GSW 110 User manual

320576-000
REV. 00 (10-11)
Models
•110
•310
•510
On-Demand Water Heater
Installation Manual and Owner’s Guide
510 model
only
Gas Tankless Water HeaterTM
Suitable for potable water heating and space-heating*
* Please refer to local codes for space-heating compliance.
FEATURING
• ENDLESS HOT WATER
• ON-DEMAND USAGE
• COMPACT, SPACE SAVING
• ENERGY CONSERVATION
• COMPUTERIZED SAFETY
• NO PILOT LIGHT
• EASY-LINK SYSTEM*
*(510 models only)
If you have any questions,
please call or write to:
GSW Water Heating
599 Hill Street West
Fergus, ON Canada N1M 2X1
Toll Free: 1-888-479-8324
WARNING
If the information in these
instructions is not followed
exactly, a fire or explosion may
result causing property dam-
age, personal injury or death.
- Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of this
or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• 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 suppli-
er'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.

2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFETY GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Included Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Optional Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High-altitude Installations . . . . . . . . . . . . . . . . . . . . . . 10
Venting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General
Exhaust venting
Venting Illustrations
Vent Termination Clearances
Gas supply and gas pipe sizing . . . . . . . . . . . . . . . . . 15
General
Gas Connections
Measuring Inlet Gas Pressure
Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Relief Valve
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Controller Connections . . . . . . . . . . . . . . . . . 17
Pump Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Easy-link System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General
Easy-Link Connection Procedures
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Space-Heating Applications . . . . . . . . . . . . . . . . . . . . 20
Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dual-purpose Hot Water Heating . . . . . . . . . . . . . . . . 21
INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
OPERATING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . .23
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Temperature Settings . . . . . . . . . . . . . . . . . . . . . . . . . 25
Without Remote Controller
Dipswitch Settings For Temperature
Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Freeze protection system . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance and service . . . . . . . . . . . . . . . . . . . . . . 27
Unit Draining and Filter Cleaning
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single Unit Installations
Easy-Link System
Fault Analysis Of Error Codes . . . . . . . . . . . . . . . . . . 31
COMPONENTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .34
Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
110
310 & 510
Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
110
310 & 510
Computer Board Assembly. . . . . . . . . . . . . . . . . . . . . 37
110 & 310
Water Way Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 37
110
Computer Board Assembly. . . . . . . . . . . . . . . . . . . . . 37
510
Water Way Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 37
310
Water Way Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 38
510
Water outlet section . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Water inlet section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
OUTPUT TEMPERATURE CHART . . . . . . . . . . . . . . . . .41
110 Models
310 Models
510 Models
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Table of Contents

3
SPECIFICATIONS
Model 110 310 510
Natural Gas 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
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 3/4” NPT
Water Connections 3/4” NPT
Water Pressure 15 - 150 psi*
Inlet
Pressure Natural Gas Min. 5.0” WC, Max. 10.5” WC
Propane Min. 8.0” WC, Max. 14.0” WC
Manifold
Pressure** Natural Gas 2.0” WC 2.0” WC 2.0” WC
Propane 2.5” WC 3.7” WC 3.7” WC
Weight 13Kg (28.7 lbs.) 15.7Kg (34.6 lbs.)
Dimensions 520mm(H) x 351mm(W) x 170mm(D)
H20.5” x W13.8” x D6.7” 520mm(H) x 351mm(W) x D216mm(D) 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
Freeze-Protection 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.
• The manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice
and without incurring obligations.

