Takagi T-D2-IN / 510, Installation Manual And Owner'S Manual

Page 1: ...g property damage personal injury or death 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 canno...

Page 2: ...OPERATION 22 OWNER S GUIDE OPERATING SAFETY 23 NORMAL OPERATION 25 General 25 Temperature Settings 25 Without Remote Controller DIP switch Settings for Temperature Flow 26 Freeze protection system 26 Maintenance and Service 27 Unit Draining and Filter Cleaning Descaling the Unit TROUBLESHOOTING 29 General 29 Error Codes 31 Single Unit Installations Easy Link System Fault Analysis of Error Codes 32...

Page 3: ...ght 13 kg 28 7 lbs 18 kg 39 6 lbs 18 kg 39 6 lbs Dimensions 520 mm H x 351 mm W x 170mm D H 20 1 2 x W 13 3 4 x D 6 3 4 520 mm H x 351 mm W x 216mm D H 20 1 2 x W 13 3 4 x D 8 1 2 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 ...

Page 4: ...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 SAFETY GUIDELINES Safety Definitions DANGER Indicates an imminently hazardous situation which if not avoid...

Page 5: ... 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 M...

Page 6: ...ranty 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...

Page 7: ...305mm 12 in 305mm 12 in 102mm 4 in 25mm 1 in 76mm 3 in T D2 IN 510 305mm 12 in 305mm 12 in 102mm 4 in 25mm 1 in 76mm 3 in 610 mm 24 inches recommended for maintenance Maintain all clearances around the water heater The diagram of clearance Included Accessories Check that these items below are included with the water heater Items Installation Manual Owner s Guide Qty 1 Communication Cable T D2 IN 5...

Page 8: ...8 F 43 C 110 F 44 C 111 F 45 C 113 F 46 C 115 F 47 C 117 F 50 C 122 F 55 C 131 F 60 C 140 F 65 C 149 F 70 C 158 F 75 C 167 F 80 C 176 F See the troubleshooting section for information on possible error codes 3 4 inches universal appliance adapter with back flow preventer and condensation drain 9008146005 2SVBFDPA04 There are three functions available for this adaptor which can be connected with th...

Page 9: ...nstead of two separate penetrations for the intake and exhaust piping The termination includes a bird screen restricting small animals pests and foreign objects from entering into the vent system This sidewall termination is available in two different sizes to cover a wide range of wall thicknesses For different wall thicknesses there are two ranges of lengths available Refer to the Flexmaster bro...

Page 10: ... edition of CSA B149 1 Natural Gas and propane Installation Code as well as applicable local building codes The manufacturer recommends the Flexmaster line However the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Metal Fab Inc and Heat Fab Inc Saf T Vent General rules for venting water heaters are Place the water heater as close as possible to the vent termination The ve...

Page 11: ...ent pipe When the horizontal vent run exceeds 1 5 m 5 ft support the vent run at 0 9 m 3 ft intervals with overhead hangers The maximum length of exhaust vent piping must not exceed 15 24 m 50 ft deducting 1 5 m 5 ft for each elbow used in the venting system Do not use more than 5 elbows Diameter Max No of Elbows Max Vertical Horizontal Total Vent Length 102 mm 4 in 5 15 24 m 50 ft For each elbow ...

Page 12: ...ashing Roof flashing Backflow preventer Recommended for freezing weather conditions 2 C 36 F and below Vertical condensation drain must be installed in accordance with local codes Horizontal Installation Diagram with Direct Vent Concentric Termination Wall Direct vent concentric termination Installation Diagram of Direct Vent Conversion Kit TK TV10 with a water heater Remove the air intake cover p...

Page 13: ...utside 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 su...

Page 14: ...If the adjacent wall is less than 610 mm 2 ft of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall 3 ft 3 ft 3 ft Air supply inlet Exhaust termination 2 ft For direct vent sidewall terminations that use two separate penetrations for the intake and exhaust distance the intake and exhaust terminations at least 915 mm 3 ft away from eac...

Page 15: ...l to or less than 1 2 psi 3 5kPa 3 Always purge the gas line of any debris inert gas and or water before connecting to the gas inlet Inert gas may be left in the line from pressure testing Note Size the gas pipe appropriately to supply the necessary volume of gas required for the water heater using CSA B149 1 Natural Gas and propane Installation Code or local codes Otherwise flow capabilities and ...

Page 16: ...and 199 000 BTU h for the T D2 IN 510 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 Follow local codes Attach the discharge tube to the pressure relief valve and run the end of the tube to within 152 mm 6 in from the floor This discharge tu...

Page 17: ...r of the remote controller and then attach the two fork terminals to connector base of the backside of the remote controller with two screws Make sure the terminals are firmly fixed 9 Pull the remote s wires through the hole at the bottom of the water heater s casing 10 Properly attach the remote s wires to the remote controller terminals on the computer board No polarity Do NOT jump or short circ...

