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A.O. Smith ATI-510U-N Technical Documents

1. EF d K es ER 7 a N F EN EN D OG Da w 716 Surge box assembly Owner s Guide Components Diagram Burner assembly Burner assembly Exhaust section Outdoor models 49 Page Owner s Guide Components Diagram Water Way assembly Bypass section 510U T D2U models outlet section To Water Water outlet section Water inlet section 50 Page PARTS LIST 001 002 003 004 005 006 007 050 051 052 053 054 055 056 057 058 059 060 061 062 063 101 102 103 104 105 106 108 109 110 111 112 113 114 115 116 117 118 119 Description Case assembly for Indoor models for Outdoor models Front cover for 110U and 310U Indoor T KJr2U IN and T K4U IN for 110U and 310U Outdoor T KJr2U OS and T K4U OS for 510U Indoor T D2U IN for 510U Outdoor T D2U OS Air blockage plate for Indoor models Bracket Junction box Power suuply code assembly Back guard panel Screw M4x12 W Washer Screw M4x10 W Washer Screw M4x10 Coated Screw M4x10 Hex head screw M4x12 W Washer Hex head screw M4x8 Screw M3x10 Tap tight screw M4x12 FEZN Screw M4x10 Screw M4x6 Screw M4x12 Screw M3x6 Screw M4x8 Wire clamp 60 Burner and mixing chamber assembly Manifold with gas valve assembly NA Fan motor for Indoor models Fan motor for Out
2. IN USE LED Green The lamp lights during combustion STAND BY LED Orange The indicator is ON to show that WARNING Temperature above 125 F 52 C can power IS ON cause severe burns or death from scalding Children disabled and the elderly are at high risk of being injured MADE IN JAPAN GENERAL Temperature above 125 F 52 C can cause severe burns or death from scalding Children disabled and the elderly are at high risk of being injured CAUTION 1 Open a hot water tap 2 Mix cold water with the hot to get 3 Close the hot water tap the correct temperature water DH NN GA gt SAD S28 il il ES NOTICE e Flow rate to activate the water heater 0 5 gallon per minute at the default set temperature 2 0 L min e Flow rate to keep the water heater running 0 4 gallon per minute 1 5 L min The remote controller has an energy saving mode Five minutes after the water heater stops operating the backlight of the remote controller turns off The backlight of the remote will turn back on once the water heater begins firing again TEMPERATURE SETTINGS Set temperature Owner s Guide Normal Operation SE EN T 2 Turn on the 120 VAC power supply to the unit the water heater or the multi unit controller Press the ON OFF button on the remote in order to turn the remote controller on When ON the STAND BY LED is lit It shows the set temperature on its display as shown the picture
3. codes 3 Pipe covers 9007670005 TK PCO1 4 Recess box 9007674005 TK RBO2 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 plumbing The Recess box will fit in between most wall studs I I 1 1 I I 1 1 I I d I The pipe cover protects the plumbing pipes to the water heater from unexpected 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 5 T Vent Wall Thimble with Termination 9007608005 TK KPWL4 and 9007609005 TK KPWH4 These terminations are used when venting out through the wall and are compatible with the T Vent pipe system These terminations are special stainless steel vents for gas appliances and are UL listed as Category II lll and IV There are two types of terminations the Louver termination and the Hood termination For different wall thicknesses Louver Termination Hood Termination there are two ranges of lengths available refer to the T Vent brochure 9007608005 9007609005 for details Install these vent terminations in accordance with their TK KPWLA TK KPWH4 installation instructions and any applicable local codes 6 Direct Vent Concentric Termination 900768005 TK KPCT43 Used when terminating direct vent sealed combustion systems wit
4. LN Unit does not ignite when water goes through the unit The fan motor is still spinning after operation has stopped Unit sounds abnormal while in operation Remote controller does not display anything when the power button is turned on An ERROR code is displayed How are the unit numbers assigned Owner s Guide Normal Operation PS PROBLEM SOLUTIONS Is the flow rate over 0 5 GPM 1 9 L min p 37 Check for the filter on cold water inlet p 41 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 Contact the manufacturer at 1 888 479 8324 Make sure the unit is supplied with power Make sure the connection to the unit is correct p 22 9008172005 TM RE40 When the remote If the stand by LED lights up the remote controller has been turned ON When the unit has not operated for five minutes or more the display turns off to conserve energy e controller turned ON stand by LED is lit Please see p 44 46 For an Easy Link system the Parent unit is always labeled 41 and all other subsequent Child units are numbered randomly To check which numbers are assigned to which Child units push the button on
5. 60 W A 52 1 0 54 75 8 0 83 81 6 0 86 W A 5 4 0 08 5 5 0 08 6 5 0 09 W A 191 1 11 131 1 1 182 AA 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 e In accordance with ANSI Z21 10 3 CO emission does not exceed 400 PPM for normal input e The manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 4 Page Installation Manual INTRODUCTION OLE A O 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 front 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 with the manufacturer or its local representative This equipment is an on demand tankless water heater designed to efficiently supply endless hot water for your needs The 110U Indoor T KJr2U IN 310U Indoor T K4U IN and 510U Indoor T D2U IN models are to be installed indoor direct vent convertible The 110U Outdoor T KJr2U OS 310U Outdoor T K4U OS and 510U Outdoor T D2U OS models are to be only installed outdoor The princi
6. When installing the vent system all applicable national and local codes must be followed If you install thimbles fire stops or other protective devices and they penetrate any combustible or noncombustible construction be sure to follow all CAUTION applicable national and local codes The water heater must be vented in accordance with the section Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the United States and or Section 7 of the CAN CSA B149 1 Natural Gas Installation Code in Canada as well as applicable local building codes The manufacturer recommends the T Vent line manufactured by TAKAGI Refer to T Vent brochure for details However the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Flex L Inc Z Flex Inc Z Vent III Metal Fab Inc and Heat Fab Inc Saf T Vent General rules for venting water heaters are 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 collar e Do not cut the vent collar of the unit e The vent must be easily removable from the top of the water heater for normal service and inspection of the unit e 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
7. Is the gas supply pressure enough p 20 e Is the set temperature set too low p 36 37 The water is too hot Is the set temperature set too high p 36 37 The hot water is not Make sure the unit has 120 VAC 60 Hz power supply available when a e If you are using the remote controller is the power button turned on fixture is opened e Is the gas supply valve fully open p 32 e Is the water supply valve fully open p 32 e Is the filter on cold water inlet clean p 41 e Is the hot water fixture sufficiently open to draw at least 0 5 GPM 1 9 L min through the water heater p 36 e Is the unit frozen p 40 The hot water turns Ils the flow rate enough to keep the water heater running p 37 cold and stays cold Ifthere isa recirculation system installed does the recirculation line have enough check valves p 29 e Is the gas supply valve fully open p 32 e Is the filter on cold water inlet clean p 41 e Are the fixtures clean of debris and obstructions e Check if the flow rate is too low p 36 37 Fluctuation in hot e Is the filter on cold water inlet clean p 41 water temperature Is the gas line sized properly p 19 e Is the supply gas pressure sufficient p 20 e Check for cross connection between cold water lines and hot water lines TEMPERATURE and AMOUNT OF HOT WATER EASY LINK SYSTEM WATER HEATER Remote controller Ea fo Ea ov fe 5 N Q 2 el
8. controller 9008172005 TM RE40 321 and 2 will intermittently flash on the display And it shows that Unit 2 has the error EPER gt EN SON I I FLOW L Error code Unit e Parent unit These units will not display anything as the error code does not pertain to them Unit 1 Unit 2 Unit 3 Unit 4 e Unit 2 The green LED on the computer board PARENT CHILD CHILD CHILD will be blinking two times just like in the single unit example e Unit 3 and 4 These units will not display anything as the error code does not pertain to them 9008172005 TM RE40 Owner s Guide 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 e Malfunction Remote Diagnosis description One Tine Incorrect DIPswitch Check the DIPswitch settings on the PCB Part 701 101 111 121 311 321 331 setting Five Times Warning for the 991 error code Three Times Ignition failure Three Times Loss of flame Two Times Outlet and Mixing thermistor failure Two Times Inlet thermistor failure Two Times Heat exchanger thermistor failure 510U T D2U models only Check the gas type of the water heater 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 d
9. during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa e The water heater must be isolated from the gas supply 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 5 kPa Always purge the gas line of any debris and or water before connecting to the gas inlet NOTICE Size the gas pipe appropriately to supply the necessary volume of gas required for the water heater using ANSI233 1 NFPA 54 in the USA or CAN CSA B149 1 in Canada or local codes Otherwise flow capabilities and output temperatures will be limited Installation Manual Installation Natural Gas Supply Piping Maximum delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe carrying Natural Gas with 0 60 Specific Gravity Based on Pressure Drop of 0 5 W C Based on Energy Content of 1 000 BTU Cubic ft The water heater requires 140 Cubic ft hr for the 110U T KJr2U models 190 Cubic ft hr for the 310U T K4U models and 199 Cubic ft hr for the 510U T D2U models Diameter 10 20 EO CE 60 70 0 90 100 125 ETEN zaj 368 249 200 ivi 152 188 127 148 iil 104 93 84 72 1 6348 700 EA 55239 E22368 PEN 2598 92228 22083 OA 7 49 ESN iss 1 1404 965 775 663 588 532 490 456 428 404 358 324 278 IES EOS PAS JE 265 kes0 EE JJ ES 62 19 605 RESEM REASON JEG 2 4 050 2 784 2 235