4
INTRODUCTION
This manual provides information necessary for the
installation, operation, and maintenance of the water
heater.
The model description is listed on the rating plate which
is attached to the 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 110, 310, & 510 models are to be installed indoors
only (direct-vent convertible).
The principle behind tankless water heaters is simple:
Exhaust vent
collar
Burners
Cold Water
Inlet
Fan motor
Thermistor
Hot Water
Outlet
Heat
exchanger
Thermistor
Flow sensor
Computer
board Gas Valves
Gas
Inlet
Flow adjustment
valve
* This diagram illustrates tankless water heater design
concepts only and does not accurately represent to the
water heater’s physical description.
A hot water tap is turned on.
Water enters the heater.
The water flow sensor detects the water flow.
The computer initiates the fan motor and sends a signal
to the igniter to create an ignition spark.
The gas ignites and flames appear within the burner
chamber.
Water circulates through the heat exchanger and then
gets hot.
Using thermistors to measure temperatures throughout
the water heater, the computer modulates the gas and
water valves to ensure proper output water tempera-
ture.
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1.
2.
3.
4.
5.
6.
7.
SAFETY GUIDELINES
Safety Definitions
DANGER
Indicates an imminently hazardous situa-
tion which, if not avoided, will result in death
or serious injury.
WARNING
Indicates an imminently hazardous situa-
tion which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates an imminently hazardous situa-
tion 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 CSA B149.1 Natural
Gas and Propane Installation Code.
2. Properly ground the unit in accordance with all local
codes or in the absence of local codes, with CSA C22.1
Canada Electrical Code Part 1.
3. Carefully plan where you intend to install the water
heater. Please ensure:
Your water heater will have enough combustible air
and proper ventilation.
Locate your heater where water leakage will not
damage surrounding areas (please refer to pg. 6).
4. Check the rating plate for the correct GAS TYPE,
GAS PRESSURE, WATER PRESSURE and ELECTRIC
RATING.
* If this unit does not match your requirements, do not
install. Consult with the manufacturer.
5. 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.
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5
WARNING
Water temperatures over 52°C (125°F)
can cause severe burns instantly or
death from scalding. The water tem-
perature is set at 50°C (122°F) from the
factory to minimize any scalding risk.
Before bathing or showering always
check the water-temperature.
Do not store or use gasoline or other
flammables, vapors, or liquids in the
vicinity of this appliance.
Do not reverse the water and/or gas
connections as this will damage the gas
valves and can cause severe injury or
death. Follow the diagram on pg. 17
when installing your water heater.
Do not use this appliance if any part has
been in contact with or been immersed
in water. Immediately call a licensed
plumber, a licensed gas fitter, or a pro-
fessional service technician to inspect
and/or 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 pg. 28 for
more information.
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INSTALLATION
General
1. Follow all local codes, or in the absence of local codes,
follow the most recent edition of CSA B149.1 Natural
Gas and Propane Installation Code.
2. All gas water heaters require careful and correct installa-
tion to ensure safe and efficient operation. This manual
must be followed exactly. Read the “Safety Guidelines”
section.
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 pg. 7 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 discon-
nection, to terminate power to the water heater for ser-
vicing 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 pg. 13).
8. Particles from flour, aerosols, and other contaminants
may clog the air vent or reduce the functions of the rotat-
ing fan and cause improper burning of the gas. Regularly
ensure that the area around the unit is dust- or debris-
free; regular maintenance is recommended for these
types of environment.
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 air-
borne and enter and build up within the fan and burner
causing damage to the water heater.
10.For the 110, 310, & 510 models:
These units may be converted to a direct-vent
(sealed combustion) appliance by installing a direct-
vent conversion kit (Part No. TK-TV10) which will
bring in all required combustible air from outside the
building. When installing the direct-vent conversion
kit, please follow all instructions included with the kit.
If the water heater is used as a direct-vent appliance,
the unit requires a 76mm (3 in.) combustible air sup-
ply pipe. The intake pipe must be sealed airtight. Air
supply pipe can be made of ABS, PVC, galvanized
steel, corrugated aluminum, corrugated stainless
steel or Category III stainless steel.
Terminating the venting through a sidewall is recom-
mended for the direct-vent system.
Running the exhaust vent and the intake pipe paral-
lel 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.
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6
WARNING
Installation and service must be per-
formed by a qualified installer (for
example, a licensed plumber or gas
fitter), otherwise the warranty will be
void.
The installer (licensed professional)
is responsible for the correct installa-
tion of the water heater and for com-
pliance with all national, state/provin-
cial, and local codes.
The manufacturer does not recom-
mend installing the water heater in a
pit or location where gas and water
can accumulate.
Do not have the vent terminal pointing
toward any operating window, door, or
opening into a building.
Do not install next to any source of air-
borne debris, such as a clothes dryer,
that can cause debris to be trapped
inside the combustion chamber, unless
the system is direct-vented.
The manufacturer does not recom-
mend installing the water heater in an
attic due to safety issues. If you install
the water heater in an attic:
Make sure the unit will have enough
combustion air and proper ventila-
tion.
Keep the area around the water
heater clean. When dust collects on
the flame sensor, the water heater
will shut down on an error code.
If the above conditions cannot be
met, use the direct vent conversion
kit TK-TV10.
Place the unit for easy access for
service and maintenance.
A drain pan, or other means of pro-
tection against water damage, is
required to be installed under the
water heater in case of leaks.
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CAUTION
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 hard-
ness leads to scale formation and
may affect/damage the water heater.
Hard water scaling must be avoided
or controlled by proper water treat-
ment.
Water pH levels must be between
6.5 and 8.5
Well water must be treated.
Do not install the unit where water,
debris, or flammable vapors may get into
the flue terminal.
The manufacturer recommends using
the direct vent kit when the water
heater is installed in a beauty salon.
Some chemicals used in a beauty salon
may affect the flame sensor. Water heat-
er may not work properly.
Although the water heater is designed to
operate with minimal sound, the manu-
facturer does not recommend install-
ing the unit on a wall adjacent to a
bedroom, or a room that is intended
for quiet study or meditation, etc.
Locate your heater close to a drain
where water leakage will not do damage
to surrounding areas. As with any water
heating appliance, the potential for leak-
age at some time in the life of the prod-
uct does exist. The manufacturer will not
be responsible for any water damage
that may occur. If you install a drain pan
under the unit, ensure that it will not
restrict the combustion air flow.
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7
Clearances
Top
Front
Side
Bottom
Back
Side
Maintain all clearances around the water
heater.
Model Top Bottom Front Back Sides
110 305mm
(12 in.) 305mm (12 in.) 610mm (24 in.) 25mm (1 in.) 51mm (2 in.)
310 305mm
(12 in.) 305mm (12 in.) 610mm (24 in.) 25mm (1 in.) 51mm (2 in.)
510 305mm
(12 in.) 305mm (12 in.) 610mm (24 in.) 25mm (1 in.) 51mm (2 in.)
Included Accessories
Check that these items below are included with the water
heater.
Items
Installation Manual & Owner’s
Guide Qty: 1
Product Registration Card Qty: 1
Communication Cable
(510 models only) Qty: 1
Optional Items
Model 110 310 510
TK-RE02 x x
TM-RE30 x
TK-BF01 x x x
TK-TV10 x x x
TK-PC01 x x
TK-PCJr2 x
TK-KPWL4 x x x
TK-KPWH4 x x x
TK-KPCT43 x x x

