American Water Heater NonCondensing Outdoor Natural Gas GT110NE user manual

							41  Page
WATER CONNECTIONS
All pipes, pipe fittings, valves and other components, including soldering materials, must be suitable for 
potable water systems.
1. A manual shutoff valve must be installed on the cold water inlet to the water heater between the main 
water supply line and the water heater.
2. In addition, a manual shutoff valve is also recommended on the hot water outlet of the unit.  If the 
water heater is installed within, or subjected to, a closed loop water system, a thermal expansion tank 
must be installed.
-Pressure relief valve-
The water heater has a high-temperature shutoff 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 
codes.
•	The discharge capacity must be at least 140,000 BTU/h for the 110U (T-KJr2U) models, 190,000 BTU/h 
for the 310U (T-K4U) models, and 199,000 BTU/h for the 510U (T-D2U) models.
•	The pressure relief valve needs to be rated for a maximum of 150 psi (1 MPa).
•	The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash 
on anyone or on nearby equipment.

5.	 Pull 	the	 remote’s	 wires	through	 the	hole	 at	the	 bottom	 of	the	 water	 heater’s	 casing.
6.	 Properly	 attach	the	remote’s	 wires	to	the	 remote	 controller	 terminal	on	the	 computer	 board
      (No polarity).
TROUBLESHOOTING
GENERAL
PROBLEMSOLUTIONS
TEMPERATURE and AMOUNT OF HOT WATER
It takes long time to 
get hot water at the 
fixtures.
•	The time it takes to deliver hot water from the water heater to your 
fixtures depends on the length of piping between the two.  The longer 
the distance or the bigger the pipes, the longer it will take to get hot 
water.
•	If you would like to receive hot water to your fixtures quicker, you may 
want to consider a hot water recirculation system. (p. 28)
The water is not hot 
enough.
•	Compare the flow and temperature.  See the charts on p. 54.
•	Check cross plumbing between cold water lines and hot water lines.
•	Is the gas supply valve fully open? (p. 30)
•	Is the gas line sized properly? (p. 18-19)
•	Is the gas supply pressure enough? (p. 20)
•	Is the set temperature set too low? (p. 34-38)
The water is too hot.•	Is the set temperature set too high? (p. 34-38)
The hot water is not 
available when a 
fixture is opened.
•	Make sure the unit has 120 VAC, 60 Hz power supply.
•	If you are using the remote controller, is the power button turned on?
•	Is the gas supply valve fully open? (p.30)
•	Is the water supply valve fully open? (p. 30)
•	Is the filter on cold water inlet clean? (p. 40)
•	Is the hot water fixture sufficiently open to draw at least 0.5 GPM 
through the water heater? (p. 34)
•	Is the unit frozen? (p. 39)
•	Is there enough gas in the tank / cylinder? ( For Propane models)
The hot water turns 
cold and stays cold.
•	Is the flow rate enough to keep the water heater running? (p. 34)
•	If there is a recirculation system installed, does the recirculation line have 
enough check valves? (p. 28)
•	Is the gas supply valve fully open? (p. 30)
•	Is the filter on cold water inlet clean? (p. 40)
•	Are the fixtures clean of debris and obstructions?
•	Check if the flow rate is too low. (p. 34)
Fluctuation in hot 
water temperature
•	Is the filter on cold water inlet clean? (p. 40)
•	Is the gas line sized properly? (p. 19)
•	Is the supply gas pressure sufficient? (p. 20)
•	Check for cross connection between cold water lines and hot water lines.
Troubleshooting
Owner's Guide  
						