10. long runs of the pipe e For rooftop venting a rain cap or other form of termination 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 terminator must be at least 12 in 305 mm 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 Installation Manual Installation Vent length and No of Elbow This is a Category Ill appliance and must be vented accordingly The vent system must be sealed air tight All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive tape having a minimum temperature rating of 350 F 177 C For best results a vent system o should be as short and straight as possible This water heate
11. seconds and then turn off power to the unit yet again Close the water shut off valve Open all hot water taps in the house When the residual water flow has ceased close all hot water taps 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 i i Drain plug Water valve Wait a few minutes to ensure all water has completely Small drained from unit Clean the filter Check the water filter located within the cold inlet With a tiny brush clean the water filter of any debris which may have accumulated and reinsert the filter back into the cold water inlet Securely screw the drain plugs back into place Hand tighten only TROUBLESHOOTING GENERAL I PROBLEM SOLUTIONS It takes long time to The time it takes to deliver hot water from the water heater to your get hot water at the fixtures depends on the length of piping between the two The longer the fixtures distance or the bigger the pipes the longer it will take to get hot water e f you would like to receive hot water to your fixtures quicker you may want to consider a hot water recirculation system p 29 The water is not hot Compare the flow and temperature See the charts on p 54 enough e Check cross plumbing between cold water lines and hot water lines e Is the gas supply valve fully open p 32 e Is the gas line sized properly p 19 e
12. to the length of that adjacent wall For direct vent sidewall terminations that use two separate penetrations for the intake and exhaust distance the intake and exhaust terminations at least 3 ft 915 mm away from each other no matter the orientation Exhaust and or direct vent sidewall terminations should be at least 2 ft 610 mm away from an opposite surface wall Do not place the termination directly in front of an opening into a building For rooftop terminations A In accordance with local codes Exhaust termination Exhaust termination Air intake For multiple unit rooftop terminations whether for standard 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 2 ft 610 mm away from a wall or surface Please follow all local and national codes in regards to proper termination clearances In the absence of such codes the following clearances can be used as CAUTION guidelines Local codes supersede these guidelines Installation Manual GAS SUPPLY AND GAS PIPE SIZING General e Check that the type of gas matches the rating plate first e Ensure that any and all gas regulators used are operating properly and providing gas pressures withi
13. 0 ft Up to 4 000 ft Up to 6 000 ft Over 6 000 ft 12345678910 EER EREN AE ELO RETA RAE JE ordo a boto SE 110U T KJr2U and 310 T K4U models No 3 OFF No 3 OFF No 3 OFF No 3 ON Consult our No 4 OFF No 4 ON No 4 OFF No 4 OFF Ne Ss OFF No 5 OFF No 5 ON No 5 ON Technical 123456 T23 456 123458 Services a OER S mn ae ok ogy REE Tl at 1 888 510U T D2U models orr EE op E Gol OE DE OFF l 479 8324 Comet pank or No 2 OFF No 2 OFF No 2 OFF No 2 ON DIPswitches ok OF l Os y Os No 3 OFF No 3 ON No 3 OFF No 3 OFF No 4 OFF No 4 OFF No 4 ON No 4 ON NOTE The dark squares indicate the direction the DIPswitches should be set to 110U T KJr2U and 310U T K4U models 510U T D2U models Computer board Computer board DIPswitches tower bank DIPswitches DO NOT adjust any DIPswitches on the upper bank for the 510U T D2U models WARNING 12 Page Installation Manual VENTING INSTRUCTIONS For indoor models General e Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death e Improper installation can cause nausea or asphyxiation severe injury or death DANGER from carbon monoxide and flue gases poisoning Improper installation will void product warranty
14. 1 913 1 696 1 536 1 413 1 315 1 234 1 165 1 033 936 801 Unit Cubic Feet per Hour Gas Sizing Example Natural Gas Water Heater Dryer 199 000 BTU h 35 000 BTU h 10 Length 3 4 Pipe Size 5 Length 15 Length 10 Length 1 1 4 Pipe Size A 1 Pipe Size 1 2 Pipe Size 10 Length qu Pi H 5 Length Pete 10 Length 15 Length 1 1 4 Pipe Size 3 4 Pipe Size C 1 2 Pipe Size Furnace Range 120 000 BTU h 65 000 BTU h Based on Energy Content of 1 000 BTU Cubic ft Divide each appliance s BTU requirement by 1 000 BTU h to get the appliances Cubic Ft requirement Take into account the distance the appliance is from the gas meter look in the above gas chart to properly size the line For sections of the gas line supplying gas to more than one appliance Ex Point A to Point B add up the cubic ft requirements of the appliances that are being supplied by that section and size to the farthest appliance For Example The section from A to B supplies gas to the furnace range and dryer Adding up the BTU requirements and dividing by 1 000 yields a cubic ft requirement of 220 cubic ft of gas The farthest appliance is the range which is 50 ft away from the meter Looking at the above chart and under the column of 50 ft Section A to B needs to be 1 in order to supply 220 cubic ft 19 Page Installation Manual Measuring inlet gas pressure 1 Turn off all electric power to the wate
15. 150 psi 1 MPa The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in 150 mm from the floor This discharge tube must allow free and complete drainage without any restrictions If the pressure relief valve installed on the water heater discharges periodically this may be due to a defective thermal expansion tank or defective pressure relief valve The pressure relief valve must be manually operated periodically to check for correct operation No valve must be placed between the relief valve and the water heater ELECTRICAL CONNECTIONS Follow the electrical code requirements of the local authority having jurisdiction In the absence of such requirements follow the latest edition of the National Electrical Code ANSI NFPA 70 in the U S or the latest edition of CSA C22 1 WARNING Canadian Electrical Code Part 1 in Canada When servicing or replacing parts within the water heater label all wires prior to disconnection to facilitate an easy and error free reconnection Wiring errors can cause improper and dangerous operation Verify proper operation after servicing CAUTION prop g p y prop p g All indoor models come with a power plug instead of a junction box The following procedure is for outdoor models only 1 2 RAW The water heater must be ele
16. 31 to 50 ft 14 Page Installation Manual Venting Illustrations For the 110U Indoor T KJr2U IN 310U Indoor T K4U IN and 510U Indoor T D2U IN models For details of the optional items refer to the Installation manual for each Optional item Horizontal Installation Diagram Vertical Installation Diagram Rain Cap Hh Roof Flashi tt Roof I oof Flashing Backflow gt f Ne Preventer FA 2 Sidewall Vent Terminator Backflow Preventer Vertical Condensation Drain Horizontal Installation Diagram Vertical Installation Diagram With direct venting With direct venting Wall ueRain Cap Zn Roof t e q i Roof rn eee Flashing q go gt a Sidewall Vent a Terminator Backflow _ Vertical Condensation Preventer 5 4 Drain o i 4 in See the picture below for detailed connection Vertical Condensation Drain instructions to Direct Vent Conversion Kit y Backflow Preventer Recommended for freezing weather conditions 36 F 2 C and below Vertical Condensation Drain must be installed in accordance with local codes Backflow Preventer Fire stop Horizontal Installation Diagram With Installation Diagram of Direct Vent Direct Vent Concentric Termination Conversion Kit with water heater Wall lt as ey OO a Intake port of Direct Vent p y I N Conversion Kit For details see P 10 Direct vent Concentric Termina
17. 46 2 for Ultra Low NOx Emissions e EASY LINK SYSTEM AND MULTI UNIT SYSTEM 510U T D2U models only Toll Free 1 877 737 2840 CONTENTS Installation Manual SPECIFICATION Sa a bee ida 4 INTRODUCTION cai aci n 5 SAFETY GUIDELINES causar aio 6 INSTALLATION id 7 Genera EEE ii 7 Heri 9 Included ACCES SONG EE EE o 9 Optional go EE a NE ev 9 alge ee Ei 0 g EEE EE 9 High altitude Installations aa 12 Venting INSTRUCTIONS imei dedicada 13 Gas Supply and gas PIPE SIM ici 18 Water CONNMECHON Sierra lira ad eiii i n tota 20 Ele circa COME CIN acido 21 Temperature Remote Controll f 55200 cocida ricas di dens deaaneindand as oia 22 ESA eee 25 Nd Ad dg dseinaameb ueen 29 APPLICATION ee 30 INITIAL OPERATION asken 32 Owner s Guide OPERATING SAFETY urinen 34 NORMALE OPERATION sisside Geert idealet aksent a a aA N 36 G nera EE 36 Temperature SCTEINGS ie nvce2 ceveceiessnetsledectevvuedeacand cana tadetesl ease raise incidencias ka 37 A enenb edad 40 Fre ze protection Syste Mssari aiana e e ea a aaia 40 Maintenance and SCrViCC i ic0 s0sccneseccccsvcciessesssseuessveseaernedsasteesvedsesesesvsssesenscdhibvessssvesvasbevsuvesns 41 Unit Draining Filter Cleaning ooccccccccncnnnnononanananonnnonnnnnnnnnnnnnnnnnnnnnnn ono nnnonnnnnnnnnnnonannnnnnnnns 41 TROUBLESHOOTING rs Sa 42 O O belde atas 42 Error Codes im ada 44 COMPONENTS DIAGRAM iss srenaeaesersdneneeberntshidndertententderknde a n EEEE AAAA a Eaa EET Ee 47 PARTS
