Takagi T-KJr2-IN, T-K4-IN, T-D2-IN, T-KJr2-OS, T-K4-OS Installation Manual And Owner's Manual

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-Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

-WHAT TO DO IF YOU SMELL GAS

. Do not try to light any appliance.  Do not touch any electric switch, do not

use any phone in your building.

 Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's instructions.

 If you cannot reach your gas supplier, call

the fire department.

-Installation and service must be performed by a qualified installer, service agency or the gas supplier.

FEATURING

 ENDLESS HOT WATER  ON DEMAND USAGE  COMPACT, SPACE SAVING  ENERGY CONSERVATION  COMPUTERIZED SAFETY  NO PILOT LIGHT  EASY-LINK SYSTEM

510 (T-D2) models only

Gas Tankless Water Heater

Suitable for potable water heating a nd spa ce -heating

*Please refer to local codes for space-heating compliance.

If you have any questions, please

call or write to:

500 Tennessee Waltz Parkway Ashland City, TN 37015

Toll Free:

877-737-2840

On-Demand Water Heater

Installation Manual and Owner’s Guide

Model

・

110 Indoor (T-KJr2-IN) ・110 Outdoor (T-KJr2-OS)

・

310 Indoor (T-K4-IN) ・310 Outdoor (T-K4-OS)

・

510 Indoor (T-D2-IN) ・510 Outdoor (T-D2-OS)

WARNING

If the information in these

instructions is not followed exactly, a fire or explosion may result causing

property damage, personal injury or death.

ANSI

Z21.10.3

and CSA 4.3

510 (T

D2) models

only

Contents

2│Page

CONTENTS

SPECIFICATIONS…………………………………………………………………………………………..………………………... INTRODUCTION…………………………………………………………………………………………………..…………………. SAFETY GUIDELINES…………….………………………………………………………………………………………..……….. INSTALLATION………………………………………………………………………………………………..…………………..…. General………………………………………………………………………………………………………………………..…..… Clearances……………………………………………………………………………………………………………………………

Included Accessories…………….………………………………………………………………………………………..….. Optional Items…………………………………………………………………………………………………………………….. High-Altitude Installations……………………………………………………………………………………………………

Venting Instructions……………………………………………………………………………………………………………

Gas Supply and Gas Pipe Sizing………......................................................................................

…

Water Connections……………..…………………………………………………………………………………………….…

Electrical Connections……………………………………………………………………..…………………………….......

Remote Controller Connections……..………………………………………………………………………………….

…

Pump Control Connections…………………………………………..………..………..

……………………………………

Easy-Link System...…………………………....…………………………………………………………………………..…..

APPLICATIONS...……………………………………………………………………………………………………………………… INITIAL OPERATION..………………………………………………………………………………………………………….……

OPERATING SAFETY………………………………………………………………………………………………………………… NORMAL OPERATION…………………………………………………………………………………………………………..…

General………..……….………….…………………………………………………………………………………………………

Temperature Settings.…….……..……………………………………………………………………………………………

Flow…………………………………………………………………………………………………………………………………….

Freeze Protection System…….…………………………………………………………………………………………..…

Maintenance and Service………………………………………………………………………………………………….…

Unit Draining and Filter Cleaning………………………………………………………………………………………… TROUBLESHOOTING……..……………………………………………………………………………………………………..…

General………..……….………….…………………………………………………………………………………………………

Error Codes.…………………….…..……………………………………………………………………………………………

…

COMPONENTS DIAGRAM……………………………………………………………………………………………………..… PARTS LIST………………….………………………………………………………………………………………………..………… OUTPUT TEMPERATURE CHART…………………………………………………………………………………………...…

LIMITED WARRANTY…………………………………………………………....…………………………………………….….

3 4 5 6 6 8 8 9 11

12 17 20 21 22 23 24 28 30

33 33 33 35 35 36 36 37 37 39 42 46 49 51

Installation Manual

Owner’s Guide

Specifications

3│Page

SPECIFICATIONS

Model

110

Indoor

(T-KJr2-IN)

110

Outdoor

(T-KJr2-OS)

310

Indoor

(T-K4-IN)

310

Outdoor

(T-K4-OS)

510

Indoor

(T-D2-IN)

510

Outdoor

(T-D2-OS)

Natural Gas Input

(Operating Range

)

Min: 19,500 Btu/h

Max: 1

,000 Btu/h

Min: 11,000 Btu/h

Max: 19

,000 Btu/h

Min: 11,000 Btu/h

Max: 199,000 Btu/h

Propane Input (Operating Range)

Min: 19,500 Btu/h Max: 140,000 Btu/h

Min: 11,000 Btu/h Max: 190,000 Btu/h

Min: 11,000 Btu/h Max: 199,000 Btu/h

Gas Connection

¾” NPT

Water Connections

¾” NPT

Water Pressure

15 - 150 psi*

Natural Gas

Inlet Pressure

Min. 5.0” WC

Max. 10.5” WC

Propane Inlet Pressure

Min. 8.0” WC

Max. 14.0” WC

Manifold Pressure**

Natural 2.0” WC 2.5” WC 2.0” WC 2.5” WC 2.0” WC 2.5” WC

Propane 2.5” WC 3.1” WC 3.7” WC 4.0” WC 3.7” WC 4.5” WC

Weight 33 lbs. 38 lbs. 39 lbs.

Dimensions

H20.5” x W13.8” x D6.7”

H20.5” x W13.8” x D8.5”

Ignition Electric Ignition

Electric

Supply 120 VAC / 60 Hz

Consumption

Operation

73.1 W / 0.61 A 87.6 W / 0.73 A 89.8 W / 0.75 A

Standby 6.2 W / 0.05 A 6.2 W / 0.05 A 6.2 W / 0.05 A

FreezeProtection

111 W / 0.93 A 111 W / 0.93 A 111 W / 0.93 A

*40 psi or above is recommended for maximum flow

**The Manifold Pressure is the factory setting and generally should not need adjustment.

NOTE:

 Check the rating plate to ensure this product matches your specifications.  In accordance with ANSI Z21.10.3, CO emission does not exceed 400 PPM for

normal input.

 The manufacturer reserves the right to discontinue, or change at any time,

specifications or designs without notice and without incurring obligations

Introduction

4│Page

INTRODUCTION

*This diagram

illustrates tankless water heater design concepts only and does not accurately represent to the water heater’s physical description.



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 principle behind tankless water heaters is simple:

1. A hot water tap is turned on.

2. Water enters the heater.

3. The water flow sensor detects the water flow.

4. The computer initiates the fan motor and sends a signal to the igniter to create an ignition

spark.

5. The gas ignites and flames appear within the burner chamber.

6. Water circulates through the heat exchanger and then gets hot.

7. Using thermistors to measure temperatures throughout the water heater, the computer

modulates the gas and water valves to ensure proper output water temperature.



The 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models are

to be only installed indoor (direct-vent convertible). The 110 Outdoor (T-KJr2-OS), 310

Outdoor

(T-K4-

OS) and 510 Outdoor (T

-D2-

OS) models ar

e to

be only installed outdoor.

Safety Guidelines

5│Page



ater temperature

s over 125°F

(52°C)

can cause severe burns instantly or

death

from scalding. The water temperature is set at 122°F (50°C) from the factory to minimize any scalding risk. Before bathing or showering always check the water temperature.

 Do not store or use gasoline or other flammables, vapors, or liquids in the vicinity

of this appliance.

 Do not reverse the water and/or gas connections as this will damage the gas

valves and can cause severe injury or death. Follow the diagram on p. 20 when installing your water heater.

 Do not use this appliance if any part has been in contact with or been immersed

in water. Immediately call a licensed plumber, a licensed gas fitter, or a professional service technician to inspect and/or service the unit if necessary.

 Do not disconnect the electrical supply if the ambient temperature will drop

below freezing. The Freeze Prevention System only works if the unit has electrical power. The warranty will not be covered if the heat exchanger is damaged due to freezing. Refer to the section on the Freeze Prevention System on p. 35 for more

information

SAFETY GUIDELINES

SAFETY DEFINITIONS

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury.

GENERAL

1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the

National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas, Propane Installation Code in Canada.

2. Properly ground the unit in accordance with all local codes or in the absence of local codes, with

the National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canada Electrical Code Part 1 in Canada.

3. Carefully plan where you intend to install the water heater. Please ensure:

 Your water heater will have enough combustible air and proper ventilation.  Locate your heater where water leakage will not damage surrounding areas (please refer

to p. 7).

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.

WARNING

CAUTION

DANGER

WARNING

Installation

6│Page

INSTALLATION

GENERAL

1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the

National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas, Propane Installation Code in Canada.

2. All gas water heaters require careful and correct installation to ensure safe and efficient

operation. This manual must be followed exactly. Read the “Safety Guidelines” section.

3. The manifold gas pressure is preset at the factory. It is computer controlled and should not

need adjustment.

4. Maintain proper space for servicing. Install the unit so that it can be connected or removed

easily. Refer to the Clearances Section on p. 8 for proper clearances.

5. The water heater must be installed in a location where the proper amount of combustible air

will be available to it at all times without obstructions.

6. The electrical connection requires a means of disconnection, to terminate power to the water

heater for servicing and safety purposes.

7. Do not install the unit where the exhaust vent is pointing into any opening in a building or where

the noise may disturb your neighbors. Make sure the vent termination meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building (refer to p. 15).

8. Particles from flour, aerosols, and other contaminants may clog the air vent or reduce the

functions of the rotating fan and cause improper burning of the gas. Regularly ensure that the area around the unit is dust- or debris-free; regular maintenance is recommended for these types of environment.

9. If you will be installing the water heater in a contaminated area with a high level of dust, sand,

flour, aerosols or other contaminants/chemicals, they can become airborne and enter and build up within the fan and burner causing damage to the water heater.

10. For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models:

 These units may be converted to a direct-vent (sealed combustion) appliance by installing a

direct-vent conversion kit Part No. 9007667005 (TK-TV10) which will bring in all required combustible air from outside the building. When installing the direct-vent conversion kit, please follow all instructions included with the kit.

 If the water heater is used as a direct-vent appliance, the unit requires a 3” combustible air

supply pipe. The intake pipe must be sealed airtight. Air supply pipe can be made of ABS, PVC, galvanized steel, corrugated aluminum, corrugated stainless steel or Category III stainless steel.

 Terminating the venting through a sidewall is recommended for the direct-vent system.  Running the exhaust vent and the intake pipe parallel is recommended.  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 110 Outdoor (T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS) models:

 To be installed outdoors and only in areas with mild, temperate climates.