8
1. Temperature Remote Controller: 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 37°C
to 75°C (99°F to 167°F), and it also works as a diagnostic tool that will give
a concise error code whenever there is a problem with the unit. The tem-
perature options are 75°C (99°F), 38°C (100°F), 39°C (102°F), 40°C (104°F),
41°C (106°F), 42°C (108°F), 43°C (109°F), 44°C (111°F), 45°C (113°F), 46°C
(115°F), 47°C (117°F), 50°C (122°F), 55°C (131°F), 60°C (140°F), 70°C
(158°F), and 75°C (167°F). See the troubleshooting section for information
on possible error codes.
2. Temperature Remote Controller: 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 37°C
to 85°C (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 75°C (99°F), 38°C (100°F), 39°C (102°F), 40°C
(104°F), 41°C (106°F), 42°C (108°F), 43°C (110°F), 111°F, 45°C (113°F),
46°C (115°F), 47°C (117°F), 50°C (122°F), 55°C (131°F), 60°C (140°F), 65°C
(149°F), 70°C (158°F), 75°C (167°F), 80°C (176°F) and 85°C (185°F). See
the troubleshooting section for information on possible error codes.
3. Backflow Preventer: 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 accor-
dance with the installation instructions and any applicable codes.
4. Direct-Vent Conversion Kit: 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.
5 . Pipe Covers: TK-PC01 and TK-PCJr2 The pipe cover protects the plumbing pipes to the water heater from unex-
pected adjustments. This pipe cover is fixed to the bottom of the water heater,
which hides the plumbing and improves the visual aspects of the whole
installation for the water heater.