18. 461 462 463 Description Igniter plate Surge box plate Gasket Gasket O ring P18 NBR Black O ring P20 NBR Black Silicon ring for Outdoor models Rain protection plate in Exhaust chamber for Outdoor models Exhaust port for Outdoor models Heat exchanger assembly for 110U and 310U Indoor T KJr2U IN and T K4U IN for 110U and 310U Outdoor T KJr2U OS and T K4U OS for 510U Indoor T D2U IN for 510U Outdoor T D2U OS Flow adjustment valve Flow sensor Bypass valve for 510U T D2U models Water inlet Inlet drain plug Inlet water filter Inlet thermistor for 110U T KJr2U and 310U T K4U models Inlet thermistor for 510U T D2U models Outlet thermistor for 110U T KJr2U and 310U T K4U models Outlet thermistor for 510U T D2U models Water outlet Outlet drain plug Heat exchanger thermistor for 510U T D2U models Hi Limit switch for 110U T KJr2U and 310U T K4U models Hi Limit switch for 510U T D2U models Overheat cut off fuse Pipe 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 510U T D2U models Fastener 14 22 Fastener 16A Fastener 16 25A for 510U T D2U models Silicon ring for Indoor models I U N 319143 051 319143 176 319143 456 319143 457 319143 350 319143 057 319143 206 31
19. 9143 458 319143 219 319143 459 319143 460 319143 461 319143 462 319143 463 319143 464 319143 193 319143 197 319143 198 319143 214 319143 465 319143 218 319143 190 319143 466 319143 199 319143 096 319143 228 319143 095 319143 149 319143 467 319143 468 319143 088 319143 125 319143 066 319143 146 319143 082 319143 080 319143 100 319143 091 319143 083 319143 097 319143 105 319143 226 319143 205 319143 065 Owner s Guide Parts List 110U 310U and T KJr2U T K4U 510U models land T D2U models EKK1B EK436 EK127 EK145 EZP18 EK042 EKK3G EK134 EKK56 EK119 EK121 EKD62 EK122 EK129 EKD58 EKK1U EKK2B EKK2C EKK4J EK137 EKK55 EKK1A EK104 EKK2E EKK2T EM212 EKN34 EK333 EK130 EK105 EKK27 EKO31 EKK26 EKO29 EZMO4 EZM06 EZM14 EZM15 EZM16 EKH30 EKK24 EM192 EKK39 EKN50 702 703 704 705 706 707 708 709 710 ZAL 712 713 714 75 716 717 718 719 720 721 Description Computer board for 110U T KJr2U models for 310U T K4U models for 510U T D2U models Rubber grommet for Indoor models Surge box 120 VAC wire for Indoor models for Outdoor models Switch wire 120 VAC Power ON OFF switch Remote controller wire for 110U T KJr2U and 310U T K4U models for 510U T D2U models Gas valve wire Flame rod wire for 110U T KJr2U and 310U T K4U models Flame rod wire for 510U T D2U models EH IG wire Igniter High voltage igniter cable Freeze protection thermosta
20. 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 and Call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Turn off all electric power to the water heater if service is to be performed Turn the manual gas valve located on the outside of the unit clockwise to the off position Owner s Guide DANGER Flammable Vapors 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 WARNING The outlet hot water temperature of the water heater is factory set at 120 F 49 C Use this heater at your own risk The set outl
21. LIST ur Te 51 OUTPUT TEMPERATURE CHART sseeccsiscecs desvisesseaccennesiaandeceatvegehsubsaadeeadiaenieedvendieabeciiesmeasvenescary 54 LIMITED WARRANTY rioris eas innsean kvadet did 55 Installation Manual Contents Installation Manual CONGRATULATIONS Congratulations and thank you for choosing our tankless Before use we recommend that you read through this s carefully Please refer to the back of the manual for details warranty Keep this manual for future reference If you lose the manual contact the manufacturer or y distributor When you call please tell us the product nar serial number of your unit written on the rating plate of i heater 3 Page SPECIFICATIONS Installation Manual Specifications Natural Gas Input Operating Range Gas Connection Water Connections Water Pressure Natural gas Inlet Pressure Manifold Natural Pressure Gas Weight Dimensions Ignition Supply Operation Standby Freeze Protection Electric Consumption 310U Outdoor T KJr2U IN T KJr2U OS T K4U IN T K4U OS T D2U IN T D2U 0S BTU h Min 15 000 Min 15 000 Min 15 000 Max 140 000 Max 190 000 Max 199 000 3 4 NPT 3 4 NPT psi 15 150 0 1 1 Mpa WC Min 5 0 1 24 kPa Max 10 5 2 61 W C 1 8 15 3 0 209 33 8 Pa 448 373 747 722 821 722 lbs kg 37 16 9 39 17 9 inch H 20 5 x W 13 8xD 8 5 mm H 520 x W 351 x D 216 Electric Ignition VAC Hz 120
22. On Demand Water Heater Installation Manual and Owner s Guide Re Rey ANSI Z21 10 3 and CSA 4 3 US E O Models PI e 110U Indoor T KJr2U IN 110U Outdoor T KJr2U OS PPK 310U Indoor T K4U IN 310U Outdoor T K4U OS 510U Indoor T D2U IN 510U Outdoor T D2U OS 510U T D2U models only If the information in these A J ER LOT instructions is not followed AI E exactly a fire or explosion may WARNING result causing property damage personal injury or death Do not store or use gasoline or other e flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building z y 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 Installation and service must be performed by a qualified installer service agency or the gas supplier Gas Tankless Water Heater Suitable for potable water heating and space heating Please refer to local codes for space heating compliance FEATURING e ENDLESS HOT WATER e ON DEMAND USAGE e COMPACT SPACE SAVING e ENERGY CONSERVATION If you have any questions please e COMPUTERIZED SAFETY call or write to e NO PILOT LIGHT 500 Tennessee Waltz Parkway e Satisfies the 2012 SCAQMD Rule Ashland City TN 37015 11
23. Parts Labor No Recirculation On Demand Recirculation g 2 Single Family Aquastat Control 5 5 a Domestic Hot Standard Pump Control l Water i 7 Recirculation Timer Only 4 No Pump Control 24 hr No Recirculation On Demand Recirculation Multi Family Aquastat Control 4 Domestic Hot q 10 Water w Standard Pump Control Recirculation Timer Only 1 No Pump Control 24 hr Heating All Types 1 1 18 Commercial All Types 1 1 18 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 Owner s Guide 3 Limited Labor Coverage e The manufacturer will provide for reasonable labor charges associated with warranty repairs or replacements within one 1 year from the date of purchase The manufacturer will only pay directly to the service provider e Warranty service must be performed by an authorized Service Representative A list of authorized Service Representatives is available upon request 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 o
24. T 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 unit CHILD 1 unit Connectors Connectors Remote controller el 1 G ey Ne ie i 5 IN2UVd T d h CJ ANSUVd T A 2 Lower bank of DIPswitches Lower bank of I J yi WwW gt amp DiPswitches Wrong Connections 17 NG Communication cable ANE MULTI UNIT SYSTEM Multiple 510U T D2U models can be combined for a Multi Unit system along with the multi unit controller Parts 9007675005 TM MCO2 and remote controller 9008172005 TM RE40 Each set of multi unit controller and remote controller can control from 2 units to 20 units for commercial or residential applications For a 20 unit system the computer can modulate between the usages of 15 000 DET to 4 oy Mullion ADE 9007675005 TM MC02 NAIA AT Cold IN An individual cut off switch is recommended for each unit in a multi unit system for the purpose of maintenance Multi Unit System Connection Diagram Multi unit controller and temperature remote controller w
25. U T K4U models Output Temperature vs GPM Max 8 0 GPM with Various Inlet Water Temperature 10 0 5 a e 40F m 50F 4 60F 3x 70F E oO E 40 E 5 B 2 gt o 00 100 105 110 115 120 125 130 135 140 150 160 165 9 40F 52 4 8 4 5 4 2 3 9 3 7 3 5 3 3 3 1 29 26 25 50F 63 5 7 5 2 4 8 45 42 3 9 3 7 3 5 3 1 2 9 2 7 4 60F 79 7 0 6 3 5 7 5 2 48 4 5 4 2 3 9 3 5 34 3 0 x 70F 80 8 0 7 9 7 0 6 3 57 52 4 8 45 3 9 3 5 3 3 510U T D2U models Output Temperature vs GPM Max 10 0 GPM with Various Inlet Water Temperature s 150 E 3 10 0 o I 5 0 53 6 0 0 100 105 110 115 120 125 130 135 140 150 160 165 170 175 180 185 e 40F 55 54 47 44 44 39 37 35 33 30 27 26 25 24 24 23 m 50F 66 6 0 55 51 47 44 41139137 33 30 29 27 26 25 24 4 60E 82 73 66 60 55 54 47 44 44 37 38 34 30 29 27 26 70F 10 0 94 82 7 3 66 60 55 5 1 47 41 37 35 33 31 30 29 When the set temperature is 131 F 55 C or higher maximum flow rate is limited to 8 0 GPM 54 Page Owner s Guide PE WARRANTY 2 General terms of limited warranty This limited warranty gives you specific legal rights and you may also have other rights which vary
26. a of any air intake or building opening Outdoor models only Refer to p 15 TITT 1 ft 305 mm USA 3 ft 914 mm Canada 3 ft 914 mm 1 ft 305 mm USA 1 ft 305 mm USA 3 ft 914 mm Canada 3 ft 914 mm Canada Do not install next to a dryer or any source of airborne debris that can be trapped inside the combustion chamber unless the system is direct vented Installation Manual Installation HIGH ALTITUDE INSTALLATIONS Check the elevation where your water heater is installed Set DIPswitches shown in the table below depending on the altitude Indoor models PT O DEFAULT Up to 2 500 ft Up to 5 000 ft Up to 7 500 ft Over 7 500 ft ih 2 2 4 15 Er ED LOODE ED 129058 EELO 12345678910 HOLO 10 Oo PTET OFF E LL dd ol Hva orp HH orp LE laiale a 110U T KJr2U and 310 T K4U models No 3 OFF No 3 OFF No 3 OFF No 3 0FF Consult our No 4 ON No 4 OFF No 4 ON f No 5 OFF No 5 ON No 5 ON Technical Services ON Suu on aay fn OM ON alas an ON jan E at 1 888 7 He A las 510U T D2U models off REI ok Ee en ER oven ap No 2 OFF No 2 OFF No 2 OFF No 2 OFF DIP itch OPZ EE 0O 48 Onze ob 745 Switches No 3 OFF No 3 ON No 3 OFF No 3 ON No 4 OFF No 4 OFF No 4 ON No 4 ON Outdoor models Pr O DEFAULT Up to 2 00
