Takagi T?KJr2?IN User manual

-Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
-WHAT TO DO IF YOU SMELL GAS
.Do not try to light any appliance.
Do not touch any electric switch, do not
use any phone in your building.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas
supplier's instructions.
If you cannot reach your gas supplier, call
the fire department.
-Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
FEATURING
ENDLESS HOT WATER
ON DEMAND USAGE
COMPACT, SPACE SAVING
ENERGY CONSERVATION
COMPUTERIZED SAFETY
NO PILOT LIGHT
EASY-LINK SYSTEM
510 (T-D2) models only
Gas Tankless Water Heater
Suitable for potable water heating and space-heating *
*Please refer to local codes for space-heating compliance.
If you have any questions, please
call or write to:
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Toll Free:
1
-
877
-
737
-
2840
On
-
Demand Water Heater
Installation Manual and Owner’s Guide
Model
s
・ 110 Indoor (T-KJr2-IN) ・ 110 Outdoor (T-KJr2-OS)
・ 310 Indoor (T-K4-IN) ・ 310 Outdoor (T-K4-OS)
・ 510 Indoor (T-D2-IN) ・ 510 Outdoor (T-D2-OS)
WARNING
If the information in these
instructions is not followed
exactly, a fire or explosion
may result causing
property damage, personal injury or death.
ANSI
Z21.10.3
and CSA 4.3
510 (T
-
D2) models
only

Contents
2│Page
CONTENTS
SPECIFICATIONS…………………………………………………………………………………………..………………………...
INTRODUCTION…………………………………………………………………………………………………..………………….
SAFETY GUIDELINES…………….………………………………………………………………………………………..………..
INSTALLATION………………………………………………………………………………………………..…………………..….
General………………………………………………………………………………………………………………………..…..…
Clearances……………………………………………………………………………………………………………………………
Included Accessories…………….………………………………………………………………………………………..…..
Optional Items……………………………………………………………………………………………………………………..
High-Altitude Installations……………………………………………………………………………………………………
.
Venting Instructions……………………………………………………………………………………………………………
..
Gas Supply and Gas Pipe Sizing………......................................................................................
…
Water Connections……………..…………………………………………………………………………………………….…
Electrical Connections……………………………………………………………………..…………………………….......
Remote Controller Connections……..………………………………………………………………………………….
…
Pump Control Connections…………………………………………..………..………..
……………………………………
Easy-Link System...…………………………....…………………………………………………………………………..…..
..
APPLICATIONS...………………………………………………………………………………………………………………………
INITIAL OPERATION..………………………………………………………………………………………………………….……
OPERATING SAFETY…………………………………………………………………………………………………………………
NORMAL OPERATION…………………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
Temperature Settings.…….……..……………………………………………………………………………………………
Flow…………………………………………………………………………………………………………………………………….
Freeze Protection System…….…………………………………………………………………………………………..…
Maintenance and Service………………………………………………………………………………………………….…
Unit Draining and Filter Cleaning…………………………………………………………………………………………
TROUBLESHOOTING……..……………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
Error Codes.…………………….…..……………………………………………………………………………………………
…
COMPONENTS DIAGRAM……………………………………………………………………………………………………..…
PARTS LIST………………….………………………………………………………………………………………………..…………
OUTPUT TEMPERATURE CHART…………………………………………………………………………………………...…
LIMITED WARRANTY…………………………………………………………....…………………………………………….….
3
4
5
6
6
8
8
9
11
12
17
20
21
22
23
24
28
30
31
33
33
33
35
35
36
36
37
37
39
42
46
49
51
Installation Manual
Owner’s Guide