9
6. Recess box: TK-RB02 The Recess box will allow for “clean” installations.The water heater fits inside
the recess box, which hides and protects the whole water heater and plumb-
ing. The Recess box will fit in-between most wall studs.
7. T-Vent Wall Thimble with Termination: TK-KPWL4 and TK-KPWH4
Louver Termination
TK-KPWL4 Hood Termination
TK-KPWH4
These terminations are used when venting out through the wall and are com-
patible with the T-Vent pipe system. These terminations are special stainless
steel vents for gas appliances and are UL listed as Category 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 termi-
nations in accordance with their installation instructions and any applicable
local codes.
8. Direct-Vent Concentric Termination: TK-KPCT43
Used when terminating direct-vent (sealed-combustion) systems, with direct-
vent models that require a 76mm (3 in.) intake and a 102mm (4 in.) exhaust.
This concentric termination provides the convenience of only having to make
one penetration through a sidewall instead of two separate penetrations
for the intake and exhaust piping. The termination includes a bird screen,
restricting small animals, pests, and foreign objects from entering into the
vent system. This sidewall termination is available in three different sizes, to
cover all ranges of wall thicknesses.
Direct-vent Concentric Termination
Part# Covering wall thickness
TK-KPCT43-1 99 - 180mm (3.9 – 7.1 in.)
TK-KPCT43-2 175 - 257mm (6.9 – 10.1 in.)
TK-KPCT43-3 249 - 330mm (9.8” – 13.0 in.)

10
High-altitude Installations
Check the elevation where your water heater is installed.
Set DIPswitches shown in the table below depending on
the altitude.
110 & 310 Models
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 ON OFF Consult
our
Technical
Services
at 1-888-
479-8324
Switch
No. 4 OFF OFF ON
ON
8765432
1
ON
8765432
1
ON
8765432
1
510 Models (Left bank of DIPswitches)
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. 4 OFF ON OFF Consult
our
Technical
Services
at 1-888-
479-8324
Switch
No. 5 OFF OFF ON
ON
654321
ON
654321
ON
654321
The dark squares indicate the direction the DIPswitches
should be set to.
110 & 310 Computer board
DIPswitches
510 Computer board
DIPswitches (Left bank)
WARNING
DO NOT adjust any DIPswitches on the
right bank for the 510 models.
Venting Instructions
General
DANGER
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.
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CAUTION
When installing the vent system, all appli-
cable national and local codes must be
followed. If you install thimbles, fire stops
or other protective devices and they pen-
etrate any combustible or noncombustible
construction, be sure to follow all applicable
national and local codes.
The water heater must be vented in accordance with the
section “Venting of Equipment" of the latest edition of CSA
B149.1 Natural Gas and Propane Installation Code as
well as applicable local building codes.
The manufacturer recommends the “T-Vent” line manufac-
tured by TAKAGI (Refer to “T-Vent” brochure for details).
However, the following are also UL listed manufacturers:
ProTech Systems Inc. (FasNSeal), Flex-L Inc., Z-Flex Inc.
(Z-Vent 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 col-
lar.
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 termina-
tion 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 ter-
minator be at least 305mm (12 in.) above grade, but the
installer may determine if it should be higher depending
on the job site condition and applicable codes.
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.
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•
•
•