27. cal codes follow the most recent edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the USA or CAN CSA B149 1 Natural Gas Installation Code in Canada 2 Properly ground the unit in accordance with all local codes or in the absence of local codes with the National Electrical Codes ANSI NFPA 70 in the USA or CSA standard C22 1 Canada Electrical Code Part 1 in Canada 3 Carefully plan where you intend to install the water heater Please ensure e Your water heater will have enough combustible air and proper ventilation e Locate your heater where water leakage will not damage surrounding areas please refer to p 8 4 Check the rating plate for the correct GAS TYPE GAS PRESSURE WATER PRESSURE and ELECTRIC RATING If this unit does not match your requirements do not install and consult with the manufacturer 5 If 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 e Water temperatures over 125 F 52 C can cause severe burns instantly or death from scalding The water temperature is set at 120 F 49 C from the factory to minimize any scalding risk Before bathing or showering always WARNING check the water temperature O e Do not store or use gasoline or other flammables vapors or liquids in the vicinity of this appliance e Do not reverse the water and or gas connections as this will damage the gas valves and can cause se
28. clearances not specified in ANSI Z223 1 NFPA 54 or CAN CSA B149 1 please use clearances in accordance with local installation codes and the requirements of the gas supplier L 7 feet t 7 feet 16 Page 1 ft 1 ft Exhaust termination Y Combined intake and exhaust e 305 mm Installation Manual For sidewall terminations 2 ft 610 mm me corner 2 ft 610 mm Inside termination corner Exhaust gt termination 3 ft 3 ft 915 mm 3 ft 915 mm O Air supply inlet For multiple sidewall exhaust terminations e g multi unit systems an exhaust termination must be at least 1 ft 305mm away from another exhaust termination An exhaust termination must also be at least 2 ft 610 mm away from an inside corner if the adjacent wall is less than 2 ft 610 mm of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall For multiple unit direct vent sidewall terminations that combine the intake and exhaust into a single penetration space each direct vent termination at least 1 ft 305 mm away from each other no matter the orientation A direct vent termination must also be at least 2 ft 610 mm away from an inside corner if the adjacent wall is less than 2 ft 610 mm of length the minimum required distance away from the inside corner will be equal
29. ctors a EZS Y DIZ A AN3Uvd T r 3 m ANaUvd wm I ANSUVd T I ANAYVd U o 2 9 v e IIN Lower bank of L i Lower bank of 1 11 Lower bank of a Lower bank of DiPswitches a DiPswitches 7 DiPswitches 7 DiPswitches 9SVEZ Communication cable NOTE The dark squares indicate the direction the DIPswitches should be set to Installation Manual NOTICE Aremote controller is required for the Easy Link system for ease of usage and maintenance e f a remote controller is used the temperature on all the units in the system will automatically be set to the same temperature that is set on the remote C Examples of incorrect settings and or connections CASE 1 Wrong DIPswitch setting on the PARENT unit e Unless you change DIPswitch No 1 of the PARENT unit to the ON PARENT unit CHILD 1 unit position the system will not work Connectors Connectors as an Easy Link system The units r will operate as individual units Wrong Setting Lower bank of DiPswitches Communication cable PAS CASE 2 Wrong connections between the PARENT unit and the CHILD 1 unit e If 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 wi
30. ctrically grounded Do not attach the ground wire to either the gas or the water piping 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 exactly as shown in the wiring diagram 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 Indoor models only Outdoor models only Connect Power supply Green screw 120VAC 60Hz PEN 4 Ne A A a SEND T v lov Ground Bottom view of water heater View of electrical connections of water heater Installation Manual Installation TEMPERATURE REMOTE CONTROLLER INCLUDED ACCESSORIES Check that these items below are included with the remote controller Temperature Screws Manual Remote controller cable Qty 2 Qty 1 Qty 1 Remote Controller INSTALLATION e This remote controller is NOT waterproof Do not install in high temperature environments steamy conditions such as a bath room outdoors in direct sunlight or within the reach of children CAUTION Make sure the remote controller does not co
31. door installations have the same clearances 24 inch recommended for maintenance INCLUDED ACCESSORIES Check that these items below are included with the water heater Installation Manual Temperature Communication Cable and Owner s Guide Remote Controller Kit 510U T D2U models only Qty 1 ae ty 1 Qty 1 Refer to the p 22 OPTIONAL ITEMS 110U 110U 310U 310U 510U 510U Model Indoor Outdoor Indoor Outdoor Indoor Outdoor T KJr2U IN T KJr2U OS T K4U IN T K4U OS T D2U IN T D2U OS Backflow Preventer Direct Vent Conversion Kit Y Y Pipe covers vA VA Y Recess box VG va V T Vent Wall Thimble with Termination Y Y Direct Vent Concentric 6 Termination Y Y 9 Page ven Manual Ins la on nstal Q 11 1 Backflow Preventer 9007678005 TK BFO1 2 Direct Vent Conversion Kit 9007667005 TK TV10 AM amp The Backflow preventer prevents the backflow of air through the exhaust vent This helps prevent i harmful exhaust gases from entering the home as This kit can be used to convert the water well as helping to prevent the unit from freezing in heater from a standard vent system to a direct areas where cold air can be blown or drawn into vent or sealed combustion system Install the exhaust system Install this vent damper in this conversion kit in accordance with the accordance with the installation instructions and installation instructions and any applicable any applicable codes
32. door models Burner fixing plate assembly Burner and mixing chamber sub assembly Burner window Rod holder gasket Flame rod with AFR function Igniter rod Rod holder Rod cap Burner damper Manifold gasket A Manifold gasket B Fixing plate Pressure port Combustion chamber tube Gas inlet Gas inlet ring 319143 428 319143 429 319143 430 319143 431 319143 432 319143 433 319143 150 319143 184 319143 014 319143 437 319143 221 319143 025 319143 325 319143 026 319143 060 319143 326 319143 063 319143 327 319143 201 319143 087 319143 328 319143 438 319143 439 319143 440 319143 048 319143 441 319143 442 319143 443 319143 043 319143 444 319143 445 319143 033 319143 446 319143 447 319143 448 319143 449 319143 450 319143 451 319143 452 319143 045 319143 453 319143 042 319143 454 319143 455 319143 342 Owner s Gu ANT Cnmnnnentc T Components D IG 110U 310U and T KJr2U T K4U 510U models and T D2U models EK103 EK111 EK110 EK123 EKD59 EKD63 EK401 EKJO9 EKJ64 EKK4D EKK5H EW000 EWOO1 EW002 EW003 EW004 EW005 EW008 EKK31 EWOOA EW009 EKK37 EW016 EK155 EM167 EK120 EK118 EK109 EKK25 EK144 EK147 EKK2V EK107 ENDE EK124 EK126 EK136 EK116 EK108 EKK2K EK140 EKK2D EM482 EK117 EXOOD 120 1211 122 123 150 sil 152 153 154 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 450 451 452 453 454 455 456 457 458 459 460
33. ds 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 applications or more than 4 grains per gallon 70 ppm for all other types of applications into the product e Introduction of untreated or poorly treated well water into the product e Introduction of water with pH levels less than 6 5 and greater than 8 5 into the product 602101
34. e Do not try to start the water heater e Do not touch any electric switches do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas WARNING supplier s instructions e If you cannot reach your gas supplier call the fire department T Once the above checks have been completed please clean filter of any debris Refer to p 40 for instructions Fully open the manual water control valve on the water supply line Open a hot water tap to verify that water is flowing to that 3 tap Then close the hot water tap Fully open the manual gas control valve installed Turn on the 120 VAC 60 Hz power supply to the water heater Now you are ready to enjoy hours of endless hot water O O O O Owner s Guide CONGRATULATIONS Congratulations and thank you for choosing our tankless wate Before use we recommend that you read through this sa carefully Please refer to the back of the manual for details warranty Keep this manual for future reference If you lose the manual contact the manufacturer or yo distributor When you call please tell us the product na date of your unit written on the rating plate of the water heate 3 3 Page Owner s Guide 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 Thi
35. e air in water pipes within a closed loop system an air vent and air separator should be installed in the system Required circulation flow rates are labeled next to each application diagram These flow rate WARNING requirements must be followed e Toxic chemicals used in boiler treatments such as alcohol glycerol and glycol groups must not be introduced into the system if the system incorporates an open loop potable water system e The water heater can be used to supply potable water and space heating and shall not be connected to any heating system or component s previously used with non potable water where any chemicals were added to the water heating appliances e 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 potential e Water temperature over 125 F 52 C can cause severe burns instantly or death from scalding e 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 excessive noise and damage to the water heater Consult with the glycol maker for specifications prior to use Recirculation The reci