							42  Page
PROBLEMSOLUTIONS
WATER HEATER
Unit does not ignite 
when water goes 
through the unit.
•	Is the flow rate over 0.5 GPM? (p. 34)
•	Check for the filter on cold water inlet. (p. 40)
•	Check for reverse connection and cross connection.
•	If you use the remote controller, is the power button turned on?
•	Check if the inlet temperature is too high.
The fan motor is 
still spinning after 
operation has stopped.
•	This is normal.  After operation has stopped, the fan motor keeps 
running from 15 to 70 seconds in order to re-ignite quickly, as well 
as purge all the exhaust gas out of the flue.
Unit sounds abnormal 
while in operation.
•	Contact the manufacturer at 1-877-737-2840.
Remote controller
Remote controller does 
not display anything 
when the power 
button is turned on.
•	Make sure the unit is supplied with power.
•	Make sure the connection to the unit is correct. (p. 22)
-9007603005 (TM-RE30) only-
If the green LED lights up, the 
remote controller has been 
turned ON.  When the unit has not
operated for five minutes or more, 
the display turns off to conserve
energy.
An ERROR code is 
displayed.
•	Please see p. 43-45.
EASY-LINK SYSTEM
510 (T-D2) model only
How are the unit 
numbers assigned?
•	For an Easy-Link System, the Parent unit is always labeled #1 and all 
other subsequent Child units are numbered randomly.
•	To check which numbers are assigned to which Child units, push the 
button on the computer board of any Child unit as shown below. 
The unit number will be displayed on the 7-Seg LED.  (Refer to p. 
25.)
Troubleshooting
Owner's Guide
When ON, green LED is lit.
Button to checkunit numbers
7-Seg LED  
						

							43  Page
ERROR CODES
-General-
•	The water heaters have self-diagnostic function for safety and convenience when troubleshooting.
•	If there is a problem with the installation or the unit, the 510 (T-D2) model will display a numerical 
error code on the 7-Seg LED on the computer board, and the 110 (T-KJr2) and 310 (T-K4) models will 
display a blinking red LED on the computer board.  If a remote controller is installed, the error codes 
will be displayed on the remote controller.
•	Consult with the table on the following page for the description of each error code.
-Single unit Installations-
Example: If your unit has the “321” error code (which signifies an inlet thermistor failure)
• 110 (T-KJr2) and 310 (T-K4) models: The red LED on the computer board will be blinking two times.
• If the remote controller 9007666005 (TK-RE02) is installed: It will display “32” on the screen in its entirety.
• 510 (T-D2) model: The 7-Seg LED on the computer board will display “3”…”2”…”1” in that order one 
digit at a time and continually repeat.
• If the remote controller 9007603005 (TM-RE30) is installed:  It will display “321” on the screen in its entirety.
-Easy-Link System for the 510 (T-D2) model only-
Error codes will be displayed differently with units installed within an Easy-Link System, not only to show 
what the error code is, but to also indicate which unit within the system has the error code.  Below is a 
sample of how the same error code is displayed in an Easy-Link System.
Example: If Unit #2 has the “321” error code (inlet thermistor failure)
•	Remote controller 9007603005 (TM-RE30): It will display “232” and on the display.  The first “2” 
indicates that Unit #2 has the error. The “32” indicates the first two digits of the “321” error code.
•	
Troubleshooting
Owner's Guide
• Parent unit: It will display 
“3”…”2”…”1”…”0”…”2” one digit at a 
time on the 7-Seg LED.  The first 3 
numbers indicate the error code. The last 
two numbers indicate that Unit #2 has 
the error code.
• Unit #2: It will display “3”…”2”…”1 on 
the 7-Seg LED, just like in the Single Unit 
example.
• Unit #3 & #4: These units will not display 
anything, as the error code does not per-
tain to them.
Red LED
blinks to indicate an error.
Error code on the 9007666005(TK-RE02)
110 (T-KJr2) and 310 (T-K4) models
7-Seg LED
Error code on the computer board
Error code on the 9007603005(TM-RE30)
510 (T-D2) model
Unit #1 PARENTUnit #2 CHILDUnit #3 CHILDUnit #4 CHILD
9007603005(TM-RE30)
“3”..”2”..”1”..”0”..”2”“3”..”2”..”1"  
						

