Takagi T-KJr2U-IN User manual

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
 • Satisfiesthe2012SCAQMDRule
1146.2forUltra-LowNOx
Emissions
 • EASY-LINKSYSTEMAND
MULTI-UNITSYSTEM
(510U (T-D2U) models only)
Models
510U(T-D2U)
modelsonly
Ifyouhaveanyquestions,please
callorwriteto:
500TennesseeWaltzParkway
AshlandCity,TN37015
TollFree:1-877-737-2840
WARNING
- 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.
On-Demand Water Heater
Installation Manual and Owner’s Guide
ANSIZ21.10.3andCSA4.3
If the information in these
instructions is not followed
exactly,afireorexplosionmay
resultcausingpropertydamage,
personalinjuryordeath.
• 110U Outdoor (T-KJr2U-OS)
• 310U Outdoor (T-K4U-OS)
• 510U Outdoor (T-D2U-OS)
• 110U Indoor (T-KJr2U-IN)
• 310U Indoor (T-K4U-IN)
• 510U Indoor (T-D2U-IN)

2Page
CONTENTS
Installation Manual
SPECIFICATIONS.......................................................................................................................... 4
INTRODUCTION.......................................................................................................................... 5
SAFETYGUIDELINES.................................................................................................................... 6
INSTALLATION............................................................................................................................. 7
General.....................................................................................................................................7
Clearances................................................................................................................................9
Includedaccessories................................................................................................................9
Optionalitems........................................................................................................................9
Warningforinstallations..........................................................................................................9
High-altitudeinstallations......................................................................................................12
Ventinginstructions...............................................................................................................13
Gassupplyandgaspipesizing...............................................................................................18
Waterconnections................................................................................................................20
Electricalconnections............................................................................................................21
Temperatureremotecontroller...........................................................................................22
Easy-linksystem....................................................................................................................25
Multi-unitsystem..................................................................................................................29
APPLICATIONS............................................................................................................................30
INITIALOPERATION...................................................................................................................32
Owner's Guide
OPERATINGSAFETY.................................................................................................................. 34
NORMALOPERATION............................................................................................................... 36
General..................................................................................................................................36
Temperaturesettings.............................................................................................................37
Flow.......................................................................................................................................40
Freezeprotectionsystem.......................................................................................................40
Maintenanceandservice.......................................................................................................41
Unitdrainingandfiltercleaning............................................................................................41
TROUBLESHOOTING...................................................................................................................42
General...................................................................................................................................42
Errorcodes............................................................................................................................44
COMPONENTSDIAGRAM...........................................................................................................47
PARTSLIST.................................................................................................................................51
OUTPUTTEMPERATURECHART................................................................................................54
LIMITEDWARRANTY..................................................................................................................55
Contents

3Page
Installaon Manual
Installation Manual
CONGRATULATIONS
Congratulationsandthankyouforchoosingourtanklesswaterheater.
Beforeuse,werecommendthatyoureadthroughthissafetymanual
carefully.Pleaserefertothebackofthemanualfordetailsaboutthe
warranty.Keepthismanualforfuturereference.
If you lose the manual, contact the manufacturer or your local
distributor.  When you call, please tell us the product name and the
serial number of your unit written on the rating plate of the water
heater.

4Page
Model 110U
Indoor
(T-KJr2U-IN)
110U
Outdoor
(T-KJr2U-OS)
310U
Indoor
(T-K4U-IN)
310U
Outdoor
(T-K4U-OS)
510U
Indoor
(T-D2U-IN)
510U
Outdoor
(T-D2U-OS)
Natural Gas Input
(OperatingRange) BTU/h Min.:15,000
Max.:140,000
Min.:15,000
Max.:190,000
Min.:15,000
Max.:199,000
Gas Connection 3/4"NPT
Water Connections 3/4"NPT
Water Pressure* psi
(Mpa) 15-150(0.1-1)
Natural gas
Inlet Pressure
"W.C.
(kPa)
Min.5.0(1.24)
Max.10.5(2.61)
Manifold
Pressure**
Natural
Gas
"W.C.
(Pa)
1.8
(448)
1.5
(373)
3.0
(747)
2.9
(722)
3.2
(796)
3.05
(759)
Weight lbs.(kg) 37(16.9) 39(17.9)
Dimensions inch H20.5xW13.8xD8.5
H520xW351xD216
mm
Ignition ElectricIgnition
Electric
Supply VAC/Hz 120/60
Consumption
Operation W/A 52.1/0.54 75.8/0.83 81.6/0.86
Standby W/A 5.4/0.08 5.5/0.08 6.5/0.09
Freeze-
Protection W/A 131/1.1 131/1.1 132/1.1
SPECIFICATIONS
*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.
Specicaons
Installaon Manual

