 3 ft intervals with overhead hangars e The maximum length of exhaust vent piping must not exceed 15 24m 50 ft deducting 1 5m 5 ft for each elbow used in the venting system Do not use more than 5 elbows Max Vertical 8 Horizontal Total Vent i Max No of Diameter Elbow Length 76mm 3 in 5 15 24m 50 ft For each elbow added deduct 1 5m 5 ft from max vent length No of Elbows Max Vertical or Horizontal Length i 2 5 Excludes elbow termination rain caps or the 76mm 3 in PVC Concentric Termination Venting Illustrations For the 110 310 amp 510 models For details of the optional items refer to the Optional item
56. sizing Damages due to fires flooding freezing electrical surges or any Acts of God Damages due to unauthorized alterations attachments and or repairs e Damages due to a lack of maintenance e g water filter water treatment system vent blockage etc e Any product installed in an improper environment e g corrosive dusty chemically contaminated excessive lint etc e Freeze damage that occurs without taking proper preventive measures as described in the installation manual e Condensate damage due to improperly installed or lack of a condensate trap drain e Any product not installed in compliance with all applicable local amp provincial codes ordinances and good trade prac tices e Any product sold to or installed in areas outside of Canada e 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 e Any failures that are not due to defects in materials or workmanship mechanical and or electrical parts e Damages due to improper installation e Gas incorrect gas pipe sizing incorrect gas meter sizing incorrect gas type and or gas pressures that fall outside the product s specified range e 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
57. stem 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 sur rounding and or outside temperatures drop below 2 5 C 36 0 F For the 110 310 8 510 e n any areas subject to freezing temperatures freez ing 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 backflow 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 manufac turer 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 pg 29 2 Disconnect power to your heater This will keep your unit from freezing and being dam aged Only pipes within the water heater are pro tected by the fr
58. the 110 190 000 BTU h for the 310 and 199 000 BTU h for the 510 e The pressure relief valve needs to be rated for a maxi mum of 150 psi The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on any one or on nearby equipment e Attach the discharge tube to the pressure relief valve and run the end of the tube to within 150mm 6 in from the floor This discharge tube must allow free and complete drainage without any restrictions e f the pressure relief valve installed on the water heater discharges periodically this may be due to a defec tive thermal expansion tank or defective pressure relief valve e The pressure relief valve must be manually operated periodically to check for correct operation e No valve must be placed between the relief valve and the water heater 16 Electrical Connections Follow the electrical code requirements of the local authority having jurisdiction In the absence of such requirements follow the latest edition of CSA C22 1 Canadian Electrical Code Part 1 WARNING When servicing or replacing parts within the water heater label all wires prior to discon nection to facilitate an easy and error free re connection Wiring errors can cause improper and dangerous operation Verify CAUTION proper operation after servicing 1 The water heater must be electrically grounded Do not attach the ground wire to either the gas or the wate
59. xic chemicals used in boiler treat ments such as alcohol glycerol and gly col groups must not be introduced into the system if the system incorporates an open loop potable water system The water heater can be used to supply potable water and space heating and shall not be connected to any heat ing system or component s previously used with non potable water where any chemicals were added to the water heat ing appliances When the system requires water for space heating at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those other uses in order to reduce scald hazard poten tial Water temperature over 52 C 125 can cause severe burns instantly or death from scalds Chemicals such as diluted Glycol can be used for radiant floor Hydro fan coil air or Baseboard heating only The diluted solution of glycol must contain between 25 and 55 of Glycol Be aware that in closed loop glycol systems low pressure in the heat exchanger can cause low temperature boiling resulting in exces sive noise and damage to the water heater Consult with the glycol maker for specifications prior to use Recirculation e The recirculation pump is to be controlled by e Dual set aquastat recommended w timer OR e Pump Control Mode 510 Models only Refer to pg 20 e The recirculation pump is to provide no less than 7 5 l min 2 GPM US and no more than 15
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