36. emote controller See the table below When the remote controller is normal operation the set temperature of the remote controller is given priority over the set temperature of the DIPswitch settings e The temperature has been preset at the factory to 120 F 49 C 110U T KJr2U and 310U T K4U models Computer board 120 F 49 C ae DEFAULT 140 F 60 C OM Er LG on 223456 78910 OFF OFF NoSo Orr No 9 ON DIPswitches 510U T D2U models Lower bank of DIPswitches DEFAULT 140 F 60 C DEFAULT l Upper bank of 2 Ja No 5 OFF Lower bank of DIPswitches OFF NOTE Only change the switches with dark squares The dark squares indicate the direction the DIPswitches should be set to e DO NOT adjust the upper bank of DIPswitches For the 510U T D2U models e Turn off the power supply to the water heater before changing the DIPswitch Owner s Guide FLOW The flow rate through the water heater is limited Household Flow Rates to a maximum of 6 6 GPM 25 L min for the 110U Flow rate T KJr2U models 8 0 GPM 30 L min for the 310U Wald ENGINE GPM US L min T K4U models and 10 0 GPM 38 L min for the 510U T D2U models Lavatory Faucet 1 0 318 The temperature setting along with the supply Bath Tub 40 100 152 378 temperature of the water will determine the flow Shower 2 0 UNS rate output of the unit Ki
37. er between the main water supply line and the water heater 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 system 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 As Close as entering your heater This will need Possible to be cleaned periodically to maintain optimum flow Refer to P 36 Gas Hot Cold inlet Pressure Relief Valve outlet inlet Installation Manual Pressure relief valve The water heater has a high temperature shut off switch built in as a standard safety feature called a H i Limit switch therefore a pressure only relief valve is required This unit does not come with an approved pressure relief valve An approved pressure relief valve must be installed on the hot water outlet The pressure relief valve must conform to ANSI Z21 22 or CAN 1 4 4 and installation must follow local code The discharge capacity must be at least 140 000 BTU h for the 110U T KJr2U models 190 000 BTU h for the 310U T K4U models and 199 000 BTU h for the 510U T D2U models The pressure relief valve needs to be rated for a maximum of
38. et water temperature can cause severe burns instantly or death from scalding Test the water before bathing or showering Do not leave children or an infirm person in the bath unsupervised DANGER Hot Water Heater temperature over 125 F 52 C can cause severe burns instantly or death from scalding Children disabled and elderly are at the highest risk of being scalded Feel water temperature before bathing or showering Temperature limiting valves are available Ask a professional WARNING California Proposition 65 lists chemical substances known to the state to cause cancer birth defects death serious illness or other reproductive harm This product may contain such substances be their origin from fuel combustion gas oil or components of the product itself Owner s Guide NORMAL OPERATION REMOTE CONTROLLER The illustration below shows an example of the display The exact display may differ from examples Display for Temperature When the stand by LED is ON the hot water temperature will be N 4 EUT 4 displayed now AAA yu INFO Button Each time the button is pressed the operation mode is selected in the sequence of the following 3 Inlet water Outlet water Water u temperature gt flow 7 p ger 5 COLD Button temperature HOT Button Press the HOT button or the COLD button to set the hot water temperature ON OFF Button Press this button to start or stop operation
39. from State to State The manufacturer will honor the warranty to the original retail buyer at the original location only and it is not transferable THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USAGE FOR THE PRODUCT S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED IN THE FOLLOWING TABLES ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND IN NO EVENT WHETHER AS A RESULT OF BREACH OF CONTRACT BREACH OF WARRANTY TORT LIABILITY INCLUDING NEGLIGENCE STRICT LIABILITY INDEMNITY OR OTHERWISE WILL BE LIABLE FOR ANY SPECIAL INCIDENTAL OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY 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 Warranty for models 510U T D2U models Unit Year pplication TX AS EA No Recirculation On Demand Recirculation Ss Single Family Aquastat Control 5 a n Hot SEEE Pump Control 1 aei Recirculation Timer Only E No Pump Control 24 hr No Recirculation Commercial or On Demand Recirculation 5 Eg Multi Family Aquastat Control 10 Domestic Hot w Standard Pump Control Water Recirculation Timer Only 3 3 No Pump Control 24 hr Heating All Types 5 5 18 Warranty for models 110U T KJr2U and 310U T K4U models Unit Year pplication x
40. ge DIPswitch No 1 on the upper bank of DIPswitches to the ON position See the computer board diagram as shown in the next page Do not change any DIPswitches on any of the CHILD units 4 Between the PARENT and the CHILD 1 units Connect the PARENT connector of the PARENT unit to the 1 connector of the CHILD 1 unit 5 Between the CHILD 1 and the CHILD 2 units Connect the 2 connector of the CHILD 1 unit to the 1 connector of the CHILD 2 unit 6 Between the CHILD 2 and the CHILD 3 units Connect the 2 connector of the CHILD 2 unit to the 1 connector of the CHILD 3 unit 7 Make sure the remote controller display the unit The numbering system automatically allocates the unit to each water heater in the Easy Link system in accordance with the table below Unit of easylink Parent 1 Child 2 3 and 4 A 510U T D2U models Computer board To change the DIPswitch unde fof the Easv Lihk Easy Link settings for the Easy Lin em o Multi unit system locate the bank of connectors DIPswitches at the bottom are next to left of the computer board Do not adjust the upper bank of DiPswitches B Basic diagram of connections between the Easy Link System units Remote controller PARENT unit Connectors CHILD 1 unit CHILD 2 unit CHILD 3 unit Connectors Connectors Conne
41. h direct vent models that require a 3 in 76 mm intake and a 4 in 102 mm 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 Convering wall thicknesss 9007680005 TK KPCT43 1 3 9 7 1 in 99 180 mm 9007772005 TK KPCT43 2 6 9 10 1 in 175 257 mm 9007773005 TK KPCT43 3 9 8 13 0 in 249 330 mm WARNING FOR INSTALLATIONS FOR YOUR SAFETY READ BEFORE INSTALLATION Do not install the heater where water debris or Do not have the vent terminal pointing toward flammable vapors may get into the flue terminal any opening into a building Do not locate your This may cause damage to the heater and void the heater in a pit or location where gas and water can accumulate warranty Prohibited Prohibited Do not install this water heater under an Do not install the water heater vent terminator overhang less than 3 ft 914 mm from its top within 1 ft 305 mm in the USA of any air intake or eaves The area under an overhang must be or building opening and with in 3 ft 914 mm open to three sides Outdoor models only in Canad
42. imes One Time Six Times N A N A Five Times Air fuel Ratio Rod failure Flow Sensor Failure Easy Link System only Abnormal Gas Solenoid Valve Abnormal Main Gas Valve Fan Motor Fault Flow Adjustment Valve Fault Easy Link System only Bypass valve Fault 510U T D2U models only Computer board Fault False Flame Detection Miscommunication between water heater and remote controller Miscommunication in Easy Link system Imperfect combustion Check for connection breakage of wires Part 709 and or soot on the AFR rod Part 108 Check for connection breakage of wires and or debris on the flow sensor impeller Part 402 Check for connection breakage of wires Part 708 and or burn marks on the computer board Part 701 Check for connection breakage of wires Part 708 and or burn marks on the computer board Part 701 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 connectors Part 103 Inspect the flow adjustment valve Part 402 for connection breakage of wires locked motor drive due to scale buildup and or water leakage Inspect the bypass valve Part 403 for connection breakage of wires locked motor drive due to scale buildup and or water leakage Check for connection breakage of wires Part 714 For indoor models check if condensate drai
43. included with the kit e If the water heater is used as a direct vent appliance the unit requires a 3 in 76 mm combustible air supply pipe The intake pipe must be sealed airtight Air supply pipe can be made of ABS PVC galvanized steel corrugated aluminum corrugated stainless steel or Category Ill stainless steel e Terminating the venting through a sidewall is recommended for the direct vent system e Running the exhaust vent and the intake pipe parallel 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 11 For the 110U Outdoor T KJr2U OS 310U Outdoor T K4U OS and 510U Outdoor T D2U OS models e To be installed outdoors and only in areas with mild temperate climates Installation Manual e 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 e The manufacturer does not recommend installing the water heater in a pit or location where gas and water can accumulate e Do not have the vent terminal pointing toward any operating window door or opening into a building e Do not install next to any sou
44. ion is a concept design only The reference to the 1 8 hole in check is only for the State of Massachusetts There are a wide variety of variations to the application of controls and equipment presented Designers must add all necessary safety and auxiliary equipment to conform to code requirements and design practice For more details contactthe manufacturer Installation Manual INITIAL OPERATION FOR YOUR SAFETY READ BEFORE OPERATING e Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time e 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 e 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 e Check the GAS PRESSURE Refer to p 20 e Do not try to light the burner manually It is equipped with an electronic ignition device which automatically lights the burner e Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater e Purge the GAS and WATER LINES to remove any air pockets e 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