Installation

7│Page

 Installation and service must be performed by a qualified installer (for

example, a licensed plumber or gas fitter), otherwise the warranty will be void.

 The installer (licensed professional) is responsible for the correct installation

of the water heater and for compliance with all national, state/provincial, and local codes.

 The manufacturer does not recommend installing the water heater in a pit or

location where gas and water can accumulate.

 Do not have the vent terminal pointing toward any operating window, door, or

opening into a building.

 Do not install next to any source of airborne debris, such as a clothes dryer,

that can cause debris to be trapped inside the combustion chamber, unless the system is direct-vented.

 The manufacturer does not recommend installing the water heater in an

attic due to safety issues. If you install the water heater in an attic:

 Make sure the unit will have enough combustion air and proper ventilation.  Keep the area around the water heater clean. When dust collects on the

flame sensor, the water heater will shut down on an error code.

 If the above conditions cannot be met, use the direct vent conversion kit

Part No. 9007667005 (TK-TV10).

 Place the unit for easy access for service and maintenance.  A drain pan, or other means of protection against water damage, is

required to be installed under the water heater in case of leaks



The warranty will not cover damage caused by water quality.

 Only potable water or potable water / glycol mixtures can be used with this

water heater. Do not introduce pool or spa water, or any chemically treated water into the water heater.

 Water hardness levels must not exceed 7 grains per gallon (120 ppm) for

single family domestic applications or more than 4 grains per gallon (70 ppm) for all other types of applications. Water hardness leads to scale formation and may affect/damage the water heater. Hard water scaling must be avoided or controlled by proper water treatment.

 Water pH levels must be between 6.5 and 8.5  Well water must be treated.

 Do not install the unit where water, debris, or flammable vapors may get into

the flue terminal.

 The manufacturer recommends using the direct vent kit when the water

heater is installed in a beauty salon. Some chemicals used in a beauty salon may affect the flame sensor. Water heater may not work properly.

 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.

 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

WARNING

Installation

8│Page

CLEARANCES

Mode

l Top Bottom

Front

Back Sides

110 Indoor* (

T-KJr2-IN)* 12” 12” 24” 1” 2 “

110 Outdoor (

T-KJr2-OS) 36” 12” 24” 1” 2 “

Model

Top Bottom

Front

Back Sides

310 Indoor

* (T-K4-IN)* 12” 12” 24” 1” 2 “ 310 Outdoor (

T-K4-OS) 36” 12” 24” 1” 2 “

Model

Top Bottom

Front

Back Sides

510 Indoor* (

T-D2-IN)* 12” 12” 24” 1” 2 “

510 Outdoor (

T-D2-OS) 36” 12” 24” 1” 2 “

*Standard indoor installations and direct-vent indoor installations have the same clearances.

INCLUDED ACCESSORIES

Check that these items below are included with the water heater.

1. Installation Manual and Owner’s Guide

Product Registration Card

3. Communication Cable

510 (T-D2) models only

Qty: 1

Bottom

Side Top

Side

Front

Back

Maintain a

ll clearances around

the water heater.

Installation

9│Page

OPTIONAL ITEMS

Model

110 Indoor

(T-KJr2-IN)

110 Outdoor

(T-KJr2-OS)

310 Indoor

(T-K4-IN)

310 Outdoor

(T-K4-OS)

510 Indoor

(T-D2-IN)

510 Outdoor

(T-D2-OS)

9007666005

(TK-

RE02

)

✔ ✔ ✔ ✔

9007603005

(TM-

RE30

)

✔ ✔

9007678005

(TK-

BF01

)

✔

9007667005

(TK-

TV10

)

✔

9007670005

(TK-

PC01

)

✔ ✔ ✔ ✔

9007671005

(TK-

PCJr2

)

✔ ✔

90076

74005

(TK-

RB02

)

✔

9007608005

(TK-KPWL4)

9007609005

(TK-

KPWH4

)

✔

9007680005

(TK-

KPCT43

)

✔

1. Temperature Remote Controller

9007666005

(TK-RE02)

The Temperature Remote Controller has two functions. It allows the output temperature from the water heater to be adjusted within the range of 99 °F to 167 °F, and it also

works as a diagnostic tool that will give a concise error code whenever there is a problem with the unit. The temperature options are 99°F, 100°F, 102°F, 104°F, 106°F, 108°F, 109°F, 111°F, 113°F, 115°F, 117°F, 122°F, 131°F, 140°F, 158°F, and 167°F. See the trouble shooting section

for information on possible error codes.

2. Temperature Remote Controller

9007603005

(TM-RE30)

The Temperature Remote Controller has two functions. It allows the output temperature from the water heater to be adjusted within the range of 99 °F to 185 °F, and it also

works as a diagnostic tool that will give a concise error code whenever there is a problem with the unit. The temperature options are 99°F, 100°F, 102°F, 104°F, 106°F, 108°F, 110°F, 111°F, 113°F, 115°F, 117°F, 122°F, 131°F, 140°F, 149°F, 158°F, 167°F, 176°F and 185°F. See the trouble shooting section for information on possible error codes.

3. Backflow Preventer: 9007678005 (TK-BF01)

The Backflow preventer prevents the backflow of air through the exhaust vent. This helps prevent harmful exhaust gases from entering the home, as well as

helping to prevent the unit from freezing in areas where cold air can be blown or drawn into the exhaust system. Install this vent damper in accordance with the installation instructions and any applicable codes.

4. Direct-Vent Conversion Kit: 9007667005 (TK-TV10)

This kit can be used to

convert the water heater from a standard vent system to a direct-vent (or sealed combustion) system. Install this

conversion kit in accordance with the installation instructions and any applicable codes.

Installation

10│Page

5. Pipe Covers: 9007670005 (TK-PC01) and 9007671005 (TK-PCJr2)

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.

6. Recess box: 9007674005 (TK-RB02)

The Recess box will allow for “clean” installations. The water heater fits inside the recess box, which hides and protects the whole water h

eater and plumbing.

The Recess box will fit in-between most wall studs.

7. 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, III and IV. There are two types of terminations: the Louver termination and the Hood termination. For different wall thicknesses, there are two ranges of lengths available (refer to the venting brochure for details). Install these vent terminations in accordance with their installation instructions and any applicable local codes.

8. Direct-Vent Concentric Termination: 9007680005 (TK-KPCT43)

Used when terminating direct-vent (sealed-combustion) systems, with direct-vent models that require a 3” intake and a 4” 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

Direct

vent Concentric

Termination

Part#

Covering wall thickness

9007680005 (

TK-KPCT43

-1) 3.9” –

7.1”

9007772005 (

TK-KPCT43

-2) 6.9” –

10.1”

9007773005 (

TK-KPCT43

-3) 9.8” –

13.0”

Louver

Termination 9007608005

(TK-KPWL4)

Hood

Termination 9007609005 (TK-KPWH4)

Installation

11│Page

 DO NOT adjust any dipswitches on the right bank for the 510 (T-D2) models.  The dark squares indicate the direction the dipswitches should be set to.

Dipswitches

HIGH-ALTITUDE INSTALLATIONS

Check the elevation where your water heater is installed. Set dipswitches shown in the table below depending on the altitude.

Altitude

0 to 2,000 ft

(DEFAULT)

2,000 to 4,000 ft

4,000 to 6,000 ft Over 6,000 ft

Switch No.3

OFF

Consult our Technical Services Department at 1-877737-2840

Switch No.4

OFF

Altitude

0 to 2,0

00 ft

(DEFAULT)

2,000 to 4,000 ft

4,000 to 6,000 ft Over 6,000 ft

Switch No.4

OFF

Consult our Technical Services Department at 1-877737-2840

Switch No.5

OFF

110 (T-KJr2) and 310 (T-K4) models

510 (T

D2) models (Left bank of dipswitches)

110 (T

KJr2) and 310 (T

K4) models

Computer board

WARNING

510 (T

D2) models Co

mputer board

Left bank of dipswitches

OFF

1 2

3 4

5 6 7 8

OFF

1 2 3 4 5 6 7 8

OFF

1 2 3 4 5 6 7 8

OFF

1 2 3 4 5 6

2 3 4 5 6

OFF

12345

Installation

12│Page

Improper venting of this appliance can result in excessive levels of carbon

monoxide which can result in severe personal injury or death.

Improper installation can cause nausea or asphyxiation, severe injury or death from carbon monoxide and flue gases poisoning. Improper installation will void product warranty.

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 applicable national and local codes.

VENTING INSTRUCTIONS

-General-

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 and Propane Installation Code in Canada, as well as applicable local building codes. The manufacturer recommends the “T-Vent” line manufactured by TAKAGI (Refer to “T-Vent” brochure for details). However, the following are also UL listed manufacturers: ProTech Systems Inc. (FasNSeal), Flex-L Inc., Z-Flex Inc. (Z-Vent III), Metal-Fab Inc., and Heat-Fab Inc. (Saf-T Vent).

General rules for venting water heaters are:

 Place the water heater as close as possible to the vent terminator.  The vent collar of the water heater must be fastened directly to an unobstructed vent pipe.  Do not weld the vent pipe to the water heater’s vent collar.  Do not cut the vent collar of the unit.  The vent must be easily removable from the top of the water heater for normal service and

inspection of the unit.

 The water heater vent must not be connected to any other gas appliance or vent stack.  Avoid using an oversized vent pipe or using extremely long runs of the pipe.  For rooftop venting, a rain cap or other form of termination that prevents rain water from

entering into the water heater must be installed.

 Do not common vent or connect any vent from other appliances to the water heater vent.

General rules for vent terminations:

 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.

 Locate the vent terminator so that it cannot be blocked by any debris, at any time. Most

codes require that the terminator be at least 12 inches above grade, but the installer may determine if it should be higher depending on the job site condition and applicable codes.

 A proper sidewall terminator is recommended when the water heater is vented through a

sidewall.

 Regarding the clearances from the exhaust terminator to the air inlet or opening, refer to

the next few pages.

CAUTION

DANGER

Installation

13│Page

-Exhaust venting-

For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor

(T-D2-IN) models

This is a Category III appliance and must be vented accordingly. The vent system must be sealed 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. For best results, a vent system should be as short and straight as possible.

 This water heater is a Category III appliance and must be vented accordingly with any 4” vent

approved for use with Category III 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 III approved or Special BH vent pipe).

 When the horizontal vent run exceeds 5 ft., support the vent run at 3 ft. intervals with

overhead hangars.

 The maximum length of exhaust vent piping must not exceed 50 ft. (deducting 5 ft. 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” 5 50 ft.

*For each elbow added, deduct 5 ft. from max. Vent length.