							44  Page
-Fault Analysis of Error Codes-
If the error code is displayed on the computer board of the water heater or remote controller, please 
check the following.  After checking, consult with the manufacturer.
Troubleshooting
Owner's Guide
110 (T-KJr2) and
310 (T-K4)
510
(T-D2)Malfunction
descriptionDiagnosisRed
 LEDRemoteRemote
7 Seg LED
One Time03031Incorrect 
DIPswitch setting
•	Check the DIPswitch settings on the PCB (Part #701).
Five 
Times
10101Warning for the 
“991” error code 
•	Check the gas type of the water heater.
•	Check if there is any blockage in the intake air and/or 
exhaust.
•	If the water heater is installed as a direct-vent system, 
check whether there is enough distance between the 
intake air terminal and the exhaust terminal.
•	Check the altitude/elevation of area of where the water 
heater is installed.
•	Check if there is grease and/or dirt in the burner (Part #101) 
and the fan motor (Part #103), especially if the water heater 
has been installed in a contaminated area.
Three 
Times
11111Ignition failure•	Check if the Hi-limit switch (Part #412) is properly 
functioning.
•	Check for connection/breakage of wires (Part #413, 708, 709, 
710, 712), burn marks on the computer board (Part #701), 
and/or soot on the flame rod (Part #108).
•	Check if there is a buzzing spark ignition sound coming 
from the burner (Part #101) when water heater prepares 
for combustion.
•	Listen for the double “clunk” sound coming from gas 
valve assembly (Part #102) when water heater goes into 
combustion.
•	Check if there is leaking from heat exchanger (Part #401).
Three 
Times
12121Loss of flame•	Check if the Hi-limit switch (Part #412) is properly 
functioning.
•	Check for connection/breakage of wires (Part #413, 708, 
709, 710, 712), burn marks on the computer board (Part 
#701), and/or soot on the flame rod (Part #108).
•	Check if there is leaking from heat exchanger (Part #401).
Two 
Times
31311Outlet 
thermistor 
failure 
•	Check for connection/breakage of wires and/or debris on 
thermistor (Part #407, 408, 411, 716).
Two 
Times
32321Inlet thermistor 
failure
N/AN/A331Mixing thermis-
tor failure  
						

							45  Page
Troubleshooting
Owner's Guide
110 (T-KJr2) and
310 (T-K4)
510
(T-D2)Malfunction
descriptionDiagnosisRed
 LEDRemoteRemote
7 Seg LED
Two 
Times
39391Air-fuel ratio 
rod failure
•	Check for connection/breakage of wires (Part #709) and/
or soot on the AFR rod (Part #108).
N/AN/A441Flow sensor 
failure (Easy-Link 
System only)
•	Check for connection/breakage of wires and/or debris on 
the flow sensor impeller (Part #402, 717).
Six Times51510Abnormal gas 
solenoid valve
•	Check for connection/breakage of wires (Part #708) and/
or burn marks on the computer board (Part #701).
Six Times55N/AAbnormal main 
gas valve
•	Check for connection/breakage of wires (Part #708) and/
or burn marks on the computer board (Part #701).
Four 
Times
61611Fan motor fault•	Check for connection/breakage of wires, dust buildup 
in the fan motor (Part #103) and/or burn marks on the 
computer board (Part #701).
•	Check for frozen/corrosion of connectors (Part #103).
N/AN/A651Flow adjustment 
valve fault (Easy-
Link System only)
•	Inspect the flow adjustment valve (Part #402), for  
connection/breakage of wires (Part #718), locked motor 
drive due to scale buildup, and/or water leakage.
One Time70701Computer board  
fault
•	Check for connection/breakage of wires (Part #714) and/
or burn marks on the computer board (Part #701).
•	Check the power supply of the water heater.
Six Times72721False flame 
detection
•	For indoor models, check if condensate drain is installed 
on the vent collar of the water heater.
•	Check if there is leaking from heat exchanger (Part #401).
N/A74741Miscommuni-
cation between
water heater 
and remote
controller
•	Check the model type of the remote controller.
•	Inspect the connections between the water heater and 
remote controller.
•	Check the power supply of the water heater.
N/AN/A761Miscommuni-
cation in Easy-
Link System
•	Check if the connections between the parent unit and the 
child units are correct. Refer to p. 24-27.
Five Times99991Imperfect 
combustion
•	Check the gas type of the water heater.
•	Inspect the environment around the water heater. 
Determine how long the unit has been installed.
•	Check the altitude/elevation of the area of where the 
water heater is installed.
•	Check if there is any blockage in the intake air and/or 
exhaust. 
•	If the water heater is installed as a direct-vent system, 
check whether there is enough distance between the 
intake air terminal and the exhaust terminal. 
•	Check if there is grease and/or dirt in the burner (Part 
#101) and the fan motor (Part #104), especially if the 
water heater has been installed in a contaminated area.  
						