5Page
INTRODUCTION
• Thismanualprovidesinformationnecessaryfortheinstallation,operation,andmaintenance
ofthewaterheater.
• Themodeldescriptionislistedontheratingplatewhichisattachedtothesidepanelofthe
waterheater.
• Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
• Ifyouhaveanyproblemsorquestionsregardingthisequipment,consultthemanufactureror
itslocalrepresentative.
• Thisequipmentisanon-demand,tanklesswaterheaterdesignedtoefficientlysupplyendless
hotwaterforyourneeds.
• The110U Indoor(T-KJr2U-IN),310U Indoor(T-K4U-IN)and 510UIndoor (T-D2U-IN) models
are only to be installed indoors (direct-vent (double vent) convertible). The 110U Outdoor
(T-KJr2U-OS),310UOutdoor(T-K4U-OS)and510UOutdoor(T-D2U-OS)modelsareonlytobe
installedoutdoors.
• Theprinciplebehindtanklesswaterheatersissimple:
 *Thisdiagramillustratestanklesswaterheaterdesignconceptsonlyanddoesnotaccurately
representthewaterheater’sphysicaldescription.
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.
8. Whenthetapisturnedoff,theunitshutsdown.
Burners
Exhaustventcollar
Heatexchanger
Gasvalves
Fanmotor
Flowadjustmentvalve
Computerboard
Thermistor
ColdwaterinletHotwateroutlet
Gasinlet
Thermistor
Burners
Flowsensor
Introducon
Installaon Manual

6Page
SAFETY GUIDELINES
SAFETY DEFINITION
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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Canadian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.8.)
4. ChecktheratingplateforthecorrectGAS TYPE, GAS PRESSURE, WATER PRESSURE and ELECTRIC
RATING.
  *Ifthisunitdoesnotmatchyourrequirements,do not install and consult with the manufacturer.
5. Ifanyproblemshouldoccur,turnoffallhotwatertapsandturnoffthegas.Thencallatrained
technicianortheGasCompanyorthemanufacturer.
WARNING
• Watertemperaturesover125°F(52°C)cancausesevereburnsinstantlyor
deathfromscalding.Thewatertemperatureissetat120°F(49°C)fromthe
factory to minimize any scalding risk. Before bathing or showering always
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 Protection 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 Protection
Systemonp.40formoreinformation.
WARNING
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
indeathorseriousinjury.
CAUTION
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.
Safety Guidelines
Installaon Manual
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultin
deathorseriousinjury.
DANGER

