American Water Heater NonCondensing Outdoor Natural Gas GT110NE user manual

							
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Models
037B0003110 Outdoor 
037B0003310 
037B0003510 
037B0003110 
037B0003310 
037B0003510 
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03F103ED03EC0003037E00640003
0175017D011A011E016F0003 017D0176016F01C7  
						

							2   Page
CONTENTS
Installation Manual
　SPECIFICATIONS ........................................................................\
..................................................4
　INTRODUCTION ........................................................................\
..................................................5
　SAFETY GUIDELINES ...................................................................................................................\
.6
　INSTALLATION ........................................................................\
.....................................................7
　　General.....................................................................................................................................7
　　Warning for installations..........................................................................................................9
　　Clearances.......................................................................\
.......................................................10
　　Included accessories..........................................................................\
....................................10
　　Optional items............................................................................................................. . . . .......10
　　High-altitude installations........................................................................\
..............................12
　　Venting instructions...............................................................................................................13
　　Gas supply and gas pipe sizing...............................................................................................18
　　Water connections................................................................................................................20
　　Electrical connections...........................................................................................\
.................21
　　Remote controller connections............................................................................................22
　　Pump control connections............................................................................................23
　　Easy-Link System........................................................................................\
............................24
　APPLICATIONS......................................................................................................................\
......28
　INITIAL OPERATION..............................................................................................................\
.....30
Owner's Guide
　OPERATING SAFETY ..................................................................................................................\
32
　NORMAL OPERATION ...............................................................................................................34
　　General........................................................................................................................\
..........34
　　Temperature settings-with remote controller-.....................................................................34
　　Temperature settings on the PCB......................................................................................38
　　Flow........................................................................\
...............................................................39
　　Freeze protection system.......................................................................................................39
　　Maintenance and service.......................................................................................................40
　　Unit draining and filter cleaning............................................................................................40
　TROUBLESHOOTING...................................................................................................................41
　　General...................................................................................................................................41
　　Error codes................................................................................................................\
............43
　COMPONENTS DIAGRAM...........................................................................................................46
　PARTS LIST..................................................................................................................................50
　OUTPUT TEMPERATURE CHART.............................................................................\
.......................54
　LIMITED WARRANTY..................................................................................................................55
Contents  
						

							3    Page
Installation 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.  
						

							4   Page
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) BTU/hMin.: 19,500 
 
Max.: 140,000 Min.: 11,000 
 
Max.: 190,000 Min.: 11,000 
 
Max.: 199,000
Propane Gas Input 
(Operating Range) BTU/hMin.: 19,500 
 
Max.: 140,000 Min.: 11,000 
 
Max.: 190,000 Min.: 11,000 
 
Max.: 199,000
Gas Connection 3/4" NPT
Water Connections 3/4" NPT
Water Pressure* psi 15 - 150*
Natural gas
Inlet Pressure " W.C.
Min. 4.0
Max. 10.5
Propane gas
Inlet Pressure " W.C.
Min. 8.0
Max. 14.0
Manifold 
Pressure** Natural" W.C.
2.02.52.02.5 2.02.5
Propane" W.C. 2.53.13.74.0 3.74.5
Weight lbs.33 3839
Dimensions inch
H 20.5 x W 13.8 x D 6.7 H 20.5 x W 13.8 x D 8.5
Ignition Electric Ignition
Electric
SupplyVAC / Hz 120 / 60
Consumption
OperationW / A73.1 / 0.61 87.6 / 0.7389.8 / 0.75
Standby W / A6.2 / 0.05 6.2 / 0.056.2 / 0.05
Freeze-
Protection W / A
111 / 0.93 111 / 0.93111 / 0.93
SPECIFICATIONS
*The maximum flow may need water pressure equal to or above 40 psi.
** The Manifold Pressure is the factory setting and generally should not need adjustment .
NOTE:
•	 Check	the 	r ating 	pla te 	t o 	ensur e 	this 	pr oduct 	ma tches 	y our 	specific ations.
•	The manufacturer reserves the right to discontinue, or change at any time, specifications or designs 
without notice and without incurring obligations.
Specifications
Installation Manual  
						