11
Exhaust venting
(For the 110, 310, & 510 models)
This is a Category III appliance and must be vented accord-
ingly. The vent system must be sealed air tight. All seams
and joints without gaskets must be sealed with high heat
resistant silicone sealant or UL listed aluminum adhe-
sive tape having a minimum temperature rating of 177°C
(350°F). For best results, a vent system should be as short
and straight as possible.
This water heater is a Category III appliance and must be
vented accordingly with any 102mm (4 in.) 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 1.5m (5 ft.), sup-
port the vent run at 0.9m (3 ft.) intervals with overhead
hangars.
The maximum length of exhaust vent piping must not
exceed 15.24m (50 ft.) (deducting 1.5m (5 ft.) for each
elbow used in the venting system). Do not use more than
5 elbows.
Diameter Max. No. of
Elbow
Max. Vertical &
Horizontal (Total) Vent
Length
76mm (3 in.) 5 15.24m (50 ft.)
* For each elbow added, deduct 1.5m (5 ft.) from max.
vent length.
No. of
Elbows Max. Vertical or Horizontal Length
0 15.24m (50 ft.)
1 13.7m (45 ft.)
2 12.2m (40 ft.)
5 7.6m (25 ft.)
Excludes elbow termination, rain caps, or the 76mm (3
in.) PVC Concentric Termination
•
•
•
•
•
Venting Illustrations
(For the 110, 310, & 510 models)
For details of the optional items, refer to the Optional item
list.
Horizontal Installation Diagram:
Wall
Sidewall Vent
Terminator
Backflow
Preventer*
Vertical
Condensation
Drain**
Vertical Installation Diagram
Roof Rain Cap
Backflow
Preventer*
Vertical
Condensation
Drain**
Roof Flashing

12
Horizontal Installation Diagram (with direct-venting)
Wall
Sidewall Vent
Terminator
Backflow
Preventer*
Vertical
Condensation
Drain**
See the picture below for
detailed connection instructions
to the Direct-Vent Conversion Kit.
Vertical Installation Diagram (With direct-venting)
See the picture below for
detailed connection instructions
to the Direct-Vent Conversion Kit.
Roof
Rain Cap
Backflow
Preventer*
Vertical
Condensation
Drain**
Roof Flashing
Roof Flashing
* Backflow Preventer (Recommended for freezing weather
conditions: 2°C (36°F) and below).
** Vertical Condensation Drain must be installed accor-
dance with local codes.
Horizontal Installation Diagram With Direct-Vent Concentric
Termination
Wall
Direct-vent Concentric
Termination
Installation Diagram of Direct-Vent Conversion Kit with
water heater
Intake port of
Direct-Vent
Conversion Kit
Plate of Direct-Vent
Conversion Kit

13
Vent Termination Clearances
Canada U.S.A
Direct vent and other
than Direct Vent Direct vent Other than Direct Vent
A Clearance above grade, veranda, porch, deck, or balcony. 1 foot 1 foot 1 foot
B 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 * * *
DVertical 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 * * *
HClearance to each side of center line extended above
meter/regulator assembly 3 feet * *
I Clearance to service regulator vent outlet. 3 feet * *
JClearance 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 3 feet
LClearance above paved sidewalk or paved driveway
located on public property. 7 feet * 7 feet
M Clearance under veranda, porch deck, or balcony. 1 foot * *
* For clearances not specified in CSA B149.1 Natural Gas and Propane Installation Code, please use clearances in
accordance with local installation codes and the requirement of the gas supplier.