7Page
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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.9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.14.)
8. Particles from flour, aerosols, and other contaminants may clog the air vent, build up and reduce
thefunctionsoftherotatingfan,causeimproperburningofthegas,orcausedamagetothewater
heater.Regularlyensurethattheareaaroundtheunitisdust-ordebris-free.Regularmaintenanceis
recommendedforthesetypesofenvironment.
9. Forthe110UIndoor(T-KJr2U-IN),310UIndoor(T-K4U-IN)and510UIndoor(T-D2U-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in.(76mm)
combustibleairsupplypipe.Theintakepipemustbesealedairtight.Airsupplypipecanbe
madeofABS,PVC,CPVC,Polypropylene,corrugatedstainlesssteel,orCategorylll/IV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.
10. The110UOutdoor(T-KJr2U-OS),310UOutdoor(T-K4U-OS)and510UOutdoor(T-D2U-OS)models
onlytobeinstalledoutdoorsandonlyintheareawithmild,temperateclimates.
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INCLUDED ACCESSORIES
OPTIONAL ITEMS
• 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.
WARNING
• 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
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Top
Back
Boom
Side
Side
Front
Model Top Bottom Front Back Sides
110UIndoor(T-KJr2U-IN)*
310UIndoor(T-K4U-IN)*
510UIndoor(T-D2U-IN)*
12in.
(305mm)
12in.
(305mm)
4in.**
(102mm)
0.5in.
(13mm)
2in.
(51mm)
110UOutdoor(T-KJr2U-OS)
310UOutdoor(T-K4U-OS)
510UOutdoor(T-D2U-OS)
36in.
(914mm)
12in.
(305mm)
24in.
(610mm)
0.5in.
(13mm)
2in.
(51mm)
Maintain all clearances around
thewaterheater.
CLEARANCES
*Standardindoorinstallationsanddirect-ventindoorinstallationshavethesameclearances.
**24inchesrecommendedformaintenance.
OPTIONAL ITEMS
#Model
110U
Indoor
(T-KJr2U-IN)
110U
Outdoor
(T-KJr2U-OS)
310U
Indoor
(T-K4U-IN)
310U
Outdoor
(T-K4U-OS)
510U
Indoor
(T-D2U-IN)
510U
Outdoor
(T-D2U-OS)
1. 4"Backflowpreventer
andF-Fadaptor ✓✓✓
2. Direct-vent
conversionkit ✓✓✓
3. Pipecover ✓✓✓✓✓✓
4. Recessbox ✓ ✓ ✓
5.
Sidewallvent
terminator(Hood)
andWallthimble ✓✓✓
6. Direct-ventconcentric
termination ✓✓✓
INCLUDED ACCESSORIES
Installation manual
and Owner’s guide
Temperature
remote controller kit*
Communication cable
510U (T-D2U) models only
Qty:1 Qty:1
Checkthattheseitemsbelowareincludedwiththewaterheater.
Qty:1
*Refertop.22.
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2. Direct-vent conversion kit: 9007667005
(TK-TV10)
This kit can be used to convert the water
heater from a single vent system to a direct-
vent (double vent) (or sealed combustion)
system with a 3 in. (76 mm) intake.  Install
this conversion kit in accordance with the
installation instructions and any applicable
codes.
The pipe cover protects the
plumbing pipes to the water
heater from 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.
4. 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
heater and plumbing.  The recess
box will fit in-between most wall
studs.
1. 4” Backflow preventer and F-F adaptor:
9007996005
Therearetwofunctionsavailableforthisadaptor,
whichcanbeconnectedwiththewaterheaterand
NovaVent venting line and prevents the backflow
ofairthroughtheexhaustvent.Thishelpsprevent
harmfulexhaustgasesfromenteringthehome,as
wellashelpingtopreventtheunitfromfreezingin
areaswherecoldaircanbeblownordrawnintothe
exhaustsystem.Installthisadaptorinaccordance
withtheinstallationinstructionsthatarepackaged
withtheadaptorandanyapplicablecodes.
5. Sidewall vent terminator (Hood) and Wall thimble:
Used when terminating direct-vent (sealed combustion) systems,
with indoor models that require a 3 in. intake and a 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twodifferentsizes,tocoverawiderangeof
wallthicknesses.Fordifferentwallthicknesses,
therearetworangesoflengthsavailable.(Refer
totheNovaVentbrochurefordetails.)
Installaon
Installaon Manual
Covering wall thicknesses Part#
TerminatorHood 9007999005
WallThimble4-7in. 9008345005
WallThimble5-10in. 9008346005
Termination+Thimble4-7in. 9008004005
Termination+Thimble5-10in. 9008005005
3. Pipe cover: 9007670005 (TK-PC01)
Covering wall thicknesses Part#
5.0–10.0in. 9008147005
12.0–18.0in. 9008148005
6. Direct-vent concentric termination:
They are used when venting out through the wall.  These terminations are special stainless steel
ventsforgasappliancesandareULlistedasCategoryII,IIIandIV.Fordifferentwallthicknesses,
therearetworangesoflengthsavailable.(RefertotheNovaVentbrochurefordetails.)Installthese
ventterminationsinaccordancewiththeirinstallationinstructionsandanyapplicablelocalcodes.
Wall Thimble
Terminator Hood