45. iring Remote controller 9007675005 TM MC02 5 aap er Remote controller cable Remote controller terminals Terminals for rusas water heaters De Unit 1 Connectors Unit 2 Connectors 510U T D2U Connectors DO iN3uva Lower bank of DiPswitches DO ESEE Lower bank of DiPswitches DO N38vdl Lower bank of DiPswitches Communication cable e The dark squares should not neet adjustment e Thisisthe connection diagram between 510 T D2U and multi unit controller for 2 to 20 water heaters As shown is a sample for 3 water heaters e The Multi unit controller automatically allocates the unit 1 20 to each water heater that is part of the Multi unit system e Ina Multi Unit system connect the 1 connector and the 2 connector with the communication cable Refet to p 26 Or the cables use 18 gage wire and can be up to 250 ft long For detailed instructions to the mult unit controller refer to the instructions that are packaged with the multi unit controller Hot Out Installation Manual APPLICATIONS Space Heating Applications e In order to purg
46. istance 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 Check if the Hi limit switch Part 4412 is properly functioning Check for connection breakage of wires Part 413 708 709 710 712 burn marks on the computer board Part 4701 and or soot on the flame rod Part 108 Check if there is a buzzing spark ignition sound coming from the burner Part 4101 when water heater prepares for combustion Listen for the double clunk sound coming from gas valve assembly Part 4102 when water heater goes into combustion Check if there is leaking from heat exchanger Part 401 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 Check for connection breakage of wires and or debris on thermistor Part 407 408 411 715 Owner s Guide ae Malfunction Remote Diagnosis description 441 510 551 611 651 661 701 711 721 741 761 991 Two Two Times Six Times Six Times Four Times Four Times Four T
47. it manifold system e The Easy Link system allows up to 4 units to manifold together e A communication cable gray color comes with each 510U T D2U models You can manifold from 2 to 4 units without the need for a multi system controller A 4 unit system has full automatic modulation between 15 000 BTU h and 796 000 BTU h Easy Link connection with other allowable heaters T K3 T K3 Pro 510 models T D2 IN T D2 0S 510U models T D2U IN T D2U OS Gas In Hot Out Cold In 5 pu hm 1 I e The Easy Link system is limited up to 4 units If you connect more than 4 units only the first 4 units will work as a part of the Easy Link system The other additional units will not work e Only listed models on the table above can be combine together as an Easy Link System Different model cannot be combine together to form an Easy Link System CAUTION When the 510U T D2U model is connected to previous models as part an Easy link system with the 9008172005 TM RE40 Contact the manufacturer WARNING 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 Installation Manual 2 Select one unit to be the PARENT unit 3 PARENT unit Locate the two banks of DIPswitches at the bottom left of the computer board of the unit that you select to be the PARENT unit Chan
48. l valve before servicing WARNINRG Clean the cold water inlet filter Refer to diagram below Be sure that all openings for combustion and ventilation air are not blocked The venting system should be checked annually for any leaks corrosion blockages or damage The burner should be checked annually for dust lint grease or dirt Keep the area around the water heater clear Remove any combustible materials gasoline or any flammable vapors and liquids In accordance with all local codes and common safety practices water discharged from the pressure relief valve can cause severe burns instantly from scalding DO NOT touch the pressure relief valve If the relief valve discharges periodically it may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation 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 Blue flame Flame NO Burner kr Satisfactory me Unsatisfactory Satisfactory 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 UNIT DRAINING and FILTER CLEANING Close the manual gas shut off valve Drain plug with Filter Turn off power to the unit and wait a couple of seconds Large Turn on again Wait 30
49. ll operate as individual units PARENT unit CHILD 1 unit Connectors Connectors PARENT unit CHILD 1 unit Connectors Connectors Lower bank of DiPswitches 98pyt 2 T Communication cable PO SP Lower bank of DiPswitches UI T 1 O Wrong Con nections Communication cable AS Wrong Connections Installation Manual CASE 3 Wrong connections between the CHILD 1 unit and the CHLD 2 unit e If you connect the PARENT connector of the CHILD 1 unit to the 1 connector of the CHILD 2 unit the CHILD 2 unit will operate as an individual unit and will not be part of the Easy Link system PARENT unit CHILD 1 unit CHILD 2 unit Connectors Connectors Connectors Lower bank of DiPswitches Lower bank of gt DIPswitche Lower bank of DiPswitches N w EN u a S9STEZT ne Communication cable A Ss Wrong Connections Connecting two PARENT connectors Eee from two separate units may damage the computer board The communication cable has a female end and a male end so it s impossible to have a PARENT to PARENT connection with the WARNING communication cable Do not splice or modify connectors CASE 4 Remote controller connected to incorrect unit e Remote controller has to be connected to the PAREN
50. me into contact with water or oil e Do not place the remote control wiring close to other wires from other products e Do not extend the remote control wiring more than 400 ft 122m lt Mounting and Wiring the Remote Controller gt 1 Take off the Back plate from the remote controller with a flat head screwdriver Fig A and B 2 Attach the Back plate on the wall with the two provided screws Fig B Press and twist flat head screwdriver against the cutout Fig B Back plate Attached the screws Het Main body N E Cut out the partition with pliers 22 Page 3 Tighten the two Fork terminals beneath the two Remote controller terminal screws on the back of the main body Fig C 1 4 Cut out the inlet for the remote controller cable from the bottom of the main body Fig C 2 5 Place the Main body back on the Back plate with the Remote controller cable running out of the bottom inlet 6 Connect the Remote controller cable to the remote controller terminal on the computer board See p 22 for details Fig C 1 AR AA Remote controller terminals Inlet for the remote Two fork terminals controller cable fs el Cut ou
51. n is installed on the vent collar of the water heater Check if there is leaking from heat exchanger Part 401 Check the model type of the remote controller Inspect the connections between the water heater and remote controller Check the power supply of the water heater Check if the connections between the parent unit and the child units are correct Refer to pg 25 28 Check the gas type of the water heater 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 exhaust 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 Owner s Guide Troubleshooting COMPONENTS DIAGRAM Indoor models Outdoor models 47 Page Owner s Guide Troubleshooting Computer board assembly 110U T KJr2U and 510U T D2U models 310U T K4U models EN i i Ni S oy ty n i N PN n N i j ES N Se N s Se N t TN an x a o N i 1
52. n the specified range shown below Excess gas CAUTION inlet pressure may cause serious accidents e Conversion of this unit from natural gas 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 The minimum and maximum inlet gas pressures are Gas type Inlet gas pressure Natural Gas Min 5 0 W C 1 24 kPa Max 10 5 W C 2 61 kPa Gas pressure above this specified range for the water heater and or insufficient gas volume will adversely affect performance These pressures are measured when the water heater is in full operation 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 Until testing of the main gas line supply pressure is completed ensure the gas line to the water heater is disconnected to avoid any damage to the water heater Gas connections Install a manual gas shut off valve between the water heater and the gas supply line 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 e The water heater and its individual shutoff valve must be disconnected from the gas supply piping system
53. nd or outside temperatures drop below 36 5 F 2 5 C For the 110U Indoor T KJr2U IN 310U Indoor T K4U IN and 510U Indoor T D2U IN models e In any areas subject to freezing temperatures the manufacturer highly recommends an indoor installation with an indoor model In such an installation freezing issues can only occur if cold air enters through the venting into the heat exchanger whether by negative pressures within the installation location or by strong outside winds e The manufacturer also highly recommends the use of a back flow vent damper to minimize the amount of cold air entering through the exhaust venting when the water heater is off It is the installer s responsibility to be aware of freezing issues and take all preventative measures The manufacturer will not be responsible for any damage to the heat exchanger as a result of freezing If you will not be using your heater for a long period of time 1 Completely drain the unit of water Refer to p 41 2 Disconnect power to your heater This will keep your unit from freezing and being damaged Only pipes within the water heater are protected by the freeze protection system Any water pipes hot or cold located outside the unit will not be protected Properly protect and insulate these pipes from freezing CAUTION Owner s Guide MAINTENENCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve and the manual water contro