14
CAUTION
Please follow all local and national codes in
regards to proper termination clearances.
In the absence of such codes, the follow-
ing clearances can be used as guidelines.
Local codes supersede these guidelines.
For sidewall terminations
Inside
corner
Exhaust
termination
610mm
(2 ft.)
305mm
(1 ft.)
305mm
(1 ft.)
Inside
corner
610mm
(2ft.)
305mm
(1 ft.)
305mm
(1 ft.)
Direct vent
termination
For multiple sidewall
exhaust terminations (e.g.
multi-unit systems), an
exhaust termination must
be at least 305mm (1 ft.)
away from another exhaust
termination. An exhaust ter-
mination must also be at
least 610mm (2 ft.) away
from an inside corner (if the
adjacent wall is less than
610mm (2 ft.) of length, the
minimum required distance
away from the inside corner
will be equal to the length of
that adjacent wall).
For multiple-unit, direct-
vent sidewall terminations
that combine the intake
and exhaust into a single
penetration, space each
direct-vent termination at
least 305mm (1 ft.) away
from each other, no matter
the orientation. A direct-vent
termination must also be at
least 610mm (2 ft.) away
from an inside corner (if the
adjacent wall is less than
610mm (2 ft.) of length, the
minimum required distance
away from the inside corner
will be equal to the length of
that adjacent wall).
3 ft.
3 ft.
3 ft.
Air supply inlet Exhaust
termination
2 ft.
For direct-vent sidewall ter-
minations that use two sep-
arate penetrations for the
intakeandexhaust,distance
the intake and exhaust ter-
minations at least 915mm
(3 ft.) away from each other,
no matter the orientation.
Exhaust and/or direct-vent
sidewall terminations should
be at least 610mm (2 ft.)
away from an opposite sur-
face/wall. Do not place the
termination directly in front
of an opening into a build-
ing.
For rooftop terminations
A
AA
Air
intake
Exhaust
termination
610mm
(2 ft.)
AA
Exhaust
termination
Air
intake
A: In accordance with local codes
For multiple-unit rooftop terminations (whether for stan-
dard or direct-vent installations) space all exhaust and
intake terminations in accordance with local codes. An
exhaust termination must be spaced from a wall or surface
in accordance with local codes as well. In the absence of
such a code, an exhaust termination must be a horizontal
distance of at least 610mm (2 ft.) away from a wall or
surface.

15
Gas supply and gas pipe sizing
General
WARNING
Check that the type of gas matches
the rating plate first.
Ensure that any and all gas regula-
tors used are operating properly and
providing gas pressures within the
specified range shown below. Excess
gas inlet pressure may cause serious
accidents.
Conversion of this unit from natural gas
to propane or vise versa will void all
warranty. Contact your local distributor
to get the correct unit for your gas type.
The manufacturer is not liable for
any property and/or personal damage
resulting from gas conversions.
•
•
•
The minimum and maximum inlet gas pressures are:
Gas type Inlet gas pressure
Natural Gas Min. 5.0” WC – Max. 10.5” WC
Propane Gas 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 com-
pleted, ensure the gas line to the water heater is discon-
nected to avoid any damage to the water heater.
Gas Connections
1. Install a manual gas shut-off valve between the water
heater and the gas supply line.
2. When the gas connections are completed, it is necessary
to perform a gas leak test (see below) either by applying
soapy water to all gas fittings and observing for bubbles
or by using a gas leak detection device.
The water heater and its individual shutoff valve
must be disconnected from the gas supply piping
system during any pressure testing of that system at
test pressures in excess of 1/2 psi (3.5 kPa).
The water heater must be isolated from the gas sup-
ply piping system by closing its individual manual
shutoff valve during any pressure testing of the gas
supply piping system at test pressures equal to or
less than 1/2 psi (3.5kPa).
3. Always purge the gas line of any debris and/or water
before connecting to the gas inlet.
Note: Size the gas pipe appropriately to supply the neces-
sary volume of gas required for the water heater using CSA
B149.1 Natural Gas and Propane Installation Code or
local codes. Otherwise, flow capabilities and output tem-
peratures may be limited.
•
•
•
•
•
•
Measuring Inlet Gas Pressure
Turn off all electric power to the water
heater if service is to be performed.
Turn the manual gas valve located on
the outside of the unit clockwise 3 to the
off position.
1.
2.
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.
Shut off the manual gas valve on the supply gas line.
Remove the screw for the pressure port located on
the gas inlet of the water heater shown in the diagram
below.
Connect the manometer to the pressure port.
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.
Check the inlet gas pressure. When the water heater is
on maximum burn, the manometer should read from 5.0”
to 10.5” WC for Natural gas, from 8.0” to 14.0” WC for
Propane.
Pressure
port
Water Connections
CAUTION
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.
•
•
All pipes, pipe fittings, valves and other components, includ-
ing 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.
1.
2.
3.
4.
5.