11 Page
WARNING FOR INSTALLATIONS
FOR YOUR SAFETY, READ BEFORE INSTALLATION:
Do not install the heater where water, debris or
flammablevaporsmaygetintotheflueterminal.
Thismaycausedamagetotheheaterandvoidthe
warranty.
Donothavetheventterminalpointingtoward
anyopeningintoabuilding.Donotlocateyour
heaterinapitorlocationwheregasandwater
canaccumulate.
Do not install this water heater under an
overhanglessthan3ft.(914mm)fromitstop
oreaves.Theareaunderanoverhangmustbe
opentothreesides(Outdoormodelsonly).
Donotinstallthewaterheaterventterminator
within1ft.(305mm)intheUSAofanyairintake
orbuilding opening,andwithin 3ft. (914mm)
inCanadaof anyairintakeorbuildingopening
(Outdoormodelsonly,refertop.16).
Do not install next to a dryer or any source
of airborne debris that can be trapped inside
the combustion chamber, unless the system is
direct-vented.
ProhibitedProhibited
1ft.(305mm)USA
3ft.(914mm)Canada
1ft.(305mm)USA
3ft.(914mm)Canada
1ft.(305mm)USA
3ft.(914mm)Canada
3ft.
(914mm)
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Installaon Manual

12 Page
HIGH-ALTITUDE INSTALLATIONS
Check the elevation where your water heater is installed.  Set DIPswitches shown in the table below
dependingonthealtitude.
BankofDIPswitches
110U (T-KJr2U) and 310U (T-K4U) models
Computer board
WARNING
DO NOT adjust any DIPswitches on the upper bank for the 510U (T-D2U)
models.
NOTE: ThedarksquaresindicatethedirectiontheDIPswitchesshouldbesetto.
LowerbankofDIPswitches
510U (T-D2U) models
Computer board
Indoor models
0 (DEFAULT) Up to 2,500 ft Up to 5,000 ft Up to 7,500 ft Over 7,500 ft
110U(T-KJr2U)and
310U(T-K4U)models No.3:OFF
No.4:OFF
No.5:OFF
No.3:OFF
No.4:ON
No.5:OFF
No.3:OFF
No.4:OFF
No.5:ON
No.3:OFF
No.4:ON
No.5:ON
Consultour
Technical
Services
at1-877-
737-2840
510U(T-D2U)models
(Lower bank of
DIPswitches) No.2:OFF
No.3:OFF
No.4:OFF
No.2:OFF
No.3:ON
No.4:OFF
No.2:OFF
No.3:OFF
No.4:ON
No.2:OFF
No.3:ON
No.4:ON
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
12345678910
OFF
ON
12345678910
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
Altitude
DIPswitches
Outdoor models
0 (DEFAULT) Up to 2,000 ft Up to 4,000 ft Up to 6,000 ft Over 6,000 ft
110U(T-KJr2U)and
310U(T-K4U)models No.3:OFF
No.4:OFF
No.5:OFF
No.3:OFF
No.4:ON
No.5:OFF
No.3:OFF
No.4:OFF
No.5:ON
No.3:ON
No.4:OFF
No.5:ON
Consultour
Technical
Services
at1-877-
737-2840
510U(T-D2U)models
(Lower bank of
DIPswitches) No.2:OFF
No.3:OFF
No.4:OFF
No.2:OFF
No.3:ON
No.4:OFF
No.2:OFF
No.3:OFF
No.4:ON
No.2:ON
No.3:OFF
No.4:ON
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
12345678910
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
OFF
ON
1 2 3 4 5 6
Altitude
DIPswitches
Installaon
Installaon Manual