No. of

Elbows

Max.

Vertical or Horizontal Length

50 ft.

45 ft.

40 ft.

25 ft.

-Venting Illustrations-

For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor

(T-D2-IN) models

Horizontal Installation Diagram

Vertical Installation Diagram

Sidewall Vent

Terminator

Wall Backflow Preventer*

Vertical Condensation Drain

For details of the optional items, refer to the Installation manual for each Optional item.

Roof Vertical Condensation

Drain**

Roof Flashing

Rain Cap

Backflow Preventer *

Installation

14│Page

Backflow Prevent

(Recommended for freezing weather conditions: 36

°F and below)

**Vertical Condensation Drain must be installed accordance with local codes.

Horizontal Installation Diagram With Direct-Vent Concentric Termination

Horizontal Installation Diagram (With direct-venting)

Vertical Installation Diagram (With direct-venting)

The water heater

Intake port of

Direct-Vent Conversion Kit

Installation Diagram of Direct-Vent Conversion Kit with water heater

Wall Direct

vent

Concentric Termination

Plate of Direct

Vent Conversion Kit

See the picture below for detailed

connection

instructions to the Direct-Vent Conversion Kit.

Vertical Condensation Drain

Backflow

Preventer *

Wall Sidewall

Vent Terminator

Roof Flashing

Vertical

Condensation Drain**

Backflow

Preventer *

Rain Cap

Roof Fire stop

Installation

15│Page

-Vent termination clearances-

Canada

U.S.A

Direct vent and

other than Direct

Vent

Direct vent Other than Direct Vent

Clearance above grade, veranda, porch, deck,

or balcony.

1 foot 1 foot 1 foot

Clearance to window or door that may be opened.

3 feet 1 foot

4 feet from below or side

opening. 1 foot from

above opening.

C Clearance to permanently closed window

* * * D

Vertical clearance to ventilated soffit located

above the vent terminator within a horizontal distance of 2 feet (61cm) from the center line

of the terminator.

* * *

E Clearance to unventilated soffit

* * * F

Clearance to outside corner

* * * G

Clearance to inside corner

* * * H

Clearance to each side of center line extended

abo

ve meter/regulator assembly

3 feet * *

I Clearance to service regulator vent outlet.

3 feet

* * J Clearance to non

mechanical air supply inlet

to building or the combustion air inlet to any

other application.

3 feet 1 foot

4 feet from below or side

opening. 1 foot from

above opening.

K Clearance to mechanical air supply inlet.

6 feet

3 feet

L Clearance above paved sidewalk or paved

driveway located on public property.

7 feet * 7 feet

Clearance under veranda, porch deck, or

balcony.

1 foot * *

*For 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.

Installation

16│Page

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 guidelines. Local codes supersede these guidelines.

For sidewall terminations

Exhaust termination

1ft.

1ft. 2ft.

Inside

corner

For multiple sidewall exhaust

terminations (e.g. multi-unit systems), an exhaust termination must be at least 1 ft. away from another exhaust termination. An exhaust termination must also be at least 2 ft. away from an inside corner (if the adjacent wall is less than 2 ft. of length, the minimum required distance away from the inside corner will be equal 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. away from each other, no matter the orientation.

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. away from each other, no matter the orientation. A direct-vent termination must also be at least 2 ft. away from an inside corner (if the adjacent wall is less than 2 ft. of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall).

For mul

tiple-unit rooftop terminations (whether for standard indoor 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. away from a wall or surface.

A: In accordance with local codes

For rooftop terminations

Air intake

Exhaust

termination

2ft.

Air intake

Exhaust

termination

Exhaust and/or d

irect-vent

sidewall terminations should be at least 2 ft. away from an opposite surface/wall. Do not place the termination directly in front of an opening into a building.

2ft.

Exhaust

termination

Air supply inlet

3ft.

Direct vent termination

1ft.

Inside

corner

2ft.

CAUTION

Installation

17│Page

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.



Check that the type of gas matches the rating plate first.

 Ensure that any and all gas regulators used are operating properly and

providing gas pressures within the specified range shown below. Excess gas inlet pressure may cause serious accidents.

 Conversion of this unit from natural gas to propane or 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.

GAS SUPPLY AND GAS PIPE SIZING

-General-

 The minimum and maximum inlet gas pressures are:

Gas type

Inlet gas pressure

Natural Gas

Min. 5.0

” WC –

Max. 10.5

” WC Propane

Min. 8.0

” WC –

Max. 14.0

” WC

 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-

1. Install a manual gas shut-off valve between the water heater and the gas supply line.

2. When the gas connections are completed, it is necessary to perform a gas leak test (see below)

either by applying soapy water to all gas fittings and observing for bubbles or by using a gas leak detection device.

 The water heater and its individual shutoff valve must be disconnected from the gas supply

piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa).

 The water heater must be isolated from the gas 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 (3.5kPa).

3. Always purge the gas line of any debris and/or water before connecting to the gas inlet.

WARNING

NOTICE

Installation

18│Page

-Natural Gas Supply Piping-

Maximum Delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe Carrying Natural Gas of 0.60 Specific Gravity Based on Pressure Drop of 0.5” WC

Based on Energy Content of 1,000 BTU/Cubic Ft.: The water heater requires 140 Cubic Ft./hr for the 110 (T-KJr2) models, 190 Cubic Ft./hr for the 310 (T-K4) models, and 199 Cubic Ft./hr for the 510 (T-D2) models.

Unit: Cubic Feet per Hour

Pipe Size

Length

Diameter

10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’ ¾” 363 249 200 171 152 138 127 118 111 104 93 84 72 1” 684 470 377 323 286 259 239 222 208 197 174 158 135 1 ¼” 1,404 965 775 663 588 532 490 456 428 404 358 324 278

1 ½” 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 416 2” 4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936 801

-Propane (LP) Supply Piping-

Maximum Capacity of Propane (LP) Based on 11” WC supply pressure at a 0.5” WC pressure drop

Unit: kBTU per Hour

Pipe Size

Length

Diameter

10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’ ¾” 567 393 315 267 237

217 196 185 173 162 146 132 112 1” 1,071

732 590 504 448 409 378 346 322 307 275 252 213 1 ¼” 2,205 1,496

1,212

1,039

913 834 771 724 677 630 567 511 440 1 ½” 3,307 2,

299 1,858 1,559

1,417

1,275

1,181

1,086

1,023

976 866 787 675 2” 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

1,260

For more information, please see the below.

Based on Energy Conten

t of 1,000BTU/Cubic Ft:

Divide each appliance’s BTU requirement by 1,000BTU 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 50ft., Section A to B needs to be 1” in order to supply 220 cubic ft.

10’ Lengt

1” Pipe Size

Gas Sizing Example

(Natural Gas)

10’ Length

3/4” Pipe Size

15’ Length

1/2” Pipe Size

10’ Length

1/2” Pipe Size

Furnace

120,000BTU

Water

Heater

199,000BTU

5’ Length

1-1/4” Pipe Size

Range

65,000BTU

10’ Length

3/4” Pipe Size

Dryer

35,000BTU

15’ Length

1” Pipe Size

5’ Length

1-1/4” Pipe Size

Gas Meter

Installation

19│Page

1. Turn off

all electric power to the water heater if serv

ice is to be performed.

2. Turn the manual gas valve located on the outside of the unit clockwise  to

the off position.

-Measuring inlet gas pressure-

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 to the right.

3. Connect the manometer to the pressure port.

4. Re-open the manual gas valve. Check to see that

there are no gas leaks. Open some of the fixtures that use the highest flow rate to turn on the water heater.

5. Check the inlet gas pressure. When the water heater

is on maximum burn, the manometer should read from 5.0” to 10.5” WC for Natural gas, from 8.0” to

14.0” WC for Propane.

Pressure port

Installation

20│Page



Do not use this water heater if any part has been submersed under water.

Immediately call a licensed professional to inspect the water heater to replace any damaged parts.

 Do not reverse the hot outlet and cold inlet connections to the water heater.

This will not properly activate the water heater.

WATER CONNECTIONS

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 heater 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 entering your heater. This will need to be cleaned periodically to maintain optimum flow.

-Pressure relief valve-

The water heater has a high-temperature shut off switch built in as a standard safety feature (called a Hi-Limit switch) therefore a “pressure only” relief valve is required.

 This unit does not come with an approved pressure relief valve.  An approved pressure relief valve must be installed on the hot water outlet.  The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow

local code.

 The discharge capacity must be at least 140,000 BTU/h for the 110 (T-KJr2) models, 190,000

BTU/h for the 310 (T-K4) models, and 199,000 BTU/h for the 510 (T-D2) models.

 The pressure relief valve needs to be rated for a maximum of 150 psi.  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"

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.

Pressure

Relief Valve

Hot

outlet

Cold

inlet

Gas

inlet

As Close as

Possibl

CAUTION

Installation

21│Page

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 Canadian Electrical Code, Part 1, in Canada.

When servicing

or replacing p

arts 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.

ELECTRICAL CONNECTIONS

1. The water heater must be electrically grounded. Do not attach the ground wire to either the gas or

the water piping.

2. The water heater requires 120 VAC / 60 Hz electrical power supply that is properly grounded.

 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).

 Connect the power supply to the water heater exactly as shown in the wiring diagram;

3. A green screw is provided in the junction box to ground the connection.

4. Can be hardwired or wired to a plug-in.

5. The use of a surge protector is recommended in order to protect the unit from power surges.

CAUTION

WARNING

Connect Power supply

120 V

AC / 60 Hz

Ground

Bottom view of water heater

View of e

lectrical

connections of water heater

Green screw

Installation

22│Page

REMOTE CONTROLLER CONNECTIONS

1. Disconnect power supply from the water heater.

2. Take off the water heater’s front cover.

3. Locate the remote controller terminal, pictured below (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.

5. Pull the remote’s wires through the hole at the bottom of the water heater’s casing.

6. Properly attach the remote’s wires to the remote controller terminal on the computer board.

(No polarity)

*Do NOT jump or short-circuit the wires or computer will be damaged.

7. Replace Front Cover securely.

8. Wires used for the remote controller connection must be:

 Minimum 18AWG wire (No polarity)  Maximum 400 feet long

*For detail

connection

instructions

to the

remote controller

, refer to the

instructions that ar

packaged with the remote controller.

510 (T

D2) models

110 (T

KJr2) and 310 (T

K4) models

Front of remote

Back of remote

Connect other end to these terminals

Connect to these

terminals

9007666005 (TK-RE02)

Front of remote

Back of remote

Connect other end to these terminals

Connect to these

terminals

9007603005 (TM-RE30)

Installation

23│Page

In an Easy-Link system, the pump must be connected to the “Pump” connector in the “PARENT” unit only. If the pump is connected to any of the “CHILD” units, the

pump will not work.