16
2. In addition, a manual shut off valve is also recommended
on the hot water outlet of the unit. If the water heater is
installed within, or subjected to, a closed loop water sys-
tem, a thermal expansion tank must be installed.
3. Before installing the water heater, flush the water line
to remove all debris, and after installation is complete,
purge the air from the line. Failure to do so may cause
damage to the heater.
4. There is a wire mesh filter within the cold inlet to trap
debris from entering your heater. This will need to be
cleaned periodically to maintain optimum flow.
Hot outlet Cold intlet Gas intlet
As close as
possible
Pressure
Relief Valve
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, 190,000 BTU/h for the 310, and 199,000
BTU/h for the 510.
The pressure relief valve needs to be rated for a maxi-
mum of 150 psi.
The discharge piping for the pressure relief valve must
be directed so that the hot water cannot splash on any-
one or on nearby equipment.
Attach the discharge tube to the pressure relief valve and
run the end of the tube to within 150mm (6 in.) from the
floor. This discharge tube must allow free and complete
drainage without any restrictions.
If the pressure relief valve installed on the water heater
discharges periodically, this may be due to a defec-
tive thermal expansion tank or defective pressure relief
valve.
The pressure relief valve must be manually operated
periodically to check for correct operation.
No valve must be placed between the relief valve and the
water heater.
•
•
•
•
•
•
•
•
•
•
Electrical Connections
WARNING
Follow the electrical code requirements of
the local authority having jurisdiction. In
the absence of such requirements, follow
the latest edition of CSA C22.1 Canadian
Electrical Code, Part 1.
CAUTION
When servicing or replacing parts within the
water heater, label all wires prior to discon-
nection to facilitate an easy and error-free
re-connection. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
1. The water heater must be electrically grounded. Do not
attach the ground wire to either the gas or the water pip-
ing.
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 exact-
ly 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.
Bottom view of water heater
Connect Power supply
120 VAC, 60 Hz
Green screw Ground
View of electrical
connections of water heater
•
•

17
Remote Controller Connections
To connect the remote controller to the water heater:
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 com-
puter 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 control-
ler 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 122m (400 ft.) long
* For detailed connection instructions to the remote con-
troller, refer to the instructions that are packaged with the
remote controller.
•
•
Connect to
these terminals
TK-RE02
Front of
remote
110 & 310 models
Back of
remote
Connect other end
to these terminals
510 models TM-RE30
Front of
remote Back of remote
Connect other end
to these terminals
Connect to
these terminals

18
Pump Control Mode
(Only available on the 510 models)
The 510 water heaters can be used to control a recirculation
pump. Proper pump control helps to preserve the life of the
system and saves energy as well.
The water heater pump control port is a “normally-open dry
contact”, and therefore needs additional components to
properly control a recirculation pump. To control a recircula-
tion pump, connect the pump to the “Pump” connector in the
water heater as shown in the diagram below. (In an Easy-
Link system, connect the pump ONLY to the “PARENT”
unit.) The pump is to be connected using suitable relays
shown in the diagram below.
Please make sure the relays are properly rated for the recir-
culation pump.
Using the water heater’s internal thermistors as a tempera-
ture control, the recirculation pump will only turn on when
recirculation is needed.
CAUTION
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.
Recirculation
pump
Connect to this
“Pump connector”
Power supply
for relay
Power supply
for pump
120 VAC
220 VAC etc
120 VAC
220 VAC etc
for relay
Thermal
relay
These components
are NOT included
with the water
heater and are
external to the
unit. They must be
acquired separately.
Easy-link System
(Only available on the 510 models)
General
The 510 water heaters can be connected with other heaters
of the same model with communication cables to work as a
multiple-unit manifold system.
The Easy-Link system allows up to 4 units to manifold
together.
•
Acommunication cable (gray color) comes with each 510
model.
You can manifold from 2 to 4 units without the need for a
multi-system controller. A 4-unit system has full automatic
modulation between 11,000 BTU/h and 796,000 BTU/h.
Gas In
Cold In
Hot Out
CAUTION
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 addi-
tional units will not work.
All units within an Easy-Link System
must be of the same exact model.
Different models cannot com-
bine together to form an Easy-Link
System.
•
•
Easy-Link Connection Procedures
1. Verify the set temperatures of all units within the system.
Every single water heater must be set to the same set
temperature.
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.
4. Between the “PARENT” and the “CHILD-1” units:
Connect the “PARENT” connector of the “PARENT” unit
to the “1” connector of the “CHILD-1” unit.
5. Between the “CHILD-1” and the “CHILD-2” units:
Connect the “2” connector of the “CHILD-1” unit to the “1”
connector of the “CHILD-2” unit.
6. Between the “CHILD-2” and the “CHILD-3” units:
Connect the “2” connector of the “CHILD-2” unit to the “1”
connector of the “CHILD-3” unit.
7. Make sure the 7-seg. LED of all the units’ computer
boards display the unit #. The numbering system auto-
matically allocates the unit # to 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
•