13 Page
VENTING INSTRUCTIONS
For indoor models
-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InstallationCodeinCanada,aswellasapplicablelocalbuildingcodes.
The manufacturer recommends the NovaVent line.  However, the following are also UL listed
manufacturers:ProTechSystemsInc.(FasNSeal),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termination.
• 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termination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terminationsothatitcannotbeblockedbyanydebris,atanytime.Mostcodes
requirethattheterminationmustbeatleast12in.(305mm)abovegrade,buttheinstallermay
determineifitshouldbehigherdependingonthejobsiteconditionandapplicablecodes.
• A proper sidewall termination is recommended when the water heater is vented through a
sidewall.
• Regardingtheclearancesfromtheexhaustterminationtotheairinletoropening,refertothe
nextfewpages.
• 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.
DANGER
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.
CAUTION
Installaon
Installaon Manual

14 Page
-Vent length and No. of Elbows-
ThisisaCategoryIIIapplianceandmustbeventedaccordingly.Theventsystemmustbesealedairtight.
Allseamsandjointswithout gaskets mustbesealedwithhighheatresistantsiliconesealantorULlisted
aluminumadhesivetapehavingaminimumtemperatureratingof350°F(177°C).Forbestresults,avent
systemshouldbeasshortandstraightaspossible.
• ThiswaterheaterisaCategoryIIIapplianceandmustbeventedaccordinglywithany4in.(102
mm)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.(1.5m),supporttheventrunat3ft.(0.9m)intervals
withoverheadhangers.
• Themaximumlengthofexhaustventpipingmustnotexceed50ft.(15.2m)(deducting5ft.(1.5
m)foreachelbowusedintheventingsystem).Donotusemorethan5elbows.
-DIPswitch settings for Vent length-
For Indoor and direct-vent models
Vent type Diameter Max. No. of Elbows Max. Vertical and Horizontal (Total) Vent Length
Intake 3in.(76mm) 550ft.(15.2m)
Exhaust 4in.(102mm) 550ft.(15.2m)
*For each elbow added, deduct 5 ft. (1.5m) from max. vent length.
No. of Elbows Max. Vertical or Horizontal Vent Length
0 50ft.(15.2m)
1 45ft.(13.7m)
2 40ft.(12.2m)
525ft.(7.6m)
Excludeselbowtermination,raincaps,orthe4in.(102mm)Concentrictermination
SetDIPswitchesshowninthetablebelowdependingontheventlength.
110U Indoor (T-KJr2U-IN)
310U Indoor (T-K4U-IN)
510U Indoor (T-D2U-IN)
(Upper bank of DIPswitches) Vent length
No.6:ON
No.7:OFF
No.3:ON
No.4:OFF
0 to 7 ft
No.6:ON
No.7:ON
No.3:ON
No.4:ON
8 to 50 ft
(DEFAULT)
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8
OFF
ON
1 2 3 4 5 6 7 8 9 10
OFF
ON
1 2 3 4 5 6 7 8 9 10
Installaon
Installaon Manual

15 Page
Venng Illustraons-
For the 110U Indoor (T-KJr2U-IN), 310U Indoor (T-K4U-IN) and 510U Indoor (T-D2U-IN) models
Fordetailsoftheoptionalitems,refertotheInstallationmanualforeachOptionalitem.
Horizontal Installaon with
Direct-vent concentric terminaon
Wall
Direct-vent
concentric
terminaon
Installaon of Direct-vent
conversion kit with water heater
Waterheater
IntakeportofDirect-vent
conversionkit
(Fordetailsseep.10.)
*Backflowpreventer(Recommendedforfreezingweatherconditions:36°F(2°C)andbelow).
**Verticalcondensationdrainmustbeinstalledinaccordancewithlocalcodes.
PlateofDirect-ventconversionkit
Horizontal Installaon
Wall
Sidewallvent
termination
Verticalcondensationdrain**
Backflow
preventer*
Vercal Installaon
Backflow
preventer*
Raincap
Roof
Verticalcondensationdrain**
Roofflashing
Vercal Installaon
(With direct-venng)
Horizontal Installaon
(With direct-venng)
Roof
Sidewallvent
terminaon
Vercalcondensaondrain**
Backow
preventer*
Seethepicturebelowfordetailedconnecon
instruconstoDirect-ventconversionkit.
Backow
preventer* Firestop
Vercalcondensaon
drain**
Wall
Roofashing
Raincap
Installaon
Installaon Manual