PUMP CONTROL CONNECTIONS

Available on the 510 (T-D2) models only

The 510 (T-D2) models water heaters can be used to control a recirculation pump. Proper pump control helps to preserve the life of the system and saves energy as well.

The water heater pump control port is a “normally open dry contact”, and therefore needs additional components to properly control a recirculation pump. To control a recirculation pump, connect the pump to the “Pump” connector in the water heater as shown in the diagram below. (In an Easy-Link system, connect the pump ONLY to the “PARENT” unit.) The pump is to be connected using suitable relays shown in the diagram below. Please make sure the relays are properly rated for the recirculation pump. Using the water heater’s internal thermistors as a temperature control, the recirculation pump will only turn on when recirculation is needed.

CAUTION

These components are

NOT in

cluded wit

the water heater

and

are

external to the unit. They must be acquired separately.

Connect to

this “Pump

connector”.

Recirculation

pump

Thermal

relay

120 VAC

220 VAC etc for relay

Power supply

for pump 120 VAC 220 VAC etc

Power supply

for relay

Installation

24│Page



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.

 All units within an Easy-Link System must be of the same exact model.

Different models cannot combine together to form an Easy-Link System.

EASY-LINK SYSTEM

Available on the 510 (T-D2) models only

-General-

The 510 (T-D2) models water heaters can be connected with other heaters of the same model with communication cables to work as a multiple-unit manifold system.

 The Easy-Link system allows up to 4 units to manifold together.  A communication cable (gray color) comes with each 510 (T-D2) 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 11,000 BTU/h and 796,000 BTU/h.

-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.

2. Select one unit to be the “PARENT” unit.

3. “PARENT” unit

Locate the two banks of dipswitches to the right of the 7-seg. LED on the computer board of the unit that you select to be the “PARENT” unit. Change dipswitch No. 1 on the right bank of dipswitches to the ON position. See the computer board diagram as shown in the next page. Do not change any dipswitches on any of the “CHILD” units.

Hot

Out

Cold

Gas

CAUTION

Installation

25│Page

The dark sq

uares indicate the direction the dipswitches should be set to.

4. Between the “PARENT” and the “CHILD-1” units

Connect the “PARENT” connector of the “PARENT” unit to the “[1]” connector of the “CHILD-1” unit.

5. Between the “CHILD-1” and the “CHILD-2” units

Connect the “[2]” connector of the “CHILD-1” unit to the “[1]” connector of the “CHILD-2” unit.

6. Between the “CHILD-2” and the “CHILD-3” units

Connect the “[2]” connector of the “CHILD-2” unit to the “[1]” connector of the “CHILD-3” unit.

7. Make sure the 7-seg. LED of all the units’ computer boards display the unit #. The numbering system automatically allocates the unit # to each water heater in the Easy-Link system, in accordance with the table below.

Parent

unit Unit # : 1

Child

units

Unit # : 2, 3 and 4

(A) 510 (T

D2) models Computer board

(B) Ba

sic diagram of connections between the Easy

Link System units.

To change the dipswitch

settings for the Easy-Link system, locate the bank of dipswitches to the right of the 7-seg LED.

Do not adjust the left bank of dipswitches.

Easy-Link connectors are next to the

computer board

Easy-Link system

“Online” LED

Right bank of

dipswitches

Left bank of

dipswitches

7-Seg. LED

CAUTION

P A R E N T

1 234 5 6

Communication c able

Co n n e c t or s

Right bank of Dipswi tches

OFF

P A R E N T

1 234 5 6

Right bank of Dipswi tches

1 234 5 6

Right bank of Dipswitches

1 234 5 6

Right bank of Dipswitches

Co n n e c t or s Co n n e c t or s Co n n e ct o r s

PARENT unit CHILD

1 unit

CHILD

2 unit

CHILD

3 unit

Installation

26│Page

 A remote controller is not required for the Easy-Link system.  If running the Easy-Link system without a remote controller, please make sure the

temperature settings on ALL the units are set to the same settings. Otherwise, the units will not operate properly.

 If a remote controller is used, the temperature on all the units in the system will

automatically be set to the same temperature that is set on the remo

te.

CASE 1:

 Unless you change dipswitch No.1 of the “PARENT” unit to the “ON” position, the

system will not work as an Easy-Link system. The units will operate as individual units.

CASE 2:

 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 will operate as individual units.

Wrong dipswitch setting on the “PARENT” unit

Wrong connections between the “PARENT” unit and the “CHILD-1” unit

s of incorrect settings and/or connections

Prohibited

NOTICE

rong S

etting

PARENT

unit CHILD

1 unit

Communication cable

OFF

212 1

P A R E N T

Co n n ec t o r s C on n ec t o r s

1 2 3 4 5 6 1 2 3 4 5 6

Right bank of Dipsw itchesRight bank of Dipswitche s

Communication cable

OFF

212 1

P A R E N T

Co n n e ct o r s Con n e c to r s

1 2 3 4 5 6

Right bank of Dipsw itches

1 2 3 4 5 6

Right bank of Dipsw itches

Wrong

Connections

PARENT

unit CHILD

1 unit

Communication cable

OFF

212 1

P A R E N T

2 3 4 5 6

Right bank of Dips witches

2 3 4 5 6

Right bank of Dip switches

Co n n ec t o rsCo n n ec t o rs

Wrong

Connections

PARENT

unit CHILD

1 unit

Installation

27│Page

Con

necting two “

PARENT

” connectors together 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 communication cable. Do not splice or modify connectors.

Communication c able

OFF

212 1

P A R E N T

Co n n e c to r s Co n n ec t o rs Con n e c to r s

1 2 3 4 5 6

Right bank of Dipsw itches

1 2 3 4 5 6

Right bank of Dip switches

1 2 3 4 5 6

Right bank of Dips witches

CASE 3:

 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.

CASE 4:

 If a remote controller (optional) is used, it has to be connected to the “PARENT” unit. If the

remote controller is connected to a “CHILD” unit,

it will only control that particular individual

“CHILD” unit and will not control the Easy-Link system as a whole.

Wrong connections between the “CHILD-1” unit and the “CHILD-2” unit

Remote controller connected to incorrect unit

WARNING

Prohibited

Wrong Connections

PARENT

unit

CHILD unit

Remote controller

Communicatio n cable

OFF

212 1

P A R E N T

Co n n ec t o rs Co nn e c to r s

1 2 3 4 5 6

Right b ank of Dipswitc hes

1 2 3 4 5 6

Right b ank of Dipswitc hes

Wrong

Connections

PARENT

unit CHILD

1 unit

CHILD

2 unit

Installation

28│Page



In order to purge air in water pipes within a closed-loop system, an air vent

and air separator should be installed in to the system. Required circulation flow rates are labeled next to each application diagram. These flow rate requirements must be followed.

 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.

 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.

 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.

 Water temperature over 125 F (52°C) can cause severe burns instantly or

death from scalds.

 Chemicals such as diluted Glycol can be used for radiant floor, Hydro/fan coil

air or Baseboard heating only. The diluted solution of glycol must contain between 25 and 55 % of Glycol. Be aware that in closed-loop glycol systems, low pressure in the heat exchanger can cause low-temperature boiling, resulting in excessive noise and damage to the water heater. Consult with the glycol maker for specifications prior to use.

This is a concept drawing only.

APPLICATIONS

-Space-Heating Applications-

* The

recirculation pump is to be controlled by:

-Dual-set aquastat (recommended w/timer) OR

-“Pump Control Connections” 510 (T-D2) models only.

Refer to p. 23. * The recirculation pump is to provide no less than 2 GPM and no more than 4 GPM through each activated unit in the system.

-Recirculation-

WARNING

Check valve

Air

separator

Recirculation

pump

Hot water outlet to

fixtures

Air Vent

Unions

Gas supply

Ball v

alves Expansion tank

Y-

Strainer

Cold water

inlet

Hot Wate r Outl et

Cold Wate r Inle t

Gas Inle t

Installation

29│Page

-Dual-purpose hot water heating(Domestic and Space Heating):

 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.

 This illustration 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, contact the manufacturer.

NOTICE

The circulation pump is to provide no less

than 2 GPM

and no more than 4 GPM

throug

h eac

h activated

unit in the system.

Takagi

An approved Pressure Only

Relief Valve, Tie to Location

approved by Local Codes and Must Meet BTU Rating of Takagi Model Used

Unions

4" Gas Exhaust Vent (Discharge Must Comply with Local and State Codes). Can Not Be Common Vented with Other Appliances

Atmospheric Vacuum Breaker

Pump (Must Be Sized Properly With Each Application). Pump Shall Run 60 Seconds Every 6

Hours

Pressure

Gauge

Apply Correct Thermal Expansion Tank-Size Per Application

Tempered Water To House

Cold Inlet

Shut-Off

Valve

Check Valve Will Have 1/8" Hole in Check, As Per Mass. Code

Thermometer

Thermostatic Mixing Valve

Shut-Off Valves

Check Valve

Hot

Water

Outlet

Cold Water Inlet

T-Handle Gas Shut-Off Valve

**Maximum allowable distance of 50-Ft. from water heater and heating panel

Heating Coil

(used with air-handler)

Diagramatic Layout of Radiant Heating and

Domestic Water Heater Per Mass. Code

Thermometer

Check Valves

Gas Inlet

Drain Plug

Water

Filter

120 VAC Switch or Outlet

**Maximum allowab le

distance of 50 ft. from water heater and heating panel

An approved Pressure Only Relied

Valve, Tie to Location approved By Local Codes and Must Meet BTU Rating of water he ater Model Used

Initial Operation

30│Page

 Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time.  Open the main gas supply valve to the unit using only your hand to avoid any spark. Never use

tools. If the knob will not turn by hand, do not try to force it; call a qualified service technician. Forced repair may result in a fire or explosion due to gas leaks.

 Be sure to check for the presence of leaking gas toward the bottom of the unit because some

gases are heavier than air and may settle towards the floor.

 Check the GAS PRESSURE. Refer to p. 19.  Do not try to light the burner manually. It is equipped with an electronic ignition device which

automatically lights the burner.

 Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater.  Purge the GAS and WATER LINES to remove any air pockets.  Do not use this water heater if any part has been submersed under water. Immediately call a

qualified service technician to inspect the water heater and to replace any damaged parts.

INITIAL OPERATION

1. Once the above checks

have been completed, please clean filter of any debris. Refer to p. 36 for instructions.