54. orrect thermal Fn be comply with local and expansion tank size Shut off J state codes Can not valve be common vented Pressure with other appliances Must gauge T N Leom Atmospheric E o vacuum 5 2 breaker 3 gt Sl Hot water 2 Le supply and 2 ES 1 return to 5 3 i heating coil 0 o Check valves h Drain l I AT Pi 120 VAC I A switch or NI outlet Check valve System installed with reverse acting aquastat to shut off fan Suggested but not required by 248 CMR 50 0 maximum distance from water heater to fan coil and black Develoed length Not including coil in heating unit Shut off valves NSF 61 product approved pump T handle gas shut off valve Electronically controlled pump timer Activates every 6 hours for 60 seconds Wire to product approved pump An approved Temperature and Pressure Relied Valve Tie to Location approved By Local Codes and Must Meet BTU Rating of water heater Model Used The recirculation pump is to provide no less than 2 GPM 7 5 L min and no more than 4 GPM 15 L min through each activated unit in the system NOTICE 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 Follow all local codes or in the absence of local codes follow the most recent edition of the National Standard Code ANSI Z21 10 3 e This illustrat
55. ple behind tankless water heaters is simple Exhaust vent collar o O pS A exchanger Flow adjustment valve Burners Computer board 58 I TI Gas valves Flow sensor Thermistor ae o y Thermistor ET Hot water outlet Cold water inlet This diagram illustrates tankless water heater design concepts only and does not accurately represent 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 The gas ignites and flames appear within the burner chamber Water circulates through the heat exchanger and then gets hot Using thermistors to measure temperatures throughout the water heater the computer modulates the gas and water valves to ensure proper output water temperature When the tap is turned off the unit shuts down Installation Manual SAFETY GUIDELINES SAFETY DEFINITION Indicates an imminently hazardous situation which if not avoided will result in death or serious injury DANGER Indicates an imminently hazardous situation which if not avoided could result in death or serious injury WARNING Indicates an imminently hazardous situation which if not avoided could result in minor or moderate injury CAUTION GENERAL 1 Follow all local codes or in the absence of lo
56. r heater if service is to be performed 2 Turn the manual gas valve located on the outside of the unit clockwise to the off position The water heater cannot perform properly without sufficient inlet gas pressure Below are instructions on how to check the inlet gas pressure THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL 1 Shut off the manual gas valve on the supply gas line 2 Remove the screw for the pressure port located on the gas inlet of the water heater shown in the diagram right 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 and minimum burn the manometer should read from 5 0 to 10 5 W C 1 24 to 2 61 kPa for Natural gas WwW 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 CAUTION Do not reverse the hot outlet and cold inlet connections to the water heater This will not properly activate the water heater All pipes pipe fittings valves and other components including soldering 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 heat
57. r is a Category Ill appliance and must be vented accordingly with any 4 in 102 mm vent approved for use with Category lll or Special BH type gas vent Follow the vent pipe manufacturer s instructions when installing the vent pipe 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 Ill approved or Special BH vent pipe When the horizontal vent run exceeds 5 ft 1 5 m support the vent run at 3 ft 0 9 m intervals with overhead hangers The maximum length of exhaust vent piping must not exceed 50 ft 15 2 m deducting 5 ft 1 5m for each elbow used in the venting system Do not use more than 5 elbows Diameter Max No of Elbow Max Vertical and Horizontal Total Vent Length 4 in 102 mm 5 50 ft 15 2 m For each elbow added deduct 1 5m 5 ft from max vent length No of Elbows Max Vertical or Horizontal Vent Length 0 50 ft 15 2 m 1 45 ft 13 7 m 2 40 ft 12 2 m 5 25 ft 7 6 m Excludes elbow termination rain caps or the 4 in 102 mm PVC Concentric Termination DIPswitch settings for Direct Vent models Set DIPswitches shown in the table below depending on the vent length 110U Direct vent T KJr2U IN 510U Direct vent T D2U IN Vent leneth 310 Direct vent T K4U IN Upper bank of DIPswitches 6 0 to 30 ft
58. r 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 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 sizing Damages due to fires flooding freezing electrical surges or any Acts of God Damages due to unauthorized alterations attachments and or repairs Damages due to a lack of maintenance e g water filter water treatment system vent blockage etc Any product installed in an improper environment e g corro
59. r must be treated e Do not install the unit where water debris or flammable vapors may get into the flue terminal e 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 heater may not work properly e Although the water heater is designed to operate with minimal sound the manufacturer does not recommend installing the unit on a wall adjacent to a bedroom or a room that is intended for quiet study or meditation etc e Locate your heater close to a drain where water leakage will not do damage to surrounding areas As with any water heating appliance the potential for leakage at some time in the life of the product 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 CAUTION n EE Be Installation Manual Installation CLEARANCES re Side a Black GD Maintain all clearances around m D the water heater a O Front T Side Model Top Bottom Front Back Sides 110U Indoor T KJr2U IN NE 12 in 12 in 4 in 05 in 2 in fr Ea x y ae 305mm 305mm 102mm 13mm 51mm ee sein 12 in 24 in 0 5 in 2in 310U Outdoor T K4U 05 914 mm 305 mm 610mm 13mm 51mm 510U Outdoor T D2U OS Standard indoor installations and direct vent in
60. rce of airborne debris such as a clothes dryer that can cause debris to be trapped inside the combustion chamber unless the system is direct vented e The manufacturer does not recommend 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 ventilation e 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 e If the above conditions cannot be met use the direct vent conversion kit Part No 9007667005 TK TV10 e Place the unit for easy access for service and maintenance e A drain pan or other means of protection against water damage is required to be installed under the water heater in case of leaks e 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 e 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 hardness leads to scale formation and may affect damage the water heater Hard water scaling must be avoided or controlled by proper water treatment e Water pH levels must be between 6 5 and 8 5 e Well wate
61. rculation pump is to be controlled by Dual set aquastat recommended w timer The recirculation pump is to provide no less than 2 GPM 7 5 L min and no more than 4 GPM 15 L min through each activated unit in the system A Air vent rl ios Do 5 5 T o T o 3 os 6 TO Hot water outlet to fixtures Pressure Unions relief valve ko gt 4 Ball valves A rh Gas supply PHHH S NI i Check valve Recirculation gt Expansion tank pump Air S separator Check valve i Cold water inlet This is a concept drawing only a Y Strainer Installation Manual 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 Automatic tempering device must be installed below the top of the water heater as per manufacturer s recommendations per application Tempered water to plumbing fixtures meet temperature Piping loop between water heater and fan coil shall be in compliance with 248 CMR requirements of 248 CMR Thermostatic mixing valve Cold water supply Heating Coil used with air handler Le Shut off valves Check valve will have re 1 8 hole drilling in Apply c
62. s 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 BEFORE OPERATING smell all around the water heater area for evidence of leaking gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS 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 If 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
63. sive dusty chemically contaminated excessive lint etc 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 amp provincial codes ordinances and good trade practices Any product sold to or installed in areas outside of the fifty states and the District of Columbia of the United States of America and Canada Any product installed in applications that cause the water heater to activate more than 300 times per day this averages to an activation every 5 minutes in a 24 hour period Any failures that are not due to defects in materials or workmanship mechanical and or electrical parts Damages due to improper installation 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 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 Damages due to water quality e Introduction of liqui
64. some information about the water heater condition by pressing the INFO button For more information follow the procedures below omme E Fist of all inlet water temperature will be displayed on 1 theremote controller by pressing the INFO button om 3 Er Inlet water temperature Outlet water temperature will be displayed on the z 2 remote controller by pressing the INFO button B LIT i And then water flow will be displayed on the remote En 3 controller by pressing the INFO button our LN Water flow Press the INFO button to finish information mode Unit conversion mode The remote controller has a function that can change units of temperature and flow rate from F to C and vice versa please follow the procedures below The same procedure is performed when changing into C from F SS Operation HE Press the ON OFF button on the remote in order to Pm 1 turn the remote controller on When ON the STAND BY LED is lit 2 The previous set temperature will display on the screen 3 EX 100 F Press the INFO buttons for at least 3 seconds 4 The set temperature should now be displayed in the 5 alternate unit of measurement Owner s Guide Normal Operation TEMPERATURE SETTINGS ON THE PCB WITHOUT REMOTE CONTROLLER There are 2 preset temperatures 120 F 49 C and 140 F 60 C that you can select from by changing the DIPswitch settings on the computer board without the r
