A.O. Smith ATI-310-P Technical Documents



‐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‐hea ting

*

*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

Models

・

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………………………………………………………………………………………………………………………..…..…

WarningforInstallations……………………………………………………………………………………………………

…

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

8

9



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: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 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

.



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moto r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.

 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aretobeonlyinstalledoutdoor.

SafetyGuidelines

5│Page



 Watertemperatures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/N FPA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he ater.Pleaseensure:

 Yourwaterheaterwillhaveenoughcombustibleairand

properventilation.

 Locateyourheaterwherewaterleakagewillnotdamagesurround ing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con sult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/C SA 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”se ction.



3. Themanifoldgaspre s sure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remo ved

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.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in stalling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dire ct‐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

uired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 hard ness 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



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feet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.intheUSAofanyairintake

orbuilding

opening, and within 3 ft. in Canada of any air

intake or building opening. (Outdoor models

only)(Refertop.15)



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.

Prohibited

FORYOURSAFETY,READBEFOREINSTALLATION:

3ft.

Installation

9│Page



CLEARANCES



Model Top Bottom Front Back Sides

110Indoor*(T‐KJr2‐IN)* 12” 12” 24” 1” 2“

110Outdoor(T‐KJr2‐OS) 36” 12” 24” 1” 2“



Model Top Bottom Front Back Sides

310Indoor*(T‐K4‐IN)* 12” 12” 24” 1” 2“

310Outdoor(T‐K4‐OS) 36” 12” 24” 1” 2“



Model Top Bottom Front Back Sides

510Indoor*(T‐D2‐IN)* 12” 12” 24” 1” 2“

510Outdoor(T‐D2‐OS) 36” 12” 24” 1” 2“

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

INCLUDEDACCESSORIES

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

1. InstallationManualand

Owner’sGuide



TemperatureRemoteController

3.CommunicationCable

510(T‐D2)modelsonly



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)

✔ ✔

   

9007674005

(TK‐RB02)



✔



✔



✔

9007608005

(TK‐KPWL4)

9007609005

(TK‐KPWH4)

✔



✔



✔



9007680005

(TK‐KPCT43)

✔



✔



✔



Qty:1

Maintain all clearances around

thewaterheater.

Bottom

Side

Top

Side

Front

Back

Seethetablebelow.

Qty:1

Installation

10│Page

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

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.

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heater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term in ation s are usedwhenventingoutthrough thewalland are

compatiblewith theT‐Ventpipesystem.

Theseterm inationsarespecialstainlesssteelventsforgasappliancesandare

ULlistedasCategoryII,IIIand IV.Therear etwotyp es of termination s:the

Louverterminat ionandtheHo od

termination .Fo rdifferentwallthi cknesses, 

thereare tworangesoflengthsavailable(refertotheventingbrochurefor

details).

Installtheseventt er min ationsinaccordancewithth ei r 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

OFF

Consult

our Technical

Services

Department

at1‐877‐

737‐2840

SwitchNo.4 OFF

OFF

ON



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

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Com

uterboard

Leftbankofdipswitches

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Cod e : 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 det ails). However, the  following are also UL listed manufacturers: ProTech Syste ms  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.

Roo

VerticalCondensation

Drain**

RoofFlashing

RainCap

BackflowPreventer*

Installation

14│Page



*BackflowPreventer (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

Roo

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

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

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.

2ft.

Inside

corner

Formultiplesidewallexhaust

terminations(e.g.multi‐unit

systems),anexhausttermination

mustbeatleast1ft.awayfrom

anotherexhausttermination.An

exhaustterminationmustalsobe

atleast2ft.awayfromaninside

corner(iftheadjacentwallisless

than2ft.oflength,theminimum



requireddistanceawayfromthe

insidecornerwillbeequaltothe

lengthofthatadjacentwall).

Fordirect‐ventsidewall

terminationsthatusetwo

separatepenetrationsforthe

intakeandexhaust,distance

theintakeandexhaust

terminationsatleast3ft.away

fromeachother,nomatterthe

orientation.

Formultiple‐unit,direct‐ventsidewall

terminationsthatcombinetheintake

andexhaustintoasinglepenetration,

spaceeachdirect‐ventterminationat

least1ft.awayfromeachother,no

mattertheorientation.Adirect‐vent

terminationmustalsobeatleast2ft.

awayfromaninsidecorner(if

the

adjacentwallislessthan2ft.of

length,theminimumrequired

distanceawayfromtheinsidecorner

willbeequaltothelengthofthat

adjacentwall).