2. Fully open the manual

water control valve on the water supply line.

3. Open a hot water tap to

verify that water is flowing to that tap.

Then close the hot water tap.

4. Fully open the manual gas

control valve installed.

5. Turn on the 120 volt 60 Hz

power supply to the water heater.

6. Now you are ready to

enjoy hours of endless hot water.

FOR YOUR SAFETY, READ BEFORE OPERATING

IF YOU SMELL GAS:

 Do not try to start the water heater.  Do not touch any electric switches; do not use any phone in your building.  Immediately call your gas supplier from a neighbor’s phone. Follow the gas

supplier’s instructions.

 If you cannot reach your gas supplier, call the fire department.

WARNING

Operating Safety

31│Page

OPERATING SAFETY

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This water heater does not have a pilot. It is equipped with an ignition device that

automatically lights the burner. Do not

try to light the burner by hand.

B. BEFORE OPERATING smell all around the water heater area for evidence of leaking gas. Be

sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS.

 Do not try to light any appliance.  Do not touch any electric switch; do not use any phone in your building.  Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's

instructions.

 If you cannot reach your gas supplier, call the fire department.

C. 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. Force or attempted repair may result in a fire of explosion.

D. 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

1. STOP! Read the safety information above or in the Owners Manual.

2. Turn off all electric power to the water heater.

3. Do not attempt to light the burner by hand.

4. Turn the manual gas valve located on the outside of the unit clockwise ↻ to the off position.

5. Wait five (5) minutes to clear out any gas. If you then smell gas. STOP! Follow "B" in the safety

information above on this label. If you don't smell gas, go to next step.

6. Turn the manual gas valve located on the outside of the unit counter clockwise ↺ to the ON

position.

7. Turn on all electrical power to the water heater.

8. 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

1. Turn off all electric power to the water heater if service is to be performed.

2. Turn the manual gas valve located on the outside of the unit clockwise ↻ to the off position.

’

Operating Safety

32│Page

DANGER

Vapors from flammable liquids will explode and catch fire causing death or severe burns.

Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater.

Keep flammable products:

1. Far away from heater

2. In approved containers

3. Tightly closed

4. Out of children's reach

Vapors:

1. Cannot be seen

2. Vapors are heavier than air

3. Go a long way on the floor

4. 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 122°F (50°C). Use this heater at your own risk. The set outlet water temperature can cause severe burns instantly or death from scalds. Test the water before bathing or showering. Do not leave children or an infirm person in the bath unsupervised.

DANGER

Hot Water 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 person.

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.

Normal Operation

33│Page



Flow rate to activate the water heater : 0.5 gallons per minute at the

default set temperature

 Flow rate to keep the water heater running : 0.4 gallon per minute

 Hot Water temperatures over 125F (52°C) can cause severe burns instantly or

death from scalding.

 The outlet hot water temperature of the water heater is factory

set at 122°F (50°C).

 Feel the water temperature before bathing or showering.

NORMAL OPERATION

GENERAL

Open a hot water tap.

Mix cold water with the hot to get

the correct temperature water.

Close the hot water tap.

*If a remote controller installed, turn the remote controller ON by pressing the power ON/OFF button

on the remote controller and then set the temperature by pressing the HOT/COLD buttons before opening a hot water tap. The temperature is displayed when the remote controller is turned ON.

TEMPERATURE SETTINGS

-Without remote controller-

Depending on the model, there are 4 or 8 temperatures that you can select from by changing the dipswitch settings on the computer board without the remote controller. See the table below.

Model

Temperatures available

110 (

T-KJr2)

310 (T-K4)

113F 122F 131F 140F

510 (T-D2)

104F 113F 122F 131F 140F 158F 176F 185F

For detailed dipswitch settings for each temperature, refer to the next page.

 The temperature has been preset at the factory to 122°F (50°C).  If temperatures other than the ones listed above are required, the remote controller can

provide several more temperature options. Refer to p. 9 for a list of available temperatures on the remote controller.

 This water heater is an on-demand, tankless water heater designed to efficiently supply

endless hot water without reference to temperature settings.

NOTICE

WARNI

Normal Operation

34│Page

 DO NOT set to 185 °F if you use your water heater in a recirculation

system. This will cause damage to the heater and void the warranty. (This temperature setting is only available on the 510 (T-D2) models.)

 DO NOT adjust the left bank of dipswitches. For the 510 (T-D2) models.  Turn off the power supply to the water heater before changing the

dipswitch settings.

 Only change the switches with the dark squares. The dark squares indicate

which direction the dipswitch should be set to.

510 (T

D2) models

110 (T

KJr2) and 310 (T

K4) models

510 (T

D2) models

110 (T

KJr2) and 310 (T

K4) models

Location of the bank of dipswitches on the c

omputer board

WARNING

Dipswitches

Right bank of

dipswi

tches

Left bank of

dipswitches

7-Seg. LED

Dipswitch settings for each temperature on the computer board

(45

OFF

113 F

1 2 3 4 5 6 7 8

OFF

1 2 3 4 5 6 7 8

(50 C)

122 F

DEFAULT

(55

OFF

131 F

1 2 3 4 5 6 7 8

(60

OFF

140 F

1 2 3 4 5 6 7 8

Temperature Settings

(45 C)

113 F

(40

OFF

104 F

(70 C)

158 F

(60 C)

140 F

(85 C)

185 F

(80 C)

176 F

1 2 3 4 5 6

OFF

1 2 3 4 5 6

OFF

1 2 3 4 5 6

OFF

1 2 3 4 5 6

OFF

1 2 3 4 5 6

OFF

1 2 3 4 5 6

(45 C)

113 F

OFF

1 2 3 4 5 6

(50 C)

122 F

DEFAULT

OFF

1 2 3 4 5 6

(55 C)

131 F

OFF

1 2 3 4 5 6

Normal Operation

35│Page

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.

Household Flow Rates

Taken from UPC 2006

FLOW

 The flow rate through the water heater is limited to a

maximum of 6.6 GPM for the 110 (T-KJr2) models, 8.0 GPM for the 310 (T-K4) models, and 10.0 GPM for the 510 (T-D2) models.

 The temperature setting, along with the supply

temperature of the water will determine the flow rate output of the unit.

 Please refer to the temperature vs. gallons per minute

chart on p. 48-49 to determine the likely flow rates based on your local ground water temperature 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 for gallons per hour (GPH) or gallons per minute (GPM) for Natural Gas and Propane, when raising the water temperature by 77F (from 58F to 135F). See the diagram below.

 Refer to the table to the top right for typical household plumbing fixture flow rates to determine

what the water heater can do in a household application.

FREEZE PROTECTION SYSTEM

 This unit comes equipped with heating blocks to protect it against damages associated with freezing.  For this freeze protection system to operate there has to be electrical power to the unit. Damage to

the heat exchanger caused by freezing temperatures due to power loss is not covered under the warranty. In cases where power losses can occur, consider the use of a backup power supply.

 The freeze protection system will activate when the surrounding and/or outside temperatures drop

below 36.5°F (2.5°C).

 For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models:

 In any areas subject to freezing temperatures, the manufacturer highly recommends an

indoor installation with an indoor model. In such an installation, freezing issues can only occur if cold air enters through the venting into the heat exchanger, whether by negative pressures within the installation location or by strong outside winds.

 The manufacturer also highly recommends the use of a back flow vent damper to minimize

the amount of cold air entering through the exhaust venting when the water heater is off.

 It is the installer’s responsibility to be aware of freezing issues and take all preventative measures.

The manufacturer will not be responsible for any damage to the heat exchanger as a result of freezing.

 If you will not be using your heater for a long period of time:

1. Completely drain the unit of water. Refer to p. 36.

2. Disconnect power to your heater.

This will keep your unit from freezing and being damaged.

Appliance / Use

Flow R

ate (GPM)

Lavatory Faucet

1.0 Bath Tub

4.0 –

10.0 Shower

2.0 Kitchen Si

1.5 Dishwasher

1.5 Washing machine

4.0

Model

110 Indoor

(T-KJr2-IN)

110 Outdoor

(T-KJr2-OS)

310 Indoor

(T-K4-IN)

310 Outdoor

(T-K4-OS)

510 Indoor

(T-D2-IN)

0 Outdoor

(T-D2-OS)

GPH GPM

Natural Gas

172 2.9 180

3.0 244 4.1 242 4.0 254 4.2 255 4.3 Propane

184 3.1 179

3.0 250 4.2 249 4.2 256 4.3 255 4.3

CAUTION

Normal Operation

36│Page

Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing.

MAINTENANCE AND SERVICE

 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 vale 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.

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

1. Close the manual gas shut off valve.

2. Turn off power to the unit and wait a couple of

seconds. Turn on again.

3. Wait 30 seconds, and then turn off power to the unit,

yet again.

4. Close the water shut off valve.

5. Open all hot water taps in the house. When the

residual water flow has ceased, close all hot water taps.

6. Have a bucket or pan to catch the water from the

unit’s drain plugs. Unscrew

the two drain plugs (Large

and small) to drain all the water out of the unit.

7. Wait a few minutes to ensure all water has

completely drained from unit.

8. Clean the filter: Check the water filter located within

the cold inlet. With a tiny brush, clean the water filter of any debris which may have accumulated and reinsert the filter back into the cold water inlet.

9. Securely screw the drain plugs back into place. Hand-

tighten only.

WARNING

Drain Plug

with Filter (Large)

Water Valve

Drain Plu

(Small)

Gas Valve

Unsatisfactory

Satisfactory

Unsatisfactory

Blue flame

Red or Yellow

flame

lame

blowing up

Troubleshooting

37│Page

GENERAL

TROUBLESHOOTING

-TEMPERATURE and AMOUNT OF HOT WATER-

PROBLEM SOLUTIONS

It takes long time to get hot water at the fixtures.

 The time it takes to deliver hot water from the water heater to

your fixtures depends on the length of piping between the two. The longer the distance or the bigger the pipes, the longer it will take to get hot water.

 If you would like to receive hot water to your fixtures quicker, you

may want to consider a hot water recirculation system. (p. 28)

The water is not hot enough.

 Compare the flow and temperature. See the charts on p. 48-49.  Check cross plumbing between cold water lines and hot water

lines.

 Is the gas supply valve fully open? (p. 30)  Is the gas line sized properly? (p. 18)  Is the gas supply pressure enough? (p. 19)  Is the set temperature set too low? (p. 33-34)

The water is too hot.

 Is the set temperature set too high? (p. 33-34)

The hot water is not available when a fixture is opened.