Page 18: ...er A communication cable gray color comes with each T D2 IN 510 model You can manifold from 2 to 4 units without the need for a Multi Unit Controller A 4 unit system has full automatic modulation between 11 000 BTU h and 796 000 BTU h Gas In Cold In Hot Out CAUTION The Easy Link System is limited up to 4 units If you connect more than 4 units only the first 4 units will work as a part of the Easy ...

Page 19: ...rature settings on ALL the units are set to the same settings Otherwise the units will not operate properly If a remote controller is used the temperature on all the units in the system will automatically be set to the same temperature that is set on the remote C Examples of incorrect settings and or connections CASE 1 Unless you change DIP switch No 1 of the PARENT unit to the ON position the sys...

Page 20: ... 3 4 5 6 PARENT 1 2 Connectors Right bank of Dipswitches OFF ON 1 2 3 4 5 6 PARENT 1 2 PARENT unit CHILD 1 unit Wrong connection Remote controller Prohibited Remote controller connected to incorrect unit APPLICATIONS Space Heating Applications WARNING In order to purge air in water pipes within a closed loop system an air vent and air separator should be installed in the system Required circulatio...

Page 21: ... hours for 60 seconds Wire to product approved pump The T D2 IN 510 built in Pump control may also be used to control pump Heating Coil used with air handler Cold water supply 4 gas exhaust vent Discharge must comply with local and state codes Cannot be common vented with other appliances An approved temperature and pressure relied valve tie to location approved by local codes and Must meet BTU ra...

Page 22: ...he GAS and WATER LINES to remove any air pockets or debris Do not use this water heater if any part has been submersed under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts WARNING IF YOU SMELL GAS Do not try to start the water heater Do not touch any electric switches do not use any phone in your building Immediately call your gas...

Page 23: ...ice technician Forced or attempted repair may result in a fire or explosion D Do not use this water heater if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts OPERATING INSTRUCTIONS 1 STOP Read the safety information above or in the Owner s Manual 2 Turn off all electric power to the water heater 3 Do not att...

Page 24: ...ts will be stored Read and follow water heater warnings and instructions If owner s manual is missing contact the manufacturer WARNING The outlet hot water temperature of the water heater is factory set at 50 C 122 F Use this heater at your own risk The set outlet water temperature can cause severe burns instantly or death from scalds Test the water before bathing or showering Do not leave childre...

Page 25: ...140 F T K4 IN 310 T D2 IN 510 40 C 104 F 45 C 113 F 50 C 122 F 60 C 140 F For detailed DIP switch settings for each temperature refer to the charts on the right The temperature has been preset at the factory to 50 C 122 F If temperatures other than the ones listed above are required the remote controller can provide several more temperature options Refer to pg 8 for a list of available temperature...

Page 26: ...Jr2 IN 110 L hr 681 681 L min 11 4 11 4 GPH US 180 180 GPM US 3 3 T K4 IN 310 L hr 931 931 L min 15 5 15 5 GPH US 246 246 GPM US 4 1 4 1 T D2 IN 510 L hr 954 954 L min 15 9 15 9 GPH US 252 252 GPM US 4 2 4 2 Freeze protection system This unit comes equipped with heating blocks to protect it against damages associated with freezing For this freeze protection system to operate there has to be electr...

Page 27: ...a licensed technician Unit Draining and Filter Cleaning Drain plug Small Water valve Gas valve Drain plug with Filter Large 1 Close the manual gas shutoff valve 2 Turn off power to the unit and wait a couple of seconds Turn on again 3 Wait 30 seconds and then turn off power to the unit yet again 4 Close the water shutoff valve 5 Open all hot water taps in the house When the residual water flow has...

Page 28: ...and D b Relieve pressure within the water heater by temporarily opening up the pressure relief valve c Drain the water heater and connect hoses pump to the drain ports of the isolation valves Outlet of the pump to valve B cold side and another hose from valve A hot side to the bucket 4 PUMP and DESCALE a Fill the bucket with 5 gallons of diluted solution Dilution ratio depends on the cleaning desc...

Page 29: ...5 Is the unit frozen Is there enough gas in the tank cylinder For Propane models Is it plumbed back with reverse plumbing If your water heater is used in a dual purpose installation with a check valve is the check valve defective Check for cross plumbing If your installation is Multi Unit is Easy Link set up correctly pg 18 to 20 The hot water turns cold and stays cold Is the flow rate enough to k...

Page 30: ...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 When ON green LED is lit An ERROR code is displayed Please see pg 30 to 33 EASY LINK SYSTEM T D2 IN 510 model only How are the unit numbers assigned For an Easy Link System the Parent unit is always labeled 1 and all other su...