16 Page
-Vent terminaon clearances-
Canada U.S.A
Direct-ventandother
thanDirect-vent
Direct-
vent
Otherthan
Direct-vent
AClearance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 * * *
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 * * *
HClearancetoeachsideofcenterlineextended
above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 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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.
INSIDECORNERDETAIL
V
Gasmeter/regulator
V
V
V
V
V
V
V
V
V
X
X
X
Ventterminal
Airsupplyinlet
Areawhereisnotpermitted
G
A
E
D
B
L
C
F
B
B
B
BA
J
OPERABLE FIXED
CLOSED
B
H
M
K
OPERABLE
FIXED
CLOSED
I
Installaon
Installaon Manual

17 Page
-For sidewall terminaons-
-For rooop terminaons-
For multiple sidewall exhaust terminations (e.g. multi-
unit systems), an exhaust termination must be at least 1
ft.(305mm)awayfromanotherexhausttermination.An
exhaust terminationmustalsobe atleast2ft. (610 mm)
awayfromaninsidecorner.(Iftheadjacentwallislessthan
2ft. (610 mm) of length,theminimum requireddistance
awayfromtheinsidecornerwillbeequaltothelengthof
thatadjacentwall.)
For multiple-unit, direct-vent sidewall terminations that
combinetheintakeandexhaustintoasinglepenetration,
spaceeachdirect-ventterminationatleast1ft.(305mm)
awayfromeachother,nomattertheorientation.Adirect-
ventterminationmustalsobeatleast2ft.(610mm)away
fromaninsidecorner.(Iftheadjacentwallislessthan2ft.
(610mm)oflength,theminimumrequireddistanceaway
fromtheinsidecornerwillbeequaltothelengthofthat
adjacentwall.)
For direct-vent sidewall
terminationsthatusetwo
separatepenetrationsfor
the intake and exhaust,
distance the intake and
exhaust terminations at
least3ft.(915mm)away
from each other, no
mattertheorientation.
For multiple-unit rooftop terminations (whether for standard or direct-vent installations) space all
exhaustandintaketerminationsinaccordancewithlocalcodes.Anexhaustterminationmustbespaced
fromawallorsurfaceinaccordancewithlocalcodesaswell.Intheabsenceofsuchacode,anexhaust
terminationmustbeahorizontaldistanceofatleast2ft.(610mm)awayfromawallorsurface.
Exhaust and/or
direct-vent sidewall
terminationsshould
beatleast2ft.(610
mm) away from an
opposite surface/
wall.  Do not place
the termination
directly in front of
an opening into a
building.
Please follow all local and national codes in regards to proper termination
clearances.In theabsenceofsuchcodes,theaboveclearancescanbeused as
guidelines.Localcodessupersedetheseguidelines.
CAUTION
A:Inaccordancewithlocalcodes
Airintake
A
Exhaustterminaon
A
A
A
A
Airintake
2.
(610mm)min
Exhaust
terminaon
3ft.
(915
mm)
min
Airsupplyinlet
3ft.(915mm)
min
3ft.(915mm)
min
Exhaust
termination
Installaon
Installaon Manual
Exhaust
termination
Inside
corner
1ft.
(305mm)min
2ft.
(610mm)min
1ft.(305mm)
min
Combined
intakeand
exhaust
termination
Inside
corner
1ft.
(305mm)min
2ft.
(610mm)min
1ft.(305mm)
min
Exhaust
termination
2ft. (610mm)
min