 Make sure the unit has 120 VAC / 60 Hz power supply.  If you are using the remote controller, is the power button turned

on?

 Is the gas supply valve fully open? (p. 30)  Is the water supply valve fully open? (p. 30)  Is the filter on cold water inlet clean? (p. 36)  Is the hot water fixture sufficiently open to draw at least 0.5 GPM

through the water heater? (p. 33)

 Is the unit frozen? (p. 35)  Is there enough gas in the tank / cylinder? (For Propane models)

The hot water turns cold and stays cold.

 Is the flow rate enough to keep the water heater running? (p. 33)  If there is a recirculation system installed, does the recirculation

line have enough check valves? (p. 28)

 Is the gas supply valve fully open? (p. 30)  Is the filter on cold water inlet clean? (p. 36)  Are the fixtures clean of debris and obstructions?  Check if the flow rate is too low. (p. 33-34)

Fluctuation in hot water temperature.

 Is the filter on cold water inlet clean? (p. 36)  Is the gas line sized properly? (p. 18)  Is the supply gas pressure sufficient? (p. 19) 

Check for cross connection between cold water lines and hot water lines.

Troubleshooting

38│Page

- WATER HEATER -

PROBLEM SOLUTIONS

Unit does not ignite when water goes through the unit.

 Is the flow rate over 0.5 GPM? (p. 33)  Check for the filter on cold water inlet. (p. 36)  Check for reverse connection and cross connection.  If you use the remote controller, is the power button

turned on?

 Check if the inlet temperature is too high.

The fan motor is still spinning after operation has stopped.

 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.

Unit sounds abnormal while in operation

 Contact the manufacturer at 1-877-737-2840.

-Remote controller- (OPTIONAL)-

Remote controller does not display anything when the power button is turned on.

 Make sure the unit is supplied with power.  Make sure the connection to the unit is correct. (p. 22)

-9007603005 (TM-RE30) only-

If the green 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.

An ERROR code is displayed.

 Please see p. 39-41.

-EASY-LINK SYSTEM- 510 (T-D2) models only

How are the unit numbers assigned?

 For an Easy-Link system, the Parent unit is always labeled

#1 and all other subsequent Child units are numbered randomly.

 To check which numbers are assigned to which Child units,

push the button on the computer board of any Child unit as shown below. The unit number will be displayed on the 7-Seg LED. (Refer to p.24 to 27)

7-Seg LED

Button to check

unit numbers

When ON, green

LED is lit.

Troubleshooting

39│Page

ERROR CODES



The units are self diagnostic for safety and convenience when trouble shooting.

 If there is a problem with the installation or the unit, depending on the model or if there is a

remote controller installed, it will either display a numerical error code on the 7-Seg LED on the computer board (for the 510 (T-D2) models only), display a blinking red LED (for the 110 (T-KJr2) and 310 (T-K4) models), or the error code will display on the remote controller if it is installed.

 Consult with the table on the following page for the cause of each error code.

-Single unit installations-

Example: If your unit displays the “321” error code (which signifies an inlet thermistor failure)



110 (T-KJr2) and 310 (T-K4) models:

The red LED on the computer board will be blinking two times.

 If the remote controller 9007666005 (TK-RE02) is installed: “32” will display on the screen in its

entirety.

 510 (T-D2) models: The 7-seg. LED on the computer board will display “3”…”2”…”1” in that

order one digit at a time and continually repeat.

 If the remote controller 9007603005 (TM-RE30) is installed: “321” will display on the screen in

its entirety.

-Easy-Link system for the 510 (T-D2) models only-

Error codes will display differently with units installed within an Easy-Link System, not only to show what the error code is, but to also indicate which unit within the system has the error code. Below is a sample of how the same error code is displayed in an Easy-Link System.

Example:

If Unit #2 has the “321” error code (inlet thermistor failure)

 Parent unit: It will display “3”…”2”…”1”…”0”…”2” one digit at a time on the 7-Seg LED. The first

3 numbers indicate the error code. The last two numbers indicate that Unit #2 has the error code.

 Unit #2: It will display “3”…”2”…”1

on the 7-Seg LED, just like in the Single Unit example.

 Unit #3 and #4: These units will not

display anything, as the error code does not pertain to them.

 Remote controller 9007603005

(TM-RE30): It will display “232” on its screen. The first “2” indicates that Unit #2 has the error. The “32” indicates the first two digits of the “321” error code.

Error code on

the

remote controller 9007666005 (TK-RE02)

110 (T

KJr2) and 310 (T

K4) models

Error code on th

computer board

Red LED

510 (T

D2) models

Error code on th

computer board

7-Seg LED

Error code on

the

remote controller 9007603005 (TM-RE30)

9007603005 (TM

RE30)

PARENT

CHILD

Troubleshooting

40│Page

-FAULT ANALYSIS OF ERROR CODES-

110 (T-KJr2) and

310 (T-K4)

510

(T-D2)

Malfunction

description

Diagnosis

Red

LED

Remote Remote

One

Time

03 031

Incorrect dipswitch setting

 Check the dipswitch settings on the PCB. (Part

#701)

Five

Times

10 101

Warning for the “991” error code



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 distance between the intake air terminal and the exhaust terminal.

 Check the altitude/elevation of area of where the

water heater installed.



Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part #103), especially if the

water heater has been installed in a contaminated

area.

Three Times

11 111

Ignition failure



heck i

f the Hi

limit switch (Part #412

) is properly

functioning.

 Check for connection/breakage of wires (Part #413,

708, 709, 710, 712), burn marks on the computer board (Part #701), and/or soot on the flame rod (Part #108).

 Check if there is a buzzing spark ignition sound

coming from the burner (Part #101) when water heater prepares for combustion.

 Listen for the double “clunk” sound coming from

gas valve assembly (Part #102) when water heater goes into combustion.



Che

ck if there is leaking from h

eat exchanger. (Pa rt #401

)

Three Times

12 121

Loss of flame



Check i

f 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).



eck if there is leaking from h

eat exchanger. (Pa rt #401

)

Two

Times

31 311

Output thermistor

failure

 Check for connection/breakage of wires and/or

debris on thermistor. (Part #407, 408, 411, 716)

32 321

Inlet

thermistor

failure

N/A N/A 331

Mixing

therm

istor

failure

Two

Times

39 391

Air –fuel Ratio Rod failure

 Check for connection/breakage of wires (Part

#709) and/or soot on the AFR rod. (Part #108)

If the error code displayed on the computer board of the Water heater or remote controller,

please check the following. After checking, Consult with the manufacturer.

Troubleshooting

41│Page

110 (T-KJr2)

and 310 (T-K4)

510

(T-D2)

Malfunction description

Diagnosis

Red

LED

Remote Remote

N/A N/A 441

Flow Sensor Failure

(Easy-L

ink

System only)

 Check for connection/breakage of wires and/or debris

on the flow sensor impeller. (Part #402, 717)

Six

Times

51 510

Abnormal

Gas

Solenoid Valve



Check

for connect

ion/breakage of wires (Part #708

)

and/or burn marks on the computer board (Part

#701).

Six

Times

55 N/A

Abnormal Main Gas Valve



Check

for connect

ion/breakage of wires (Part #708

)

and/or burn marks on the computer board (Part

#701).

Four

Times

61 611

Fan Motor Fault



Check

for connection/brea

kage of wires, dust bui

ldup

in the fan motor (Part #103) and/or burn marks on the computer board (Part #701).



Check for frozen/corrosion of connectors

(Part #103

N/A N/A 651

Flow

adjustment Valve Fault

(Easy-Link

ystem

only)

 Inspect the flow adjustment valve (Part #402), for

connection/breakage of wires (Part #718), locked motor drive due to scale buildup, and/or water leakage.

One

Time

70 701

Computer board Fault



Check for

connection/b

reakage of wires (Part #714

)

and/or burn marks on the computer board (Part #701).

 Check the power supply of the water heater.

Six

Times

72 721

False Flame Detection



For indoor models

, check if

condensate drain

installed on the vent collar of the water heater.

 Check if there is leaking from heat exchanger (Part

#401

N/A 74 741

Miscommunication

between Water heater and remote

controller



Check the model type of the remote controller.

 Inspect the connections between the water heater

and remote controller.



eck the power supply of the water heater.

N/A N/A

761

Misco

mmunication in

Easy-L

ink system



Check if the connections betwe

en the parent

unit and

the child

units are correct. Refer to p.24 to 27.

Five

Times

99 991

Imperfect combustion



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.

Components Diagram

42│Page

COMPONENTS DIAGRAM

Case assembly

110 Indoor (T

KJr2

IN) 110 Outdoor

(T-

KJr2

OS)

310 and 510 Indoor (T-K4-IN and T-D2-IN)

310 and 510 Outdoor (T-K4-OS and T-D2-OS)

00 2

05 0

70 2

05 2

00 7

70 4

00 6

00 5

05 3

06 6

05 3

05 2

00 1

00 4

05 6

00 4

00 1

00 2

05 0

70 2

05 2

00 7

704

006

005

053

066

05 3

052

05 2

05 6

05 2

00 4

001

05 2

00 3

00 2

05 0

702

05 2

00 7

70 4

00 6

00 5

05 3

06 6

05 2

05 6

05 1

00 2

05 0

70 2

05 2

00 7

70 4

00 6

00 5

05 3

06 6

05 2

00 3

05 2

00 1

00 4

05 6

05 1

Components Diagram

43│Page

Burner assembly

110 (T

KJr2) models

Burner assembly

Manifold

assembly

10 610 7

10 8

10 9

11 0

06 5

71 2

70 1

05 3

12 0

05 3

71 2

7 11

05 3

71 4

06 2

05 5

11 9

15 1

11 8

05 2

12 1

70 3

05 3

70 4

70 5

40 1

10 4

10 5

10 1

70 9

11 1

05 2

05 3

11 2

11 3

11 4

70 8

05 3

06 7

05 5

05 3

70 6

05 3

05 9

10 3

11 5

05 8

71 3

15 0

06 1

On l y T- K J r2 - I N

05 9

10 1

70 9

11 1

10 2

110 Indoor

(T-

KJr2-IN) only

Components Diagram

44│Page

310 (T

K4) models and 510 (T

D2) models

Fan motor section for outdoor models

Power control

section

Burner assembly

Fan motor

section

for indoor models

Manifold

assembly

11 6

11 7

05 3

10 3

05 4

11 5

05 7

05 8

71 3

10 610 7

10 8

10 9

11 0

06 5

71 2

12 1

70 3

05 3

70 6

70 4

70 5

12 0

05 3

71 1

05 3

71 4

06 2

05 5

05 3

11 7

T- K 4 - O S T- D 2 - O S

12 1

70 3

05 3

70 4

70 5

40 1

05 9

06 0

10 3

40 1

10 4

10 5

05 2

05 3

11 2

11 3

11 4

70 8

06 7

06 6

05 5

06 2

05 3

70 6

05 3

11 6

15 0

06 1

T- D 2 - IN T- D 2 - OS

T- K 4 - IN T- K 4 - OS

T- K 4 - IN T- D 2 - IN

T- D 2 - IN T- D 2 - OS

11 9

15 1

11 8

05 2

10 1

70 9

11 1

10 1

70 9

11 1

70 1

05 3

71 2

10 2

05 3

310 (T-K4)

models

510 (T-D2)

models

510 (T-

D2)

models

10 Indoor

(T-K4-

IN)