Specifications
3│Page
SPECIFICATIONS
Model
110
Indoor
(T-KJr2-IN)
110
Outdoor
(T-KJr2-OS)
310
Indoor
(T-K4-IN)
310
Outdoor
(T-K4-OS)
510
Indoor
(T-D2-IN)
510
Outdoor
(T-D2-OS)
Natural Gas Input
(Operating Range
)
Min: 19,500 Btu/h
Max: 1
40
,000 Btu/h
Min: 11,000 Btu/h
Max: 19
0
,000 Btu/h
Min: 11,000 Btu/h
Max: 199,000 Btu/h
Propane Input
(Operating Range)
Min: 19,500 Btu/h
Max: 140,000 Btu/h
Min: 11,000 Btu/h
Max: 190,000 Btu/h
Min: 11,000 Btu/h
Max: 199,000 Btu/h
Gas Connection ¾” NPT
Water Connections ¾” NPT
Water Pressure 15 - 150 psi*
Natural Gas
Inlet Pressure
Min. 5.0” WC
Max. 10.5” WC
Propane
Inlet Pressure
Min. 8.0” WC
Max. 14.0” WC
Manifold
Pressure**
Natural
2.0” WC
2.5” WC 2.0” WC
2.5” WC 2.0” WC 2.5” WC
Propane
2.5” WC 3.1” WC 3.7” WC 4.0” WC 3.7” WC 4.5” WC
Weight 33 lbs. 38 lbs. 39 lbs.
Dimensions H20.5” x W13.8” x D6.7”
H20.5” x W13.8” x D8.5”
Ignition Electric Ignition
Electric
Supply 120 VAC / 60 Hz
Consumption
Operation 73.1 W / 0.61 A 87.6 W / 0.73 A 89.8 W / 0.75 A
Standby 6.2 W / 0.05 A 6.2 W / 0.05 A 6.2 W / 0.05 A
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.
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.
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Introduction
4│Page
INTRODUCTION
*This diagram
illustrates tankless
water heater design
concepts only and
does not accurately
represent to the water
heater’s physical
description.

This manual provides information necessary for the installation, operation, and
maintenance of the water heater.

The model description is listed on the rating plate which is attached to the front panel
of the water heater.

Please read all installation instructions completely before installing this product.

If you have any problems or questions regarding this equipment, consult with the
manufacturer or its local representative.

This equipment is an on-demand, tankless water heater designed to efficiently supply
endless hot water for your needs.

The principle behind tankless water heaters is simple:
1. A hot water tap is turned on.
2. Water enters the heater.
3. The water flow sensor detects the water flow.
4. The computer initiates the fan motor and sends a signal to the igniter to create an ignition
spark.
5. The gas ignites and flames appear within the burner chamber.
6. Water circulates through the heat exchanger and then gets hot.
7. Using thermistors to measure temperatures throughout the water heater, the computer
modulates the gas and water valves to ensure proper output water temperature.

The 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models are
to be only installed indoor (direct-vent convertible). The 110 Outdoor (T-KJr2-OS), 310
Outdoor
(
T
-
K4
-
OS) and 510 Outdoor (T
-
D2
-
OS) models ar
e to
be only installed outdoor.

Safety Guidelines
5│Page

W
ater temperature
s over 125°F
(
52
°
C
)
can cause severe burns instantly or
death
from scalding. The water temperature is set at 122°F (50°C) from the factory to
minimize any scalding risk. Before bathing or showering always check the water
temperature.
Do not store or use gasoline or other flammables, vapors, or liquids in the vicinity
of this appliance.
Do not reverse the water and/or gas connections as this will damage the gas
valves and can cause severe injury or death. Follow the diagram on p. 20 when
installing your water heater.
Do not use this appliance if any part has been in contact with or been immersed
in water. Immediately call a licensed plumber, a licensed gas fitter, or a
professional service technician to inspect and/or service the unit if necessary.
Do not disconnect the electrical supply if the ambient temperature will drop
below freezing. The Freeze Prevention System only works if the unit has electrical
power. The warranty will not be covered if the heat exchanger is damaged due to
freezing. Refer to the section on the Freeze Prevention System on p. 35 for more
information
.
SAFETY GUIDELINES
SAFETY DEFINITIONS
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, could result
in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, could result
in minor or moderate injury.
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the
National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas, Propane
Installation Code in Canada.
2. Properly ground the unit in accordance with all local codes or in the absence of local codes, with
the National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canada Electrical
Code Part 1 in Canada.
3. Carefully plan where you intend to install the water heater. Please ensure:
Your water heater will have enough combustible air and proper ventilation.
Locate your heater where water leakage will not damage surrounding areas (please refer
to p. 7).
4. Check the rating plate for the correct GAS TYPE, GAS PRESSURE, WATER PRESSURE and ELECTRIC
RATING.
*If this unit does not match your requirements, do not install and consult with the manufacturer.
5. If any problem should occur, turn off all hot water taps and turn off the gas. Then call a trained
technician or the Gas Company or the manufacturer.
WARNING
CAUTION
DANGER
WARNING