							46  Page
Case assembly
Temperature remote controller
Components Diagram
Owner's Guide
COMPONENTS DIAGRAM
722
110 (T-KJr2) and
310 (T-K4) models
722
510 (T-D2) model
110 Indoor (T-KJr2-IN)110 Outdoor (T-KJr2-OS)
052004
001
720
704
721
052 702
003
052
052
007
002
051
050 052
004
001
704 006
053
005
066
056
052
053
702
052
007
002 050
052004
001
704 006
053
005
066
056
052
053
702
052
007
002050
052
004
001
720
704
721
052
702
052 052
003
007
002 051
050
310 and 510 Indoor
(T-K4-IN and T-D2-IN)
310 and 510 Outdoor
(T-K4-OS and T-D2-OS)  
						

							47  Page
Components Diagram
Owner's Guide
101
709 111 712
110
065 108
107
106
109 105
104
059
052
053
706 121
703
053
704
705
053 053
059103
112
113
114 708
150
102119151
118
052
062
055
714
053 711
712 053
120 053
067
053
701
713058
115
061
055 401
101
709 111
Burner assembly
Manifold
Assembly
110 Indoor (T-KJr2-IN) only
110 (T-KJr2) model
Burner assembly  
						

							48  Page
Components Diagram
Owner's Guide
Burner assembly
310 (T-K4) and 510 (T-D2) models
A
A
A
105 104
106
107
108
065
110109
401
101
709 111 712
053
052116 053
117 103054
121
706
703
053
704
705
053 121
706
703
053
704
705
053
701
053
053 067
120
053
712 711
053 062
714 066
062
055 052
118
151
119
102
061 708
114
113
150
103
117 053 060
059
116
401
713 058 057
115
101
709 111
053112
055
Burner assembly
Power control
section
310 (T-K4)
model 510 (T-D2)
model
Manifold
AssemblyFan motor section for indoor models
Fan motor section for outdoor models
310 Indoor (T-K4-IN)
510 Indoor (T-D2-IN)
310 Outdoor (T-K4-OS)
510 Outdoor (T-D2-OS)  
						

							49    Page
Components Diagram
Owner's Guide
Water Way assembly
Bypass 
section
Computer board assembly
701707
710
708
715
716
709
719
718
717
103
719 408 407
402
402
714
709 707
701
710
708 103
110 (T-KJr2) and
310 (T-K4) models
510 (T-D2) model
Water outlet sectionWater inlet sectionExhaust section (Outdoor model)
110 (T-KJr2) model310 (T-K4) model510 (T-D2) model
B
C
B
B
C
C
C B
453
414
401
454
411
459
414
451 063
412450
452 413
463
403
462
458
460456
402
461
458 052
415
064
460
456
404
406
457
405
454
407
456
460409
454
408 064
455
410451
414
401
414
063 412
450 453
463
413
452
401
153
154
053
152 451
414
401
414
063 412450
452 413
453
463  
						