510 Indoor (T-D2-IN)

Out

door (T-K4-OS)

510 Outdoor (T-D2-OS)

Components Diagram

45│Page

Water way assembly

110 (T

KJr2) models

310 (T

-K4) models

510 (T

D2) models

110 (T-KJr2) and 310 (T-K4) models

510 (T

D2) models

70 7

71 0

70 8

71 5

10 3

71 7

71 8

70 1

70 9

71 9

71 6

70 1

70 7

70 9

71 4

71 0

70 8

10 3

40 240 2

40 740 871 9

Computer

board Assembly

Exhaust section (

outdoor

model)

Water outlet section

Water inlet section

Bypass

section

40 2

46 1

45 8

05 2

41 5

06 4

46 0

45 6

40 4

40 6

40 5

45 4

40 7

45 7

45 6

46 0

40 9

45 5

41 0

45 4

40 8

06 4

40 3

46 2

45 8

46 0

45 6

45 4

41 1

45 9

05 3

15 3

15 4

15 2

46 3

41 3

45 2

45 0

45 3

45 1

41 4

46 3

41 3

45 2

45 0

45 3

40 1

46 3

41 3

45 3

41 4

41 2

06 3

45 1

40 1

41 4

45 2

45 0

41 4

45 1

41 2

06 3

41 2

06 3

40 1

Output Temperature Chart

46│Page

PARTS LIST

Item#

Description

Part#

110, 310,

510 models

T-KJr2, T

K4,

T-D2 models

001

Case assembly

for 110 Indoor (

T-KJr2-IN)

for 110 Outdoor (T-KJr2-OS) for 310 and 510 Indoor (T-K4-IN and T-D2-IN)

for 310 and 510 Outdoor (T

-K4-

OS and

T-D2-OS)

319143

159

319143-172 319143-151

319143

211

EK415

EK432 EK402

EKK41

002

ront cover for

110 Indoor (

T-KJr2-IN)

for 110 Outdoor (T-KJr2-OS)

for 310 Indoor (T-K4-IN)

for 310 Outdoor (T-K4-OS)

for 510 Indoor (T-D2-IN)

for 510 Outdoor (

T-D2-OS)

319143

163

319143-173 319143-152 319143-371 319143-174

319143

175

419

EK433 EK403 EK409 EK434

EK435

003

004

Air blockage plate

for 110 Indoor (

T-KJr2-IN

), 310 Indoor (

T-K4-IN

)

and 510 Indoor (T-D2-IN)

Bracket

319143

150

319143

184

EK401

J09

005

006

Junction b

Junction box inner plate

319143

014

319143

128

J64

EKJ66

007

Back guard panel for 110

(T-KJr2)

models

Back guard panel for 310

(T-K4

) and

510 (T-D2) models

319143

338

319143

221

EX00M

EKK5H

050

051 052

053

crew M4

×12

(W/Washer)

Screw M4×10 (W/Washer)

Screw M4×10 (Coated)

Screw M4x10

319143

025

319143-325 319143-026

319143

060

EW000

EW001 EW002

EW003

054

055

056

Hex head s

crew M4

×12 (W/Washer)

Hex head screw M4x8

Screw M4x10

319143

326

319143-063

319143

372

W004

EW005

EX014

057

058

059

Screw

M3x6 SUS3

Screw M3x10

Pan screw M4x12 (W/Washer)

319143

330

319143-327

319143

061

EW00B

EW008

EW00H

060

061 062 063

064

Pan screw M4x10 FEZN

Tap tight screw M4x12 FEZN

Pan screw M4x10

Screw M3x6

Screw M4x6

319143

332

319143-201 319143-062 319143-087

31914

3-328

W024

EKK31 EW006 EW00A

EW009

065

066

067

Pan screw M4x8

Nylon clamp

Wire clamp 60

319143

059

319143-143

319143

048

EW00D

EC00X

EM167

101 Burner

assembly for 110

(T-KJr2)

models

Burner assembly for 310

(T-K4

) and

510 (T-D2) models

319143

161

319143

030

EK417

EKH5W

102 Manifold with gas valve assembly LP

for 110 (

T-KJr2)

models

Manifold with gas valve a ssembly LP for 310 (T-K4) and 510 (T-D2) models

Manifold with gas valve assembly NA for 110 (T-KJr2) models

Manifold with gas valve assembly NA f

310 (T-K4) and 510 (

T-D2)

models

319143

169

319143-046 319143-165

319143

368

429

EKH6T

EK421

EKK5K

103

Fan motor for 110

(T-KJr2)

models

Fan motor for 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN)

Fan motor for

310 Outdoor (

T-K4-OS

) and 510 Outdoor (

T-D2-OS)

319143

347

319143-043

319143

217

EX02E

EKK25

EKK54

Output Temperature Chart

47│Page

Item#

Description

Part#

110, 310,

510 models

T-KJr2, T

K4,

T-D2 models

104 Burner holder gasket for 110

(T-KJr2)

models

rner holder gasket for 3

10 (T-K4) and

510 (T-D2) models

319143

-341

319143

032

EX00V

EKK0G

105

106

107

Burner gasket

Burner window

Rod holder gasket

319143

031

319143-033

319143

034

EKK2X

EKK2V

KK2W

108

Flame rod for 110

(T-KJr2)

models

Flame rod for 310 (

T-K4

) and

510 (T-D2) models

319143

339

319143

035

X00R

KK0E

109 Igniter rod for 110

(T-KJr2)

models

Igniter rod for 310 (T-K4) and 510 (T-D2) models

319143

373

319143-037

X00S

EKK0F

110

111

Rod holder for 110

(T-KJr2)

models

Rod holder for 310 (T-K4) and 510 (T-D2) models

Rod cap

319143

340

319143-036

319143

038

EX00U

EKK32

EKN61

112

Burner damper for 110

(T-KJr2)

models

Burner damper for 310 (

T-K4

) and

510 (T-D2) models

319143

170

319143

156

K430

EK412

113

114 115

Manifold gasket A

Manifold gasket B

Fan damper for 110 Indoor (T-KJr2-IN)

Fan damper for 310

door (

T-K4-IN

) and

510 Indoor

(T-D2-IN)

319143

044

319143-045 319143-160

319143

367

EKK2Y

EKK2K

EK416

TU001

116

117

Pressure port for 310

(T-K4

) and

510 (T-D2) models

Combustion chamber tube for 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN)

Combustion chamber tube for 310 Outdoor (T-K4-OS) and

510 Outdoor (

T-D2-OS)

319143

042

319143-041 319143-344

EKK2D

EKK2N

EX019

118

119

120

Gas inlet

Gas inlet ring

Igniter plate

319143

050

319143-049

319143

051

EKK1E

EKK2Z

EKK1B

121 S

urge box plate for 110 (

T-KJr2

) a

310 (T-K4) models

urge box plate for 510

(T-D2)

models

319143

213

319143

176

KK4H

EK436

150

151 152

O-ring P

18 NBR (Black)

O-ring P20 NBR (Black)

Silicon ring for 110 Outdoor (T-KJr2-OS)

Silicon ring

for 310 Outdoor (

T-K4-OS

) and 510 Outdoor (

T-D2-OS)

319143

350

319143-057 319143-370

319143

206

EZP18

EK042

EK442

EKK3G

153

Rain protection plate in Exhaust chamber for 110

Outdoor

(T-

KJr2-OS), 310

Outdoor (

T-K4-OS

) and

510 Outdoor

(T-D2-OS)

319143

216 EKK53

154 Exhaust port

319143

219 EKK56

401 Heat exchanger assembly for 110 Indoor

(T-KJr2-IN)

for 110 Outdoor (T-KJr2-OS)

for 310 Indoor (T-K4-IN)

for 310 Outdoor (T-K4-OS)

for 510 Indoor (T-D2-IN)

for 510 Outdoor

(T-D2-OS)

319143

162

319143-166 319143-153 319143-157 319143-369

319143

177

K418

EK426

EK406

EK413

TU002

EK437

402 Flow adjustment valve/Flow sensor

for 110 (T-KJr2) and 310 (T-K4) models

Flow adjustment valve/Flow sensor for 510

(T-D2)

models

319143

167

319143

178

EK427

EK438

403

404 405

406

Bypass valve for 510

(T-D2)

models

Water inlet

Inlet drain plug

Inlet water filter

319143

186

319143-193 319143-197

319143

198

EKK0U

EKK1U

EKK2B

EKK2C

407 Inlet thermistor for 110

(T-KJr2

) and

310 (T-K4) models

Inlet thermistor for 510

(T-D2)

models

319143

214

319143

085

EKK4J

EKK38

Output Temperature Chart

48│Page

Item#

Description

Part#

110, 310,

510 models

T-KJr2, T

K4,

T-D2 models

408

Outlet thermistor for 110

(T-KJr2)

and

310 (T-K4) models

Mixing thermistor for 510

(T-D2)

models

319143

218

319143

190

EKK55

EKK1A

409

410

411

Water outlet

Outlet drain plug

Output thermistor for 510

(T-D2)

models

319143

194

319143-199

319143

096

EKK1V

EKK2E

EKK2T

412 Hi-Limit switch for 110 (

T-KJr2

) and

310 (T-K4) models

Hi-Limit switch for 510

(T-D2)

models

319143

228

319143

095

EM212

EKN34

413

414

415

Overheat

cut-off

fuse

Heater

Inlet heater

319143

149

319143-200

319143

078

EK333

EKK2R

EKK2P

450

451 452 453

454

Pipe heater fixing plate

Heater fixing plate 16

Fuse fixing plate 18 Fuse fixing plate 14

O-ring P4 FKM

319143

088

319143-125 319143-066 319143-146

319143

082

K27

EK031

EKK26

EK029

EZM04

455

456

457

O-ring P6 FKM

O-ring P14 FKM

O-ring P15 FKM

319143

080

319143-100

319143

091

EZM06

EZM14

EZM15

458

459 460 461 462

463

O-ring P16 FKM

Fastener “4-11” for 510 (T-D2) models

Fastener “14-22”