65. t Proportional gas valve wire 24V cables for 510U T D2U models Computer board cover Cable strap for Indoor models Cable Remote fixing plate for 510 T D2U models Flow adjustment plate Temperature remote controller 5 3 Page 110U 310U 510U models 319143 469 319143 470 319143 471 319143 426 319143 128 319143 427 319143 138 319143 472 319143 141 319143 473 319143 474 319143 475 319143 476 319143 477 319143 478 319143 479 319143 480 319143 185 319143 481 319143 482 319143 191 319143 425 319143 483 319143 484 319143 485 Owner s Guide Parts List 2U T K4U EKJ6V EK106 EK149 EK148 EK280 EK146 EKK3C EK115 EKK4V EK138 EKD61 EK114 EK150 EKD64 EK113 EK153 EK154 EKJ59 EK112 EKD60 EKK1M EW022 EK151 EK152 EK156 ERO14 OUTPUT TEMPERATURE CHART Chart is based on properly sizes gas line 110U T KJr2U models 8 0 6 0 4 0 2 0 0 0 Output Hot Water GPM 100 Owner s Guide Output Temperature Chart Output Temperature vs GPM Max 6 6 GPM with Various Inlet Water Temperature 9 40F m 50F g 60F 3 70F 105 110 115 120 125 130 135 140 150 40F 3 9 3 6 3 3 3 1 29 2 7 2 6 2 4 2 3 2 1 m 50F 46 4 2 3 9 36 3 3 3 1 29 27 26 23 2 1 2 0 4 60F 58 5 2 4 6 4 2 3 9 3 6 3 3 3 1 29 26 23 2 2 70F 66 66 58 52 46 42 39 36 33 29 26 24 310
66. t Remote controller cable lt How to connect the remote controller to the water heater gt 1 Disconnect power supply from the water heater 2 Take off the water heater s front 110U T KJr2U and 310U T K4U models cover 3 Locate the remote controller terminal pictured to the right located around the lower right hand side of the computer board 4 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 9008172005 TM RE40 Connect other end to these terminals Front of remote Pull the remote s wires through the hole at the bottom of the water heater s casing Properly attach the remote s wires to the remote controller terminal on the computer board No polarity Do NOT jump or short circuit the wires or computer will be damaged Replace Front Cover securely Wires used for the remote controller connection must be e Minimum 18AWG wire No polarity e Maximum 400 ft 122m long 510U T D2U models 9008172005 TM RE40 Connect other end to these terminals Front of remote Installation Manual EASY LINK SYSTEM Available on the 510U T D2U models only General The 510U T D2U models water heaters can be connected with other allowable heaters see the table below with communication cables to work as a multiple un
67. tchen Sink 1 5 5 6 Please refer to the temperature vs gallons per aa 1 5 BG minute charts on p 54 to determine the likely flow p er dwatert J t Washing machine 4 0 15 2 rates base on your local ground watertemperature _ raken from UPC 2006 and your desired outlet water temperature Based on the United States Department of Energy method of testing water heater output the water heater is rated fi ll h GPH lit eater is rated for gallons per hour litres per Unit GPM L min hour L hr or gallons per minute GPM litres per minute L min for Natural Gas when raising the Model water temperature by 77 F 43 C from 58 F to Indoor 135 F 14 C to 57 C See the following chart 110U T KJr2U Om 3 0 11 4 Refer to the table to the top right for typical RES household plumbing fixture flow rates to determine 310U T K4U AA MISS what the water heater can do in a household Outdoor application 510U T D2U Indoor 4 2 15 9 Outdoor 4 3 16 3 FREEZE PROTECTION SYSTEM This unit comes equipped with heating blocks to protect it against damages associated with freezing For this freeze protection system to operate there has to be electrical power to the unit Damage to the heat exchanger caused by freezing temperatures due to power loss is not covered under the warranty In cases where power losses can occur consider the use of a backup power supply The freeze protection system will activate when the surrounding a
68. the computer board of any Child unit as shown below The unit number will be displayed on the remote controller Refer to p 25 28 aig Button to check unit numbers 43 Page Owner s Guide ERROR CODES General e The units are self diagnostic for safety and convenience when trouble shooting e If there is a problem with the installation or the unit the error code will display on the remote controller e Consult with the table on the following page for the cause of each error code 110U T KJr2U and 310U T K4U models 510U T D2U models Error code on the remote controller 9008172005 TM RE40 Green LED Green LED Error code on the computer board Single unit Installations Example If your unit has the 321 error code which signifies an inlet thermistor failure e Remote controller 9008172005 TM RE40 321 will display on the screen in its entirety TG 1 on GJE a Error code e Water heater The green LED on the computer board will be blinking two times Easy Link System For the 510U T D2U 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 e Remote
69. tible air will be available to it at all times without obstructions The electrical connection requires a means of disconnection to terminate power to the water heater for servicing 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 termination meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building refer to p 14 Particles from flour aerosols and other contaminants may clog the air vent or reduce the functions of the rotating fan and cause improper burning of the gas Regularly ensure that the area around the unit is dust or debris free regular maintenance is recommended for these types of environment If you will be installing the water heater in a contaminated area with a high level of dust sand flour aerosols or other contaminants chemicals they can become airborne and enter and build up within the fan and burner causing damage to the water heater 10 For the 110U Indoor T KJr2U IN 310U Indoor T K4U IN and 510U Indoor T D2U IN models e These units may be converted to a direct vent sealed combustion appliance by installing a direct vent conversion kit Part No 9007667005 TK TV10 which will bring in all required combustible air from outside the building When installing the direct vent conversion kit please follow all instructions
70. tion Sn Plate of Direct Vent Conversion Kit Installation Manual Installation Vent termination clearances INSIDE CORNER DETAIL Vent terminal X Air supply inlet y G Area where is not permitted bs i LI SAG FANE CELLE GAG Lie LL ba HUE Gas meter regulator than Direct Vent vent Direct Vent Clearance above grade veranda porch deck or balcony A 1 foot 1 foot 1 foot 4 feet from below or B Clearance to window or door that may be opened 3 feet 1foot side opening 1 foot from above opening C Clearance to permanently closed window he s s Vertical clearance to ventilated soffit located above D the vent terminator within a horizontal distance de 5 S of 2 feet 61cm from the center line of the terminator E Clearance to unventilated soffit z En F Clearance to outside corner s G Clearance to inside corner se i S Clearance to each side of center line extended F A H 3 feet above meter regulator assembly I Clearance to service regulator vent outlet 3 feet Clearance to non mechanical air supply inlet to 4 feet from below or J building or the combustion air inlet to any other 3 feet 1 foot side opening 1 foot application from above opening K Clearance to mechanical air supply inlet 6 feet 3 feet 3 feet Clearance above paved sidewalk or paved driveway located on public property M Clearance under veranda porch deck or balcony 1 foot E he For
71. to the right EX 120 F Press the HOT button or the COLD button to set the temperature setting of the unit Increasing temperature example 140 F to 145 F Press the HOT button or the COLD button to set 140 F Simultaneously press and hold the HOT and INFO buttons for at least 3 seconds It shows the 145 F on its display The display will be blinking for 5 seconds and set COLD ON OFF O STAND BY EX 120 F HOTA da HOTA BM INFO TEMPERATURE TABLE OF REMOTE CONTROLLER a For 110U T KJr2U and 310U T K4U models KE 1005 BOSE MALOS Biss 120 1257 1801 HUSO 1140 ES 40 43 as BOR gt 55 57 GO b For 510U T D2U models El 100 105 110 115 120 125 130 135 140 145 150 155 160 165 175 185 ES 40 43 as BOM gt 5 oval CON MOS ROOM OS LOM SE ESO RSS Factory setting Default 120 F X NOTICE J This water heater is an on demand tankless water heater designed to efficiently N supply endless hot water without reference to temperature settings p p N I DO NOT set to 185 F 85 C if you use your water heater in a recirculation system This will cause damage to the heater and void the warranty WARNING This temperature setting is only available on the 510U T D2U models XY J IS Page Owner s Guide Normal Operation ADDITIONAL FEATURES Information mode You can get
72. vere injury or death Follow the diagram on p 20 when installing your water heater e 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 professional service technician to inspect and or service the unit if necessary e 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 p 39 for more information Installation Manual INSTALLATION GENERAL Follow all local codes or in the absence of local codes follow the most recent edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the USA or CAN CSA B149 1 Natural Gas Installation Code in Canada 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 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 p 9 for proper clearances The water heater must be installed in a location where the proper amount of combus

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