Page 31: ... its entirety T D2 IN 510 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 TM RE30 is installed 321 will display on the screen in its entirety Easy Link System For the T D2 IN 510 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...

Page 32: ...rt 103 especially if the water heater has been installed in a contaminated area Check the DIP switches match gas type of unit Check the manifold pressure at Max and Min Check the proportional gas valve hose Three Times 11 111 Ignition 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 boar...

Page 33: ...signs of vent corrosion Check gas valve contacts and gas valve wire harness connections for signs of rust or corrosion Four Times 61 611 Fan 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 A N A 651 Flow adjustment valve fault Inspect the flow adjustment va...

Page 34: ... the water heater is installed and match DIP switches 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 103 especially if the water heater has been in...

Page 35: ... IN 110 Temperature remote controller T KJr2 IN 110 T K4 IN 310 TK RE02 T K4 IN 310 T D2 IN 510 T D2 IN 510 TM RE30 002 050 702 052 007 052 052 001 004 051 720 704 721 052 003 052 004 001 052 003 002 050 702 052 007 052 051 720 704 721 722 722 ...

Page 36: ...ote Fan motor section of this model does NOT have 116 or 117 like T K4 IN 310 T D2 IN 510 101 709 111 065 108 712 107 110 106 109 706 053 121 053 703 053 704 705 053 105 104 401 059 052 112 059 103 113 114 150 708 115 713 058 102 119 151 118 061 055 711 120 701 053 053 053 067 062 052 714 712 053 055 ...

Page 37: ...05 120 053 711 053 714 062 055 121 703 053 704 705 401 104 105 052 053 112 113 114 708 067 066 055 062 053 A A 706 053 A 150 061 119 151 118 052 101 709 111 101 709 111 701 053 053 712 102 053 T K4 IN 310 T D2 IN 510 T K4 IN 310 T D2 IN 510 Burner assembly Power control section Manifold assembly Fan motor section ...

Page 38: ...710 708 103 402 402 407 408 719 Water way assembly T KJr2 IN 110 463 413 453 414 412 063 451 B C 401 414 452 450 Computer board assembly T D2 IN 510 707 710 708 715 103 717 718 701 709 719 716 Water way assembly T K4 IN 310 414 463 413 452 450 453 B C 401 414 451 412 063 ...

Page 39: ...510 403 462 458 460 456 454 411 459 463 413 452 450 453 451 414 B C 401 414 412 063 Bypass section Water outlet section 456 460 409 455 410 454 408 064 C Water inlet section 402 461 458 052 415 064 460 456 404 406 405 454 407 457 B ...

Page 40: ...KJr2 IN 110 EX00S Igniter rod for T K4 IN 310 T D2 IN 510 EKK0F Item Description Part 110 Rod holder for T KJr2 IN 110 EX00U Rod holder for T K4 IN 310 T D2 IN 510 EKK32 111 Rod cap EKN61 112 Burner damper for T KJr2 IN 110 EK430 Burner damper for T K4 IN 310 T D2 IN 510 EK2AJ 113 Manifold gasket A EKK2Y 114 Manifold gasket B EKK2K 115 Fan damper for T KJr2 IN 110 EK416 Fan damper for T K4 IN 310 ...

Page 41: ...d wire for T KJr2 IN 110 EK431 Flame rod wire for T K4 IN 310 EKK3L Flame rod wire for T D2 IN 510 EKK11 710 EH IG wire for T KJr2 IN 110 T K4 IN 310 EKK3R EH IG wire for T D2 IN 510 EKK0Z 711 Igniter EKN74 712 High voltage igniter cable EKK2M 713 Freeze protection thermostat EKJ59 714 Proportional gas valve wire for T KJr2 IN 110 T K4 IN 310 EKK58 Proportional gas valve wire for T D2 IN 510 EKK12...

Page 42: ... Various Inlet Water Temperature Set Temp T D2 IN 510 Model When the set temperature is 55 C 131 F or higher maximum flow rate is limited to 8 0 GPM Output temperatue vs GPM Max 6 6 GPM with Various Inlet Water Temperature Set Temp Output Hot Water GPM Incoming Temp Output temperature vs GPM Max 10 0 GPM with Various Inlet Water Temperature Set Temp Incoming Temp Output Hot Water GPM ...

Page 43: ... location only within the United States or Canada and it is not transferable THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USAGE FOR THE PRODUCT S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED IN THE TABLE ABOVE ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND IN NO EVENT WHETHER AS A RESULT...

Page 44: ...e product s specified range Water incorrect water pipe sizing water pressures that fall outside the product s specified range recirculation flow rates that fall outside the product s specified range air removal and or lack of proper methods of air removal in a closed loop circulation system See installation manual for details Electric supply power voltages that fall outside the product s specified...