							5  Page
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 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN), and 510 Indoor (T-D2-IN) models are only 
to be installed indoors (direct-vent convertible).  The 110 Outdoor (T-KJr2-OS), 310 Outdoor 
(T-K4-OS), and 510 Outdoor (T-D2-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 inletThermistor
Burners
Flow sensor
Introduction
Installation Manual  
						

							6  Page
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	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 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 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 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. 39 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
Installation Manual
Indicates an imminently hazardous situation which, if not avoided, will result in 
death or serious injury.
DANGER  
						

							7  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	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. 10 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. 16.)
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. 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 in. (76 mm) 
combustible air supply pipe.  The intake pipe must be sealed airtight.  Air supply pipe can be 
made of ABS, PVC (solid core), CPVC (solid core), Polypropylene, corrugated stainless steel, or 
Category lll / IV stainless steel.
•	Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenylsulfone) in non-
metallic venting systems is prohibited.  Covering non-metallic vent pipe and fittings with thermal 
insulation is prohibited.
•	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.  The 110 Outdoor (T-KJr2-OS), 310 Outdoor (T-K4-OS), and 510 Outdoor (T-D2-OS) models are
      only to be installed outdoors and only in the area with mild, temperate climates.
Installation
Installation Manual  
						

							8  Page
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 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
Installation
Installation Manual  
						

							9  Page
WARNING FOR INSTALLATIONS
FOR YOUR SAFETY, READ BEFORE INSTALLATION:
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. 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. 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.
 
Prohibited
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.
Prohibited
1 ft. (305 mm) USA3 ft. (914 mm) Canada1 ft. (305 mm) USA3 ft. (914 mm) Canada
1 ft. (305 mm) USA3 ft. (914 mm) Canada3 ft.
(915 mm)
Installation
Installation Manual
Water heater vent terminator must be at least 2 
ft. (610 mm) away from an inside corner for both 
outdoor installation and direct-vent installation.
Inside
Corner
2 ft.
(610 mm)  
						

							10   Page
To p
Back
Bottom
Side
Side
FrontMaintain all clearances around 
the water heater.
CLEARANCES
ModelTo pBottomFrontBackSides
110 Indoor* (T-KJr2-IN)*
310 Indoor* (T-K4-IN)*
510 Indoor* (T-D2-IN)*
12 in.
(305 mm)
12 in.
(305 mm)
4 in.**
(102 mm)
1 in.
(25 mm)
3 in.
(76 mm)
110 Outdoor (T-KJr2-OS)
310 Outdoor (T-K4-OS)
510 Outdoor (T-D2-OS)
36 in.
(914 mm)
12 in.
(305 mm)
24 in.
(610 mm)
1 in.
(25 mm)
3 in.
(76 mm)
*Standard indoor installations and direct-vent indoor installations have the same clearances.
OPTIONAL ITEMS
No.Model
110Indoor(T-KJr2-IN)
110 Outdoor(T-KJr2-OS)
310Indoor(T-K4-IN)
310Outdoor(T-K4-OS)
510Indoor(T-D2-IN)
510Outdoor(T-D2-OS)
19007996005
(4” Backflow preventer and F-F adaptor)✓✓✓
29007667005
(Direct-vent conversion kit)✓✓✓
39007670005(Pipe cover)✓✓✓✓
9007671005 (Pipe cover)✓✓
49007674005 (Recess box)✓✓✓
59008004005/9008005005 (Termination & Wall thimble kit)✓✓✓
69008147005/9008148005
(Direct-vent concentric Termination)✓✓✓
Installation
Installation Manual
INCLUDED ACCESSORIES
  1. Installation manual 
    and Owner’s guide
2. Temperature 
  remote controller
  3. Communication cable
 510 (T-D2) model only
Qty: 1
Check that these items below are included with the water heater.
Qty: 1
Qty: 1or
TK-RE02TM-RE30
Model110 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)✓✓
**24 inches recommended for maintenance