Installation
6│Page
INSTALLATION
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the most recent edition of the
National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or CAN/CSA B149.1 Natural Gas,
Propane Installation Code in Canada.
2. All gas water heaters require careful and correct installation to ensure safe and efficient
operation. This manual must be followed exactly. Read the “Safety Guidelines” section.
3. The manifold gas pressure is preset at the factory. It is computer controlled and should not
need adjustment.
4. Maintain proper space for servicing. Install the unit so that it can be connected or removed
easily. Refer to the Clearances Section on p. 8 for proper clearances.
5. The water heater must be installed in a location where the proper amount of combustible air
will be available to it at all times without obstructions.
6. The electrical connection requires a means of disconnection, to terminate power to the water
heater for servicing and safety purposes.
7. Do not install the unit where the exhaust vent is pointing into any opening in a building or where
the noise may disturb your neighbors. Make sure the vent termination meets the required
distance by local code from any doorway or opening to prevent exhaust from entering a building
(refer to p. 15).
8. Particles from flour, aerosols, and other contaminants may clog the air vent or reduce the
functions of the rotating fan and cause improper burning of the gas. Regularly ensure that the
area around the unit is dust- or debris-free; regular maintenance is recommended for these
types of environment.
9. If you will be installing the water heater in a contaminated area with a high level of dust, sand,
flour, aerosols or other contaminants/chemicals, they can become airborne and enter and build
up within the fan and burner causing damage to the water heater.
10. For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN) models:
These units may be converted to a direct-vent (sealed combustion) appliance by installing a
direct-vent conversion kit Part No. 9007667005 (TK-TV10) which will bring in all required
combustible air from outside the building. When installing the direct-vent conversion kit,
please follow all instructions included with the kit.
If the water heater is used as a direct-vent appliance, the unit requires a 3” combustible air
supply pipe. The intake pipe must be sealed airtight. Air supply pipe can be made of ABS,
PVC, galvanized steel, corrugated aluminum, corrugated stainless steel or Category III
stainless steel.
Terminating the venting through a sidewall is recommended for the direct-vent system.
Running the exhaust vent and the intake pipe parallel is recommended.
Terminating the exhaust and intake on the same wall / surface is recommended.
Terminating in the same pressure zone allows for pressure balancing, which prevents
nuisance shutdowns.
11. For the 110 Outdoor (T-KJr2-OS), 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS) models:
To be installed outdoors and only in areas with mild, temperate climates.

Installation
7│Page
Installation and service must be performed by a qualified installer (for
example, a licensed plumber or gas fitter), otherwise the warranty will be
void.
The installer (licensed professional) is responsible for the correct installation
of the water heater and for compliance with all national, state/provincial,
and local codes.
The manufacturer does not recommend installing the water heater in a pit or
location where gas and water can accumulate.
Do not have the vent terminal pointing toward any operating window, door, or
opening into a building.
Do not install next to any source of airborne debris, such as a clothes dryer,
that can cause debris to be trapped inside the combustion chamber, unless
the system is direct-vented.
The manufacturer does not recommend installing the water heater in an
attic due to safety issues. If you install the water heater in an attic:
Make sure the unit will have enough combustion air and proper ventilation.
Keep the area around the water heater clean. When dust collects on the
flame sensor, the water heater will shut down on an error code.
If the above conditions cannot be met, use the direct vent conversion kit
Part No. 9007667005 (TK-TV10).
Place the unit for easy access for service and maintenance.
A drain pan, or other means of protection against water damage, is
required to be installed under the water heater in case of leaks
.

The warranty will not cover damage caused by water quality.
Only potable water or potable water / glycol mixtures can be used with this
water heater. Do not introduce pool or spa water, or any chemically
treated water into the water heater.
Water hardness levels must not exceed 7 grains per gallon (120 ppm) for
single family domestic applications or more than 4 grains per gallon (70
ppm) for all other types of applications. Water hardness leads to scale
formation and may affect/damage the water heater. Hard water scaling
must be avoided or controlled by proper water treatment.
Water pH levels must be between 6.5 and 8.5
Well water must be treated.
Do not install the unit where water, debris, or flammable vapors may get into
the flue terminal.
The manufacturer recommends using the direct vent kit when the water
heater is installed in a beauty salon. Some chemicals used in a beauty salon
may affect the flame sensor. Water heater may not work properly.
Although the water heater is designed to operate with minimal sound, the
manufacturer does not recommend installing the unit on a wall adjacent to a
bedroom, or a room that is intended for quiet study or meditation, etc.
Locate your heater close to a drain where water leakage will not do damage to
surrounding areas. As with any water heating appliance, the potential for
leakage at some time in the life of the product does exist. The manufacturer
will not be responsible for any water damage that may occur. If you install a
drain pan under the unit, ensure that it will not restrict the combustion air
flow.
CAUTION
WARNING