19
(A) 510 Computer board
Easy-Link system
“Online” LED
Left bank of
DIPswitches
7-Seg. LED
Right bank of
DIPswitches
Easy-Link connectors
are next to the
computer board.
To change the DIPswitch settings for the Easy-Link system,
locate the bank of DIPswitches to the right of the 7-seg LED.
Do not adjust the left bank of DIPswitches.
(B) Basic diagram of connections between the Easy-Link
System units.
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit CHILD-2 unit CHILD-3
unit
CAUTION
The dark squares indicate the direction the
DIPswitches should be set to.
Note:
A remote controller is not required for the Easy-Link
system.
If running the Easy-Link system without a remote control-
ler, please make sure the temperature settings on ALL
the units are set to the same settings. Otherwise, the
units will not operate properly.
If a remote controller is used, the temperature on all the
units in the system will automatically be set to the same
temperature that is set on the remote.
•
•
•
(C) Examples of incorrect settings and/or connections
CASE 1:
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.
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit
Wrong
setting
Prohibited
Wrong DIPswitch setting on the “PARENT”
unit
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.
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit
Wrong
connection
Wrong
connection
OR
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit
Wrong
connection
Wrong
connection
Prohibited
Wrongconnectionsbetweenthe“PARENT”
unit and the “CHILD-1” unit
•
•

20
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.
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit
Wrong
connection
CHILD-2
unit
Prohibited
Wrong connections between the “CHILD-
1” unit and the “CHILD-2” unit
WARNING
Connecting two “PARENT” connectors
together from two separate units may dam-
age the computer board. The communi-
cation cable has a female end and a male
end so it’s impossible to have a PARENT-
to-PARENT connection with the commu-
nication cable. Do not splice or modify
connectors.
CASE 4:
If a remote controller (optional) is used, it has to be con-
nected to the “PARENT” unit. If the remote controller
is connected to a “CHILD” unit, it will only control that
particular individual “CHILD” unit and will not control the
Easy-Link system as a whole.
Communication
cable
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
Connectors
Right bank of
Dipswitches
OFF
ON
1
23456
PARENT
1
2
PARENT
unit CHILD-1 unit
Wrong
connection
Remote
controller
Prohibited
Remote controller connected to incorrect
unit
•
•
APPLICATIONS
Space-Heating Applications
WARNING
In order to purge air in water pipes
within a closed-loop system, an air
vent and air separator should be
installed in to the system. Required
circulation flow rates are labeled next
to each application diagram. These
flow rate requirements must be fol-
lowed.
Toxic chemicals used in boiler treat-
ments such as alcohol, glycerol and gly-
col groups must not be introduced into
the system if the system incorporates an
open-loop potable water system.
The water heater can be used to supply
potable water and space heating and
shall not be connected to any heat-
ing system or component(s) previously
used with non-potable water where any
chemicals were added to the water heat-
ing appliances.
When the system requires water for
space heating at temperatures higher
than required for other uses, a means
such as a mixing valve shall be installed
to temper the water for those other uses
in order to reduce scald hazard poten-
tial.
Water temperature over 52°C (125°F)
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-loopglycolsystems, low pressure
in the heat exchanger can cause low-
temperature boiling, resulting in exces-
sive noise and damage to the water
heater. Consult with the glycol maker for
specifications prior to use.
•
•
•
•
•
•