							50   Page
Parts List
Owner's Guide
PARTS LIST
Item #Description
Part #
110, 310 and 
510  models
T-KJr2, T-K4 and 
T-D2 models
001Case assembly for 110 Indoor (T-KJr2-IN)
for 110 Outdoor (T-KJr2-OS)
for 310 and 510 Indoor (T-K4-IN and T-D2-IN)
for 310 and 510 Outdoor (T-K4-OS and T-D2-OS)
319143-159
319143-172
319143-151
319143-211
EK415
EK432
EK402
EKK41
002Front cover for 110 Indoor (T-KJr2-IN)
for 110 Outdoor (T-KJr2-OS)
for 310 Indoor (T-K4-IN)
for 310 Outdoor (T-K4-OS)
for 510 Indoor (T-D2-IN)
for 510 Outdoor (T-D2-OS)
319143-163
319143-173
319143-152
319143-371
319143-174
319143-175
EK419
EK433
EK403
EK409
EK434
EK435
003
004
005
006
007
Air blockage plate for 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN) 
and 510 Indoor (T-D2-IN)
Bracket
Junction box
Junction box inner plate
Back guard panel for 110 (T-KJr2) model
Back guard panel for 310 (T-K4) and 510 (T-D2) models
319143-150
319143-184
319143-014
319143-128
319143-338
319143-221
EK401
EKJ09
EKJ64
EKJ66
EX00M
EKK5H
050
051
052
053
Screw M4×12 (W/Washer)
Screw M4×10 (W/Washer)
Screw M4×10 (Coated)
Screw M4x10
319143-025
319143-325
319143-026
319143-060
EW000
EW001
EW002
EW003
054
055
056
057
Hex head screw M4×12 (W/Washer)
Hex head screw M4x8
Screw M4x10
Screw M3x6 SUS3
319143-326
319143-063
319143-372
319143-330
EW004
EW005
EX014
EW00B
058
059
060
061
062
063
064
065
066
067
Screw M3x10
Pan screw M4x12 (W/Washer)
Pan	screw	 M4x10	 FEZN
Tap	tight	 screw	 M4x12	 FEZN
Pan screw M4x10
Screw M3x6
Screw M4x6
Pan screw M4x8
Nylon clamp
Wire clamp 60
319143-327
319143-061
319143-332
319143-201
319143-062
319143-087
319143-328
319143-059
319143-143
319143-048
EW008
EW00H
EW024
EKK31
EW006
EW00A
EW009
EW00D
EC00X
EM167
101Burner assembly for 110 (T-KJr2) model
Burner assembly for 310 (T-K4) and 510 (T-D2) models 
319143-161
319143-030
EK417
EKH5W
102Manifold with gas valve assembly LP for 110 (T-KJr2) model
Manifold with gas valve assembly LP for 310 (T-K4) and 510 (T-D2) models
Manifold with gas valve assembly NA for 110 (T-KJr2) model
Manifold with gas valve assembly NA for 310 (T-K4) and 510 (T-D2) models
319143-169
319143-046
319143-165
319143-368
EK429
EKH6T
EK421
EKK5K
103Fan motor for 110 (T-KJr2) model
Fan motor for 310 Indoor (T-K4-IN) and 510 Indoor (T-D2-IN)
Fan motor for 310 Outdoor (T-K4-OS) and 510 Outdoor (T-D2-OS)
319143-347
319143-043
319143-217
EX02E
EKK25
EKK54
104Burner holder gasket for 110 (T-KJr2) model
Burner holder gasket for 310 (T-K4) and 510 (T-D2) models
319143-341
319143-032
EX00V
EKK0G
105
106
107
Burner gasket
Burner window
Rod holder gasket
319143-031
319143-033
319143-034
EKK2X
EKK2V
EKK2W