Installation
8│Page
CLEARANCES
Mode
l
Top
Bottom
Front
Back
Sides
110 Indoor* (
T
-
KJr2
-
IN
)
*
12
”
12
”
24
”
1
”
2
“
110 Outdoor (
T
-
KJr2
-
OS
)
36
”
12
”
24
”
1
”
2
“
Model
Top
Bottom
Front
Back
Sides
310 Indoor
* (
T
-
K4
-
IN
)
*
12
”
12
”
24
”
1
”
2
“
310 Outdoor (
T
-
K4
-
OS
)
36
”
12
”
24
”
1
”
2
“
Model
Top
Bott
om
Front
Back
Sides
510 Indoor* (
T
-
D2
-
IN
)
*
12
”
12
”
24
”
1
”
2
“
510 Outdoor (
T
-
D2
-
OS
)
36
”
12
”
24
”
1
”
2
“
*Standard indoor installations and direct-vent indoor installations have the same clearances.
INCLUDED ACCESSORIES
Check that these items below are included with the water heater.
1. Installation Manual and
Owner’s Guide
2. Product Registration Card 3. Communication Cable
510 (T-D2) models only
Qty: 1
Qty: 1
Qty: 1
Bottom
Side
Top
Side
Front
Back
Maintain a
ll clearances around
the water heater.

Installation
9│Page
OPTIONAL ITEMS
Model
110 Indoor
(T-KJr2-IN)
110 Outdoor
(T-KJr2-OS)
310 Indoor
(T-K4-IN)
310 Outdoor
(T-K4-OS)
510 Indoor
(T-D2-IN)
510 Outdoor
(T-D2-OS)
9007666005
(
TK
-
RE02
)
✔ ✔ ✔ ✔
9007603005
(
TM
-
RE30
)
✔ ✔
9007678005
(
TK
-
BF01
)
✔ ✔ ✔
9007667005
(
TK
-
TV10
)
✔ ✔ ✔
9007670005
(
TK
-
PC01
)
✔ ✔ ✔ ✔
9007671005
(
TK
-
PCJr2
)
✔ ✔
90076
74005
(
TK
-
RB02
)
✔ ✔ ✔
9007608005
(TK-KPWL4)
9007609005
(
TK
-
KPWH4
)
✔ ✔ ✔
9007680005
(
TK
-
KPCT43
)
✔ ✔ ✔
1
.
Temperature Remote Controller
:
9007666005
(TK-RE02)
The Temperature Remote
Controller has two functions. It
allows the output temperature
from the water heater to be
adjusted within the range of
99 °F to 167 °F, and it also
works as a diagnostic tool that
will give a concise error code whenever there is a
problem with the unit. The temperature options
are 99°F, 100°F, 102°F, 104°F, 106°F, 108°F, 109°F,
111°F, 113°F, 115°F, 117°F, 122°F, 131°F, 140°F,
158°F, and 167°F. See the trouble shooting section
for information on possible error codes.
2
.
Temperature Remote Controller
:
9007603005
(TM-RE30)
The Temperature Remote
Controller has two functions. It
allows the output temperature
from the water heater to be
adjusted within the range of
99 °F to 185 °F, and it also
works as a diagnostic tool that
will give a concise error code whenever there is a
problem with the unit. The temperature options
are 99°F, 100°F, 102°F, 104°F, 106°F, 108°F, 110°F,
111°F, 113°F, 115°F, 117°F, 122°F, 131°F, 140°F,
149°F, 158°F, 167°F, 176°F and 185°F. See the
trouble shooting section for information on
possible error codes.
3. Backflow Preventer: 9007678005 (TK-BF01)
The Backflow preventer prevents
the backflow of air through the
exhaust vent. This helps prevent
harmful exhaust gases from
entering the home, as well as
helping to prevent the unit from
freezing in areas where cold air can be blown or
drawn into the exhaust system. Install this vent
damper in accordance with the installation
instructions and any applicable codes.
4. Direct-Vent Conversion Kit: 9007667005
(TK-TV10)
This kit can be used to
convert the water
heater from a
standard vent system
to a direct-vent (or
sealed combustion)
system. Install this
conversion kit in accordance with the installation
instructions and any applicable codes.

Installation
10│Page
5. Pipe Covers: 9007670005 (TK-PC01) and
9007671005 (TK-PCJr2)
The pipe cover protects the
plumbing pipes to the water heater
from unexpected adjustments.
This pipe cover is fixed to the
bottom of the water heater, which
hides the plumbing and improves
the visual aspects of the whole
installation
for the water heater.
6. Recess box: 9007674005 (TK-RB02)
The Recess box will allow for
“clean” installations. The water
heater fits inside the recess box,
which hides and protects the
whole water h
eater and plumbing.
The Recess box will fit in-between
most wall studs.
7. T-Vent Wall Thimble with Termination: 9007608005 (TK-KPWL4) and 9007609005 (TK-KPWH4)
These terminations are used when venting out through the wall
and are compatible with the T-Vent pipe system.
These terminations are special stainless steel vents for gas
appliances and are UL listed as Category II, III and IV. There are
two types of terminations: the Louver termination and the Hood
termination. For different wall thicknesses, there are two ranges
of lengths available (refer to the venting brochure for details).
Install these vent terminations in accordance with their
installation instructions and any applicable local codes.
8. Direct-Vent Concentric Termination: 9007680005 (TK-KPCT43)
Used when terminating direct-vent (sealed-combustion) systems,
with direct-vent models that require a 3” intake and a 4” exhaust.
This concentric termination provides the convenience of only
having to make one penetration through a sidewall instead of two
separate penetrations for the intake and exhaust piping. The
termination includes a bird screen, restricting small animals,
pests, and foreign objects from entering into the vent system.
This sidewall termination is available in three different sizes, to
cover all ranges of wall thicknesses
.
Direct
-
vent Concentric
Termination
Part#
Covering wall thickness
9007680005 (
TK
-
KPCT43
-
1
)
3.9
”
–
7.1
”
9007772005 (
TK
-
KPCT43
-
2
)
6.9
”
–
10.1
”
9007773005 (
TK
-
KPCT43
-
3
)
9.8
”
–
13.0
”
Louver
Termination
9007608005
(TK-KPWL4)
Hood
Termination
9007609005
(TK-KPWH4)

Installation
11│Page
DO NOT adjust any dipswitches on the right bank for the 510 (T-D2) models.
The dark squares indicate the direction the dipswitches should be set to.
Dipswitches
HIGH-ALTITUDE INSTALLATIONS
Check the elevation where your water heater is installed. Set dipswitches shown in the table below
depending on the altitude.
Altitude 0 to 2,000 ft
(DEFAULT) 2,000 to 4,000 ft
4,000 to 6,000 ft
Over 6,000 ft
Switch No.3
OFF ON OFF Consult
our Technical
Services
Department
at 1-877-
737-2840
Switch No.4
OFF OFF ON
Altitude
0 to 2,0
00 ft
(DEFAULT) 2,000 to 4,000 ft
4,000 to 6,000 ft
Over 6,000 ft
Switch No.4
OFF ON OFF Consult
our Technical
Services
Department
at 1-877-
737-2840
Switch No.5
OFF
OFF
ON
110 (T-KJr2) and 310 (T-K4) models
510 (T
-
D2) models (Left bank of dipswitches)
110 (T
-
KJr2) and 310 (T
-
K4) models
Computer board
WARNING
510 (T
-
D2) models Co
mputer board
Left bank of dipswitches
OFF
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
OFF
ON 1 2 3 4 5 6
O
FF
ON 12 3 4 5 6
OFF
ON
1
2
3
4
5
6

Installation
12│Page
Improper venting of this appliance can result in excessive levels of carbon
monoxide which can result in severe personal injury or death.
Improper installation can cause nausea or asphyxiation, severe injury or death from
carbon monoxide and flue gases poisoning. Improper installation will void product
warranty.
When installing the vent system, all
applicable national and local codes must be
followed. If you install thimbles, fire stops or other protective devices and they
penetrate any combustible or noncombustible construction, be sure to follow all
applicable national and local codes.
VENTING INSTRUCTIONS
-General-
The water heater must be vented in accordance with the section “Venting of Equipment" of the latest
edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 7 of the
CAN/CSA B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local
building codes.
The manufacturer recommends the “T-Vent” line manufactured by TAKAGI (Refer to “T-Vent”
brochure for details). However, the following are also UL listed manufacturers: ProTech Systems Inc.
(FasNSeal), Flex-L Inc., Z-Flex Inc. (Z-Vent III), Metal-Fab Inc., and Heat-Fab Inc. (Saf-T Vent).
General rules for venting water heaters are:
Place the water heater as close as possible to the vent terminator.
The vent collar of the water heater must be fastened directly to an unobstructed vent pipe.
Do not weld the vent pipe to the water heater’s vent collar.
Do not cut the vent collar of the unit.
The vent must be easily removable from the top of the water heater for normal service and
inspection of the unit.
The water heater vent must not be connected to any other gas appliance or vent stack.
Avoid using an oversized vent pipe or using extremely long runs of the pipe.
For rooftop venting, a rain cap or other form of termination that prevents rain water from
entering into the water heater must be installed.
Do not common vent or connect any vent from other appliances to the water heater vent.
General rules for vent terminations:
Avoid locating the water heater vent terminator near any air intake devices. These fans can
pick up the exhaust flue products from the water heater and return them to the building.
This can create a health hazard.
Locate the vent terminator so that it cannot be blocked by any debris, at any time. Most
codes require that the terminator be at least 12 inches above grade, but the installer may
determine if it should be higher depending on the job site condition and applicable codes.
A proper sidewall terminator is recommended when the water heater is vented through a
sidewall.
Regarding the clearances from the exhaust terminator to the air inlet or opening, refer to
the next few pages.
CAUTION
DANGER

Installation
13│Page
-Exhaust venting-
For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor
(T-D2-IN) models
This is a Category III appliance and must be vented accordingly. The vent system must be sealed air tight.
All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed
aluminum adhesive tape having a minimum temperature rating of 350°F. For best results, a vent system
should be as short and straight as possible.
This water heater is a Category III appliance and must be vented accordingly with any 4” vent
approved for use with Category III or Special BH type gas vent.
Follow the vent pipe manufacturer’s instructions when installing the vent pipe.
Do not common vent this appliance with any other vented appliance (Do not terminate vent
into a chimney. If the vent must go through the chimney, the vent must run all the way
through the chimney with Category III approved or Special BH vent pipe).
When the horizontal vent run exceeds 5 ft., support the vent run at 3 ft. intervals with
overhead hangars.
The maximum length of exhaust vent piping must not exceed 50 ft. (deducting 5 ft. for each
elbow used in the venting system). Do not use more than 5 elbows.
Diameter
Max. No. of Elbow
Max. Vertical
and
Horizontal
(Total) Vent
Length
4
”
5
50
ft.
*For each elbow added, deduct 5 ft. from max. Vent length.
No. of
Elbows
Max.
Vertical or Horizontal Length
0
50 ft.
1
45 ft.
2
40 ft.
5
25 ft.
-Venting Illustrations-
For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) and 510 Indoor
(T-D2-IN) models
Horizontal Installation Diagram
Vertical Installation Diagram
Sidewall Vent
Terminator
Wall
Backflow Preventer*
Vertical Condensation Drain
**
For details of the optional items, refer to the Installation manual for each Optional item.
Roof
Vertical Condensation
Drain**
Roof Flashing
Rain Cap
Backflow Preventer *

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

Installation
15│Page
-Vent termination clearances-
Canada
U.S.A
Direct vent and
other than Direct
Vent
Direct vent
Other than Direct Vent
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
*
*
*
D
Vertical clearance to ventilated soffit located
above the vent terminator within a horizontal
distance of 2 feet (61cm) from the center line
of the terminator.
* * *
E
Clearance to unventilated soffit
*
*
*
F
Clearance to outside corner
*
*
*
G
Clearance to inside corner
*
*
*
H
Clearance to each side of center line extended
abo
ve meter/regulator assembly
3 feet * *
I
Clearance to service regulator vent outlet.
3 feet
*
*
J
Clearance to non
-
mechanical air supply inlet
to building or the combustion air inlet to any
other application.
3 feet 1 foot
4 feet from below or side
opening. 1 foot from
above opening.
K
Clearance to mechanical air supply inlet.
6 feet
3 feet
3 feet
L
Clearance 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.

Installation
16│Page
Please follow all
local and national codes in regards to proper termination clearances.
In the absence of such codes, the following clearances can be used as guidelines. Local
codes supersede these guidelines.
For sidewall terminations
Exhaust termination
1ft
.
1ft
.
2
ft
.
Inside
corner
For multiple sidewall exhaust
terminations (e.g. multi-unit
systems), an exhaust termination
must be at least 1 ft. away from
another exhaust termination. An
exhaust termination must also be
at least 2 ft. away from an inside
corner (if the adjacent wall is less
than 2 ft. of length, the minimum
required distance away from the
inside corner will be equal to the
length of that adjacent wall).
For direct
-
vent sidewall
terminations that use two
separate penetrations for the
intake and exhaust, distance
the intake and exhaust
terminations at least 3 ft. away
from each other, no matter the
orientation.
For multiple
-
unit, direct
-
vent sidewall
terminations that combine the intake
and exhaust into a single penetration,
space each direct-vent termination at
least 1 ft. away from each other, no
matter the orientation. A direct-vent
termination must also be at least 2 ft.
away from an inside corner (if the
adjacent wall is less than 2 ft. of
length, the minimum required
distance away from the inside corner
will be equal to the length of that
adjacent wall).
For mul
tiple
-
unit rooftop terminations (whether for standard indoor or
direct-vent installations) space all exhaust and intake terminations in
accordance with local codes. An exhaust termination must be spaced from
a wall or surface in accordance with local codes as well. In the absence of
such a code, an exhaust termination must be a horizontal distance of at
least 2 ft. away from a wall or surface.
A:
I
n accordance with local codes
For rooftop terminations
Air intake
Exhaust
termination
A
A
A
A
A
2ft.
Air intake
Exhaust
termination
Exhaust and/or d
irect
-
vent
sidewall terminations should
be at least 2 ft. away from an
opposite surface/wall. Do
not place the termination
directly in front of an
opening into a building.
2ft.
Exhaust
termination
Air supply inlet
3ft
.
3ft
.
3ft
.
Direct vent termination
1ft
.
1ft
.
Inside
corner
2
ft
.
CAUTION

Installation
17│Page
Size the gas pipe appropriately to supply the necessary volume of gas required for
the water heater using ANSI233.1/NFPA 54 in the USA or CAN/CSA B149.1 in Canada
or local codes. Otherwise, flow capabilities and output temperatures will be limited.

Check that the type of gas matches the rating plate first.
Ensure that any and all gas regulators used are operating properly and
providing gas pressures within the specified range shown below. Excess gas
inlet pressure may cause serious accidents.
Conversion of this unit from natural gas to propane or vise versa will void all
warranty. Contact your local distributor to get the correct unit for your gas
type. The manufacturer is not liable for any property and/or personal
damage resulting from gas conversions.
GAS SUPPLY AND GAS PIPE SIZING
-General-
The minimum and maximum inlet gas pressures are:
Gas type
Inlet gas pressure
Natural Gas
Min. 5.0
”
WC
–
Max. 10.5
”
WC
Propane
Min. 8.0
”
WC
–
Max. 14.0
”
WC
Gas pressure above this specified range for the water heater and/or insufficient gas volume will
adversely affect performance. These pressures are measured when the water heater is in full
operation.
Inlet gas pressure must not exceed the above maximum values; gas pressure above the specified
range will cause dangerous operating conditions and damage to the unit.
Until testing of the main gas line supply pressure is completed, ensure the gas line to the water
heater is disconnected to avoid any damage to the water heater.
-Gas connections-
1. Install a manual gas shut-off valve between the water heater and the gas supply line.
2. When the gas connections are completed, it is necessary to perform a gas leak test (see below)
either by applying soapy water to all gas fittings and observing for bubbles or by using a gas leak
detection device.
The water heater and its individual shutoff valve must be disconnected from the gas supply
piping system during any pressure testing of that system at test pressures in excess of 1/2 psi
(3.5 kPa).
The water heater must be isolated from the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 psi (3.5kPa).
3. Always purge the gas line of any debris and/or water before connecting to the gas inlet.
WARNING
NOTICE

Installation
18│Page
-Natural Gas Supply Piping-
Maximum Delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe Carrying Natural Gas of 0.60 Specific Gravity
Based on Pressure Drop of 0.5” WC
Based on Energy Content of 1,000 BTU/Cubic Ft.: The water heater requires 140 Cubic Ft./hr for the 110 (T-KJr2)
models, 190 Cubic Ft./hr for the 310 (T-K4) models, and 199 Cubic Ft./hr for the 510 (T-D2) models.
Unit: Cubic Feet per Hour
Pipe Size
Length
Diameter
10’
20’
30’
40’
50’
60’
70’
80’
90’
100’
125’
150’
200’
¾”
363
249
200
171
152
138
127
118
111
104
93
84
72
1”
684
470
377
323
286
259
239
222
208
197
174
158
135
1 ¼”
1
,
404
965
775
663
588
532
490
456
428
404
358
324
27
8
1 ½”
2
,
103
1
,
445
1
,
161
993
880
798
734
683
641
605
536
486
416
2”
4
,
050
2
,
784
2
,
235
1
,
913
1
,
696
1
,
536
1
,
413
1
,
315
1
,
234
1
,
165
1
,
033
936
801
-Propane (LP) Supply Piping-
Maximum Capacity of Propane (LP) Based on 11” WC supply pressure at a 0.5” WC pressure drop
Unit: kBTU per Hour
Pipe Size
Length
Diameter
10’
20’
30’
40’
50’
60’
70’
80’
90’
100’
125’
150’
200’
¾”
567
393
315
267
2
37
217
1
96
1
85
1
73
1
62
146
132
112
1”
1,071
732
590
504
448
409
378
346
322
307
275
252
213
1 ¼”
2
,
205
1,496
1,212
1,03
9
913
834
771
724
677
630
567
511
440
1 ½”
3
,
3
07
2
,
299
1
,
858
1,559
1,417
1,275
1,181
1,086
1,023
976
866
787
675
2”
6
,
221
4
,
331
3
,
465
2
,
992
2
,
6
4
6
2
,
394
2
,
205
2
,
047
1
,
921
1
,
811
1
,
606
1,496
1,260
For more information, please see the below.
Based on Energy Conten
t of 1
,
000BTU/Cubic Ft:
Divide each appliance’s BTU requirement by 1,000BTU to get
the appliances Cubic Ft. requirement.
Take into account the distance the appliance is from the gas
meter, look in the above gas chart to properly size the line.
For sections of the gas line supplying gas to more than one
appliance (Ex: Point A to Point B), add up the cubic ft.
requirements of the appliances that are being supplied by that
section, and size to the farthest appliance.
For Example: The section from A to B supplies gas to the
furnace, range, and dryer. Adding up the BTU requirements
and dividing by 1,000 yields a cubic ft. requirement of 220
cubic ft. of gas. The farthest appliance is the range, which is 50
ft. away from the meter. Looking at the above chart, and
under the column of 50ft., Section A to B needs to be 1” in
order to supply 220 cubic ft.
10’ Lengt
h
1” Pipe Size C
Gas Sizing Example
(Natural Gas)
10’ Length
3/4” Pipe Size
15’ Length
1/2” Pipe Size
10’ Length
1/2” Pipe Size
Furnace
120,000BTU
Water
Heater
199,000BTU
5’ Length
1-1/4” Pipe Size
Range
65,000BTU
10’ Length
3/4” Pipe Size
Drye
r
35,000BTU
15’ Length
1” Pipe Size
5’ Length
1-1/4” Pipe Size
Gas Meter
B
A

Installation
19│Page
1.
Turn off
all electric power to the water heater if serv
ice is to be performed.
2. Turn the manual gas valve located on the outside of the unit clockwise  to
the off position.
-Measuring inlet gas pressure-
The water heater cannot perform properly without sufficient inlet gas pressure. Below are instructions
on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL.
1. Shut off the manual gas valve on the supply gas line.
2. Remove the screw for the pressure port located on
the gas inlet of the water heater shown in the
diagram to the right.
3. Connect the manometer to the pressure port.
4. Re-open the manual gas valve. Check to see that
there are no gas leaks. Open some of the fixtures
that use the highest flow rate to turn on the water
heater.
5. Check the inlet gas pressure. When the water heater
is on maximum burn, the manometer should read
from 5.0” to 10.5” WC for Natural gas, from 8.0” to
14.0” WC for Propane.
Pressure port

Installation
20│Page

Do not use this water heater if any part has been submersed under water.
Immediately call a licensed professional to inspect the water heater to replace
any damaged parts.
Do not reverse the hot outlet and cold inlet connections to the water heater.
This will not properly activate the water heater.
WATER CONNECTIONS
All pipes, pipe fittings, valves and other components, including soldering materials, must be suitable for
potable water systems.
1. A manual shut off valve must be installed on the cold water inlet to the water heater between
the main water supply line and the water heater.
2. In addition, a manual shut off valve is also
recommended on the hot water outlet of the
unit. If the water heater is installed within, or
subjected to, a closed loop water system, a
thermal expansion tank must be installed.
3. Before installing the water heater, flush the
water line to remove all debris, and after
installation is complete, purge the air from the
line. Failure to do so may cause damage to the
heater.
4. There is a wire mesh filter within the cold inlet
to trap debris from entering your heater. This
will need to be cleaned periodically to maintain
optimum flow.
-Pressure relief valve-
The water heater has a high-temperature shut off switch built in as a standard safety feature (called a
Hi-Limit switch) therefore a “pressure only” relief valve is required.
This unit does not come with an approved pressure relief valve.
An approved pressure relief valve must be installed on the hot water outlet.
The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow
local code.
The discharge capacity must be at least 140,000 BTU/h for the 110 (T-KJr2) models, 190,000
BTU/h for the 310 (T-K4) models, and 199,000 BTU/h for the 510 (T-D2) models.
The pressure relief valve needs to be rated for a maximum of 150 psi.
The discharge piping for the pressure relief valve must be directed so that the hot water cannot
splash on anyone or on nearby equipment.
Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6"
from the floor. This discharge tube must allow free and complete drainage without any
restrictions.
If the pressure relief valve installed on the water heater discharges periodically, this may be due
to a defective thermal expansion tank or defective pressure relief valve.
The pressure relief valve must be manually operated periodically to check for correct operation.
No valve must be placed between the relief valve and the water heater.
Pressure
Relief Valve
Hot
outlet
Cold
inlet
Gas
inlet
As Close as
Possibl
e
CAUTION