18 Page
GAS SUPPLY AND GAS PIPE SIZING
-General-
• Theminimumandmaximuminletgaspressuresare:
• Inlet gas pressures that fall outside the range of values listed above may adversely affect the
performance of the water heater.  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 connecons-
1. Installamanualgasshutoff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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(3.5kPa).
3. Alwayspurgethegaslineofanydebrisand/orwaterbeforeconnectingtothegasinlet.
Sizethegaspipeappropriatelytosupply thenecessaryvolumeof gasrequired
forthewaterheaterusingANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1in
Canadaorlocalcodes.Otherwise,flowcapabilitiesandoutputtemperatureswill
belimited.
NOTICE
Gas type Inlet gas pressure
NaturalGas Min.5.0”W.C.(1.24kPa)–Max.10.5”W.C.(2.61kPa)
• Check that the type of gas matches the rating plate first.
• Ensure that any and all gas regulators used are operating properly and
providing gas pressures within the specified range shown below. Excess gas
inlet pressure may cause serious accidents.
• Conversion of this unit from natural gas to propane or vice versa will void
all warranty.  Contact your local distributor to get the correct unit for your
gas type.  The manufacturer is not liable for any property and/or personal
damage resulting from gas conversions.
CAUTION
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19 Page
-Natural Gas Supply Piping-
MaximumdeliverycapacityofcubicfeetofgasperhourofIPSpipecarryingNaturalGaswith0.60specificgravity
basedonpressuredropof0.5"W.C.
Based on energy content of 1,000 BTU/Cubic ft.: The water heater requires 140 Cubic ft./hr for the 110U (T-KJr2U)
models, 190 Cubic ft./hr for the 310U (T-K4U) models, and 199 Cubic ft./hr for the 510U (T-D2U) models.
Pipe size Length
Diameter 10' 20' 30' 40' 50' 60' 70' 80' 90' 100' 125' 150' 200'
3/4" 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 1/4" 1,404 965 775 663 588 532 490 456 428 404 358 324 278
1 1/2" 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
Unit: Cubic feet per hour
BasedonEnergyContentof1,000BTU/Cubicft:
Divideeachappliance'sBTUrequirementby1,000BTU/htogettheappliancesCubicFt.requirement.
Takeintoaccountthedistancetheapplianceisfromthegasmeter,lookintheabovegascharttoproperly
sizetheline.
Forsectionsofthegaslinesupplyinggastomorethanoneappliance(Ex:PointAtoPointB),addupthecubic
ft.requirementsoftheappliancesthatarebeingsuppliedbythatsection,andsizetothefarthestappliance.
For Example: The section from A to B supplies gas to the furnace, range and dryer.  Adding up the BTU
requirements and dividing by 1,000 yields a cubic ft. requirement of 220 cubic ft. of gas.  The farthest
applianceistherange,whichis50ft.awayfromthemeter.Lookingattheabovechart,andunderthecolumn
of50ft.,SectionAtoBneedstobe1"inordertosupply220cubicft.
Water
heater
199,000BTU/h Dryer
35,000BTU/h
Gas meter Furnace
120,000BTU/h
Range
65,000BTU/h
AB
C
10'Length
1/2"Pipesize
15'Length
1/2"Pipesize
15'Length
1"Pipesize
10'Length
3/4"Pipesize
10'Length
1"Pipesize
5'Length
1-1/4"Pipesize
10'Length
3/4" Pipe size
5'Length
1-1/4"Pipesize
Gas sizing example
(Natural Gas)
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20 Page
-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.
WATER CONNECTIONS
Allpipes,pipefittings,valvesandothercomponents,includingsolderingmaterials,mustbesuitablefor
potablewatersystems.
1. Amanualshutoff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shutoff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.
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.
• Do not use this water heater if any part has been submersed under water.
Immediatelycallalicensedprofessionaltoinspectthewaterheatertoreplace
anydamagedparts.
• Do not reverse the hot outlet and cold inlet connections to the water heater.
Thiswillnotproperlyactivatethewaterheater.
CAUTION
1. Shutoffthemanualgasvalveonthegassupplyline.
2. Removethescrewforthepressureportlocatedonthegas
inletofthewaterheatershowninthediagramon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andminimumburn,themanometershouldread
from5.0”to10.5”W.C.(1.24to2.61kPa)forNaturalgas.
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.(Refertop.41.)
Pressureport
Cold
inlet
Hot
outlet
Gas
inlet
As Close as
Possible
Pressure relief valve
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