Formultiple‐unitrooftopterminations(whetherforstandardindooror

direct‐ventinstallations)spaceallexhaustandintaketerminationsin

accordance

withlocalcodes.Anexhaustterminationmustbespacedfrom

awallorsurfaceinaccordance withlocalcodes aswell.Intheabsenceof

suchacode,anexhaustterminationmustbeahorizontaldistanceofat

least2ft.awayfromawallorsurface.

A:Inaccordancewith

localcodes

Forrooftopterminations



Airintake

Exhausttermination

A

A

2ft.

Airintake

Exhaust

termination

Exhaustand/ordirect‐vent

sidewallterminationsshould

beatleast2ft.awayfroman

oppositesurface/wall.Do

notplacethetermination

directlyinfrontofan

openingintoabuilding.

2ft.

Exhaust

termination

Airsupplyinlet

3ft.

Directventtermination

1ft.

Inside

corner

2ft.

CAUTION

Installation

17│Page

Sizethegaspipeappropriatelytosupplythenecessaryvolumeofgasrequiredfor

thewaterheaterusingANSI233.1/NFPA54intheUSAorCAN/CSAB149.1inCanada

orlocalcodes.Otherwise,flowcapabilitiesandoutputtemperatureswillbelimited.

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

 Ensure that any and all gas regulators used are operating properly and

providing gas pressures within the specified range shown be low. Excess gas

inletpressuremaycauseseriousaccidents.

 Conversion of thisunit from naturalgas to propane orvise versa will void all

warranty. Contact your local distributor to get the correct unit for your gas

type.The manufacturer is not liable for any property and/or personal

damageresultingfromgasconversions.



GASSUPPLYANDGASPIPESIZING

‐General‐



 Theminimumandmaximuminletgaspressuresare:

Gastype Inletgaspressure

NaturalGas Min.5.0”WC–Max.10.5”WC

Propane Min.8.0”WC–Max.14.0”WC

 Gas pressure above this specified range for the water heater and/or insufficient gas volume will

adversely affect performance.These pressures are measured when the water heater is in full

operation.

 Inlet gas pressuremust not exceedthe above maximumvalues; gas pressureabove the specified

rangewillcausedangerous

operatingconditionsanddamagetotheunit.

 Until testing of the main gas line supply pressure is completed, ensure the gas line to the water

heaterisdisconnectedtoavoidanydamagetothewaterheater.



‐Gasconnections‐

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

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

eitherbyapplyingsoapywatertoallgasfittingsandobserving for bubblesorbyusing

agasleak

detectiondevice.

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

pipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2psi

(3.5kPa).

 Thewaterheatermustbeisolatedfromthegassupplypipingsystembyclosingitsindividual

manual shutoff valve during any pressure testing of the gas supply piping system at test

pressuresequaltoorlessthan1/2psi(3.5kPa).

3. Alwayspurgethegaslineofanydebrisand/orwater

beforeconnectingtothegasinlet.



WARNING

NOTICE

Installation

18│Page



‐NaturalGasSupplyPiping‐

MaximumDeliveryCapacityofCubicFeetofGasperHourofIPSPipeCarryingNaturalGasof0.60SpecificGravity

BasedonPressureDropof0.5”WC



BasedonEnergyContentof1,000BTU/CubicFt.:Thewaterheaterrequires140CubicFt./hrforthe110(T‐KJr2)

models,190CubicFt./hrforthe310(T‐K4)models,and199CubicFt./hrforthe510(T‐D2)models.

Unit:CubicFeetperHour

PipeSize Length

Diameter 10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’

¾” 363 249 200 171 152 138 127 118 111 104 93 84 72

1” 684 470 377 323 286 259 239 222 208 197 174 158 135

1¼” 1,404 965 775 663 588 532 490 456 428 404 358 324 278

1½” 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 416

2” 4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936 801

‐Propane(LP)SupplyPiping‐

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

Unit:kBTUperHour

PipeSize

Length

Diameter

10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’

¾” 567 393 315 267 237 217 196 185 173 162 146 132 112

1” 1,071 732 590 504 448 409 378 346 322 307 275 252 213

1¼” 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 440

1½” 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 675

2” 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 1,260

Formoreinformation,pleaseseethebelow.



BasedonEnergyContent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’Length

1”PipeSize

GasSizingExample

(NaturalGas)

10’Length

3/4”PipeSize

15’Length

1/2”PipeSize

10’Length

1/2”PipeSize

Furnace

120,000BTU

Water

Heater

199,000BTU

5’Length

1‐1/4”PipeSize

Range

65,000BTU

10’Length

3/4”PipeSize

Dryer

35,000BTU

15’Length

1”PipeSize

5’Length

1‐1/4”PipeSize

GasMeter

Installation

19│Page

1. Turnoffallelectricpowertothewaterheaterifservice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he ater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. The re 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

Possible

CAUTION

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