Fastener “16A”

Fastener “16-25A” for 510 (T-D2) models

Silicon ring

319143

083

319143-097 319143-105 319143-226 319143-205

319143

065

EZM16

EKH30

EKK24 EM192

EKK39

EKN50

701

702

Computer board for 110

(T-KJr2)

models

for 310 (T-K4) models for 510 (T-D2) models

Transformer

319143

164

319143-158 319143-179

319143

182

K420

EK414

EK439

EKH09

703

704

Surge box

AC120V wire for 110 (T-KJr2) models

AC 120 V wire for 310

(T-K4

) and

510 (T-D2) models

319143

168

319143-222

319143

138

428

EKK5M

EKK3C

705 Transformer wire for 110 (

T-KJr2)

models

Transformer wire for 310 (T-K4) and 510 (T-D2) models

319143

155

319143-180

EK408

EK440

706

707

AC120V Power ON

OFF switch

Switch wire for 110 (T-KJr2) models

Switch wire for 310

(T-K4

) a

510 (T-D2) models

319143

141

319143-154

319143

181

EKK4V

EK407

EK441

708 Gas

valve wire for 11

0 (T-

KJr2

) and

310 (T-K4) models

Gas

valve wire for 510

(T-D2)

models

319143

207

319143

188

EKK3K

EKK10

709 Flame rod wire for 110

(T-KJr2)

models

for 310 (T-K4) models

for 510

(T-D2)

models

319143

171

319143-208

319143

189

EK431

EKK3L

EKK11

710 EH-IG wire for 110

Indoor (

T-KJr2-IN

) and

310 Indoor

(T-K4-IN)

EH-IG wire with freeze protection thermostat for 110 Outdoor

(T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS)

EH-IG wire for 510 Indoor

(T-D2-IN)

319143

209

319143-210

319143

187

EKK3R

EKK40

EKK0Z

711

712

Igniter

High voltage igniter cable

319143

052

319143

039

EKN74

EKK2M

Output Temperature Chart

49│Page

OUTPUT TEMPERATURE CHART

Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

Out Put Hot Water GPM

40 F 50 F 60 F 70 F

40 F

3.8 3.5 3.3 3.1 2.9 2.7 2.5 2.4 2.3 2.1 1.9 1.8

50 F

4.6 4.2 3.8 3.5 3.3 3.1 2.9 2.7 2.5 2.3 2.1 2.0

60 F

5.7 5.1 4.6 4.2 3.8 3.5 3.3 3.1 2.9 2.5 2.3 2.2

70 F

6.6 6.6 5.7 5.1 4.6 4.2 3.8 3.5 3.3 2.9 2.5 2.4

100 105 110 115 120 125 130 135 140 150 160 165

Item#

Description

Part#

110, 310,

510 models

T-KJr2, T-K4,

T-D2 models

713 Freeze protection thermostat for 110 Indoor (T-KJr2-IN),

310

Indoor (

T-K4-IN

) and

510 Indoo

r (T-D2-IN)

319143-185 EKJ59

714 Proportional gas valve wire for 110 (T-KJr2) and 310 (T-K4) models

Proportional gas valve wire for 510

(T-D2)

models

319143-220

319143

133

EKK58

EKK12

715 716 717

718

Pump and multi cable for 510 (T-D2) models

Thermistors wire for 510 (T-D2) models

RS-VG wire for 510 (T-D2) models

Water valves wire for 510

(T-D2)

model

319143-204 319143-195 319143-203

319143

202

EKK36

EKK1Z

EKK35

EKK33

719 Computer board cover for 110 (T-KJr2) and 310 (T-K4) models

Computer board cover for 510

(T-D2)

models

319143-212

319143

191

EKK49

EKK1M

110 (T

KJr2) models

Chart is based on properly sizes gas line

Output Temperature Chart

50│Page

Output Temperature vs. GPM (Max. 8.0 GPM) with Various Inlet Water Temperature

0.0

2.0

4.0

6.0

8.0

10.0

Out Put Hot Water GPM

40 F 50 F 60 F 70 F

40 F

5.2 4.8 4.4 4.1 3.9 3.7 3.5 3.3 3.1 2.8 2.6 2.5

50 F

6.2 5.7 5.2 4.8 4.4 4.1 3.9 3.7 3.5 3.1 2.8 2.7

60 F

7.8 6.9 6.2 5.7 5.2 4.8 4.4 4.1 3.9 3.5 3.1 3.0

70 F

8.0 8.0 7.8 6.9 6.2 5.7 5.2 4.8 4.4 3.9 3.5 3.3

100 105 110 115 120 125 130 135 140 150 160 165

Output Temperature vs. GPM (Max. 10.0 GPM) with Various Inlet Water Temperature

0.0

2.0

4.0

6.0

8.0

10.0

12.0

Out Put Hot Water GPM

40 F 50 F 60 F 70 F

40 F

5.4 5.0 4.7 4.3 4.1 3.8 3.6 3.4 3.3 3.0 2.7 2.6 2.5 2.4 2.3 2.2

50 F

6.5 5.9 5.4 5.0 4.7 4.3 4.1 3.8 3.6 3.3 3.0 2.8 2.7 2.6 2.5 2.4

60 F

8.1 7.2 6.5 5.9 5.4 5.0 4.7 4.3 4.1 3.6 3.3 3.1 3.0 2.8 2.7 2.6

70 F

10.0 9.3 8.1 7.2 6.5 5.9 5.4 5.0 4.7 4.1 3.6 3.4 3.3 3.1 3.0 2.8

100 105 110 115 120 125 130 135 140 150 160 165 170 175 180 185

*When the set temperature i

s 131°F or higher, maximum flow rate is limited to

8.0 GPM.

510 (T

D2) models

310 (T

K4) models

Warranty

51│Page

LIMITED WARRANTY

1. General terms of limited warranty:

This limited warranty gives you specific legal rights, and you may also have other rights which vary from State to State. The manufacturer will honor the warranty to the original retail buyer at the original location only, and it is not transferable.

THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USAGE FOR THE PRODUCT’S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED IN THE FOLLOWING TABLES. ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND, IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT, BREACH OF WARRANTY, TORT LIABILITY (INCLUDING NEGLIGENCE), STRICT LIABILITY, INDEMNITY OR OTHERWISE WILL BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY DAMAGE, PERSONAL DAMAGES, LOSS OF USE, OR INCONVENIENCE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITA TION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION MAY NO T APPLY TO YOU.

2. Warranty for models: 510 (T-D2) models

[Unit: Year]

Application

(1)

Parts Labor

Single Family

Domestic Hot

Water

No Recirculation

(3)

On-Demand Recirculation

(2)

w/ Standard

Recirculation

Aquastat Control

5 Pump Control

Timer Only

3 3

No Pump Control (24 hr.)

Commercial

Multi-Family

Domestic Hot

Water

No Recirculation

5 5

(3)

On-Demand Recirculation

(2)

w/ Standard

Recirculation

Aquastat Control

Pump Control

Timer Only

3 3

No Pump

Control (24 hr.)

Heating

(4)

All Types

5 5

(3)

Warranty for models: 110 (T-KJr2) and 310 (T-K4) models

[Unit: Year]

Application

(1)

Parts Labor

Single Family

Domestic Hot

Water

No Recirculation

12 5

(3)

On-Demand Recirculation

(2)

w/ Standard

Recirculation

Aquastat Control

3 3

Pump Control

Timer Only

1 1

No Pump Control (24 hr.)

Multi-Family

Domestic Hot

Water

No Recirculation

3 3

(3)

On-Demand Recirculation

(2)

w/ Standard

Recirculation

Aquastat Control

Pump Control

Timer Only

1 1

No Pump Control (24 hr.)

Heating

(4)

All Types

1 1

(3)

Commercial

All Types

1 1

(3)

(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.

Warranty

52│Page

(3) Limited Labor Coverage

 The manufacturer will provide for reasonable labor charges associated with warranty repairs

or replacements within one (1) year from the date of purchase. The manufacturer will only pay directly to the service provider.

 Warranty service must be performed by an authorized Service Representative. A list of

authorized Service Representatives is available upon request.

 All warranty claims and warranty service must be authorized and approved by the

manufacturer.

(4) Includes dual-purpose applications (combination heating and domestic).

3. Repair, Replacement or Refund:

The manufacturer or its authorized Service Representative will, at its sole discretion, repair or replace any failed or defective mechanical or electrical parts, or components thereof, or, if the manufacturer or its authorized Service Representative cannot replace said parts, and repair is not commercially practicable, the manufacturer or its authorized Service Representative will refund the purchase price. The manufacturer or its authorized Service Representative may, at its sole discretion, use new, refurbished or reconditioned parts.

4. Limitation on Duration of Implied Warranties:

ANY IMPLIED WARRANTIES ARISING UNDER STATE LAW, INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, SHALL IN NO EVENT EXTEND PAST THE EXPIRATION OF ANY WARRANTY PERIOD HEREUNDER. 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. corrosive, 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 & state codes, ordinances, and good

trade practices.

 Any product sold to or installed in areas outside of the fifty states (and the District of Columbia) of the

United States of America and Canada.

 Any product installed in applications that cause the water heater to activate more than 300 times per

day (this averages to an activation every 5 minutes in a 24-hour period).

 Any failures that are not due to defects in materials or workmanship (mechanical and/or electrical parts).  Damages due to improper installation:

 Gas: incorrect gas pipe sizing, incorrect gas meter sizing, incorrect gas type, and/or gas pressures

that fall outside the product’s specified range.



Water: incorrect water pipe sizing, water pressures that fall outside the product’s specified range, recirculation flow rates that fall outside the product’s specified range (air removal), and/or lack of proper methods of air removal in a closed-loop, circulation system (see installation manual for details).



Electric: supply power voltages that fall outside the product’s specified range.

 Damages due to water quality:

 Introduction of liquids other than potable water or potable water / glycol mixtures into the product. 

Introduction of pool water, spa water, or any chemically treated water into the product.



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.



Introduction of untreated or poorly treated well water into the product.



Introduction of water with pH levels less than 6.5 and greater than 8.5 into the product.

62S051

-3

ATKJ2

ATK4 ATD2

Takagi T-KJr2-IN, T-K4-IN, T-D2-IN, T-KJr2-OS, T-K4-OS Installation Manual And Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual