American Water Heater NonCondensing Outdoor Natural Gas GT110NE user manual

							11    Page
2. Direct-vent conversion kit: 9007667005
   (TK-TV10)
This kit can be used to convert the water 
heater from a single vent system to a direct-
vent (double vent) (or sealed combustion) 
system with a 3 in. (76 mm) intake.  Install 
this conversion kit in accordance with the 
installation instructions and any applicable 
codes.
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.
4. 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.
1. 4” Backflow preventer and F-F adaptor: 
    9007996005
There are two functions available for this adaptor, 
which can be connected with the water heater and 
NovaVent venting line and 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 adaptor in accordance 
with the installation instructions that are packaged 
with the adaptor and any applicable codes.
5. Sidewall vent terminator (Hood) and Wall thimble kit:9008004005 /9008005005
Installation
Installation Manual
Covering wall thicknessesPart#
Terminator Hood9007999005
Wall Thimble 4 - 7 in.9008345005
Wall Thimble 5 - 10 in.9008346005
Termination + Thimble 4 - 7 in.9008004005
Termination + Thimble 5 - 10 in.9008005005
3. Pipe cover: 9007670005 (TK-PC01) and
                        9007671005 (TK-PCJr2)
They are used when venting out through the wall.  These terminations are special stainless steel 
vents for gas appliances and are UL listed as Category II, III and IV.  For different wall thicknesses, 
there are two ranges of lengths available. (Refer to the NovaVent brochure for details.)  Install these 
vent terminations in accordance with their installation instructions and any applicable local codes.
Wall ThimbleTerminator Hood
Used when terminating direct-vent (sealed combustion) systems, with 
indoor models that require a 3 in. (76 mm) intake and a 4 in. (102 mm) 
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 two 
different sizes, to cover a wide range of wall thicknesses.
Covering wall thicknessesPart#
5.0 – 10.0 in. (127 - 254 mm)9008147005 
 12.0 – 18.0 in. (305 - 457 mm)9008148005
6. Direct-vent concentric termination:
For different wall thicknesses, there are two ranges of lengths available. (Refer to the NovaVent 
brochure for details.)  
						

							12  Page
WARNING
DO NOT adjust any DIPswitches on the upper bank for the 510 (T-D2) 
model.
NOTE: The dark squares indicate the direction the DIPswitches should be set to.
Installation
Installation Manual
110 (T-KJr2) and 310 (T-K4) models
Altitude0 to 2,000 ft. 
(DEFAULT)2,000 to 4,000 ft.4,000 to 6,000 ft.
Switch No. 3OFFONOFF
Switch No. 4OFFOFFON
ON8
7
6
5
4
3
2
1ON 8
7
6
5
4
3
2
1ON 8
7
6
5
4
3
2
1
510 (T-D2) model (Left bank of dipswitches)
Altitude0 to 2,000 ft. 
(DEFAULT)2,000 to 4,000 ft.4,000 to 6,000 ft.
Switch No. 4OFFONOFF
Switch No. 5OFFOFFON
ON 6
5
4
3
2
1ON 6
5
4
3
2
1ON 6
5
4
3
2
1
110 (T-KJr2) and 310 (T-K4) models 
Computer board
DIPswitches
510 (T-D2) model
 Computer board
DIPswitches	(Left	bank)
Installation altitude
The maximum certified or allowable installed altitude is 6,000 ft. for indoor 
and outdoor models.
Check the elevation where your water heater is installed.  Set DIPswitches shown in the table 
below depending on the altitude.
HIGH-ALTITUDE INSTALLATIONS  
						

							13  Page
VENTING INSTRUCTIONS
-General-
The water heater must be vented in accordance with the section “Venting of Equipment" of the current 
edition	of	the	 National	 Fuel	Gas	Code:	 ANSI	Z223.1/NFPA	 54	in	the	 United	 States	and/or	 Section	 8	of	 the		
B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local building codes.
The manufacturer recommends the NovaVent 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 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 termination 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 termination so that it cannot be blocked by any debris, at any time.  Most codes 
require that the termination must be at least 12 in. (305 mm) above grade, but the installer may 
determine if it should be higher depending on the job site condition and applicable codes.
•	A proper sidewall termination is recommended when the water heater is vented through a 
sidewall.
•	Regarding the clearances from the exhaust termination to the air inlet or opening, refer to the 
next few pages.
•	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.
DANGER
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.CAUTION
Installation
Installation Manual  
						

							14   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 airtight. 
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 (177 °C).  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 in. (102 
mm) 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. (1.5 m), support the vent run at 3 ft. (0.9 m) intervals 
with overhead hangers.
•	When the vent run exceeds 5 ft. (1.5 m), a condensate drain is recommended.  It should be 
installed as close to the heater as possible.
•	The maximum length of exhaust vent piping must not exceed 50 ft. (15.2 m) (deducting 5 ft. (1.5 
m) for each elbow used in the venting system). Do not use more than 5 elbows.
DiameterMax. No. of ElbowsMax. Vertical and Horizontal (Total) Vent Length
4 in. (102 mm)550 ft. (15.2 m )
*For each elbow added, deduct 5 ft. (1.5m) from max. vent length.
No. of ElbowsMax. Vertical or Horizontal Vent Length
050 ft. (15.2 m)
145 ft. (13.7 m)
240 ft. (12.2 m)
335 ft. (10.7 m)
430 ft. (9.1 m)
525 ft. (7.6 m)
Excludes elbow termination, rain caps, or the 4 in. (102 mm) Concentric termination
Installation
Installation Manual  
						

							15  Page
Venting Illustrations-
For the 110 Indoor (T-KJr2-IN), 310 Indoor (T-K4-IN), and 510 Indoor (T-D2-IN) models
For details of the optional items, refer to the Installation manual for each Optional item.
Horizontal Installation with 
Direct-vent concentric termination
Wall
Direct-vent concentric termination
Installation of Direct-vent conversion kit 
(TK-TV10) with a water heater
Installation
Installation Manual
*Backflow preventer (Recommended for freezing weather conditions: 36 °F (2 °C) and below).
**Vertical condensation drain must be installed in accordance with local codes.
See	the	picture	below	for	detailed	connection	instructions	to	Direct-vent	conversion	kit.
Vertical Installation 
(With direct-venting)
Roof
Vertical	condensation	drain**
Backflow	preventer* Fire stop
Roof	flashing
Rain cap
Horizontal Installation
(With direct-venting)
Sidewall vent termination
Backflow	preventer*
Vertical	condensation	drain**
Wall
Hanger
Hanger
Horizontal Installation
Hanger
Wall
Sidewall vent termination
Vertical condensation drain**
Backflowpreventer*
Vertical Installation 
Backflow preventer*
Rain cap
Roof
Vertical condensation drain**
Roof flashing
Fire stop
 Air intake cover plate 
 
 
 
Remove the air intake 
cover plate to attach
the air intake port from 
the Direct-vent 
conversion kit (TK-TV10)
into there.
Cover the louver of the 
water heater with the plate 
provided in the Direct-vent 
conversion kit to complete 
the conversion to sealed 
combustion.  
						

							16  Page
-Vent termination clearances-
CanadaU.S.A
Direct-vent and other 
than Direct-vent
Direct- 
vent
Other than  
Direct-vent
AClearance above grade, veranda, porch, deck, or 
balcony1 foot1 foot1 foot
B Clearance to window or door that may be opened3 feet1 foot 
4 feet from below or 
side opening. 1 foot 
from above opening.
CClearance 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
***
EClearance to unventilated soffit***
FClearance to outside corner***
GClearance to inside corner***
HClearance to each side of center line extended 
above meter/regulator assembly 3 feet**
IClearance to service regulator vent outlet3 feet**
J
Clearance to non-mechanical air supply inlet to 
building or the combustion air inlet to any other 
application
3 feet1 foot
4 feet from below or 
side opening. 1 foot 
from above opening.
KClearance to mechanical air supply inlet.6 feet3 feet3 feet
LClearance above paved sidewalk or paved driveway  
located on public property7 feet*7 feet
MClearance under veranda, porch deck, or balcony1 foot**
   *For	clearances	 not	specified	 in	ANSI	 Z223.1	 /	NFPA	 54	(US)	 or	B149.1	 (Canada),	 please	use	clearances	 in	accor-
dance with local installation codes and the requirements of the gas supplier.
INSIDE CORNER DETAIL
V
Gas meter / regulator
V
V
V
V
V
V
V
V
V
X
X
X
Vent terminal
Air supply inlet
Area where is not permittedG
A
E
D
B
L
C
F
B
B
B
BA
J
OPERABLEFIXEDCLOSED
B
H
M
K
OPERABLE
FIXEDCLOSED
I
Installation
Installation Manual  
						

							17  Page
-For sidewall terminations-
-For rooftop terminations-
For multiple sidewall exhaust terminations (e.g. multi-
unit systems), an exhaust termination must be at least 
1 ft. (305mm) away from another exhaust termination.  
An exhaust termination must also be at least 2 ft. (610 
mm) away from an inside corner.  (If the adjacent wall is 
less than 2 ft. (610 mm) of length, the minimum required 
distance away from the inside corner will be equal to the 
length of that adjacent wall.)
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. (305 mm) 
away from each other, no matter the orientation.  A direct-
vent termination must also be at least 2 ft. (610 mm) away 
from an inside corner. (If the adjacent wall is less than 2 ft. 
(610 mm) 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. (915 mm) away 
from each other, no 
matter the orientation.
For multiple-unit rooftop terminations (whether for standard 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. (610 mm) away from a wall or surface.
Exhaust and/or 
direct-vent sidewall 
terminations should 
be at least 2 ft. (610 
mm) away from an 
opposite surface/
wall.  Do not place 
the termination 
directly in front of 
an opening into a 
building.
Please follow all local and national codes in regards to proper termination 
clearances.  In the absence of such codes, the above clearances can be used as 
guidelines.  Local codes supersede these guidelines.CAUTION
A: In accordance with local codes
Air intake
A
Exhaust	termination
A
A
A
A
Air intake
		2ft.(610 mm) min.
Exhaust termination
 3 ft.(915 mm) min.
Air supply inlet
3 ft. (915 mm)min.
3 ft. (915 mm)min.
Exhaust termination
Installation
Installation Manual
Exhaust terminationInsidecorner
 1 ft.(305 mm) min.
 2 ft.(610 mm) min.1 ft. (305 mm)min.
Combinedintake andexhausttermination
Insidecorner
 1 ft. (305 mm) min.
 2 ft.(610 mm) min.1 ft. (305 mm)       min.
Exhausttermination2 ft. (610 mm)  min.  
						

							18   Page
GAS SUPPLY AND GAS PIPE SIZING
-General-
•	The minimum and maximum inlet gas pressures are:
•	Inlet gas pressures that fall outside the range of values listed above may adversely affect the 
performance of the water heater.  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 shutoff 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 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 (3.5 kPa).
3. Always purge the gas line of any debris, air, and/or water before connecting to the gas inlet.
Size  the gas pipe appropriately to supply the necessary volume of gas required for 
the	 water	 heater	 using	ANSI	Z223.1/NFPA	 54	in	the	 USA	 or	B149.1	 in	Canada	 or	
local codes.  Otherwise, flow capabilities and output temperatures will be limited.
NOTICE
Gas typeInlet gas pressure
Natural GasMin. 4.0” W.C. – Max. 10.5” W.C.
PropaneMin. 8.0” W.C. – Max. 14.0” W.C.
•	Check that the type of gas matches the rating plate first.
•	Ensure that any and all gas regulators used are operating properly and 
providing gas pressures within the specified range shown below.  Excess gas 
inlet pressure may cause serious accidents.
•	Conversion of this unit from natural gas to propane or vice 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.
CAUTION
Installation
Installation Manual  
						

							19    Page
-Natural Gas Supply Piping-
Maximum delivery capacity of cubic feet of gas per hour of IPS pipe carrying Natural Gas with 0.60 specific gravity 
Based on pressure drop of 0.5" W.C.
Based on energy content of 1,000 BTU/Cubic ft.: The water heater requires 140 Cubic ft./hr for the 110 (T-KJr2) 
model, 190 Cubic ft./hr for the 310 (T-K4) model, and 199 Cubic ft./hr for the 510 (T-D2) model.
-Propane (LP) Supply Piping-
Maximum Capacity of Propane (LP) Based on 11” W.C. supply pressure at a 0.5” W.C. pressure drop
Based on Energy Content of 1,000 BTU/Cubic ft:
Divide each appliance's BTU/h requirement 
by 1,000 BTU/ft3 to get the appliances ft3/h 
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. per hour requirements 
of the appliances that are being supplied by that 
section, and size to the farthest appliance.
Installation
Installation Manual
Pipe SizeLength
Diameter10'20'30'40'50'60'70'80'90'100'125'150'200'
3/4"360247199170151137126117110104928371
1"678466374320284257237220207195173157134
1 1/4"1,390957768657583528486452424400355322275
1 1/2"2,0901,4301,150985873791728677635600532482412
2"4,0202,7602,2201,9001,6801,5201,4001,3001,2201,1601,020928794
Unit: Cubic feet per hour
Pipe SizeLength
Diameter10'20'30'40'50'60'70'80'90'100'125'150'200'
3/4"567393315267237217196185173162146132112
1"1,071732590504448409378346322307275252213
1 1/4"2,2051,4961,2121,039913834771724677630567511440
1 1/2"3,3072,2991,8581,5591,4171,2751,1811,0861,023976866787675
2"6,2214,3313,4652,9922,6462,3942,2052,0471,9211,8111,6061,4961,260
Unit: kBTU per Hour
For more information, please see the below.
     Water     heater199,000 BTU/hDryer 35,000 BTU/h
Gas meterFurnace120,000 BTU/h      Range65,000 BTU/h
AB
C
10' Length1/2" Pipe size
15' Length1/2" Pipe size
15' Length1" Pipe size
10' Length3/4" Pipe size
10' Length1" Pipe size5' Length1-1/4" Pipe size
10' Length3/4" Pipe size5' Length1-1/4" Pipe size
Gas  sizing  example    
    (Natural Gas)
For Example: The section from A to B supplies gas to the furnace, range and dryer.  Adding up the BTU/h requirements and 
dividing by 1,000 yields a cubic ft. per hour requirement of 220 cubic ft. of gas per hour.  The farthest appliance is the range, 
which is 50 ft. away from the meter.  Looking at the above chart, and under the column of 50 ft., Section A to B needs to 
be 1" in order to supply 220 cubic ft.  
						

							20  Page
-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.
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 
or code approved device to handle thermal expansion must be installed.
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.
1. Shut off the manual gas valve on the gas supply line.
2. Remove the screw for the pressure port located on the gas 
inlet of the water heater shown in the diagram on 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 and minimum burn, the manometer should read 
from 4.0" to 10.5" W.C. for Natural gas, from 8.0" to 14.0" 
W.C. for Propane.
3. Before installing the water heater, flush 
the water line to remove all debris, and 
after installation is complete, purge 
the air from the line.  Failure to do so 
may cause damage to the heater.
4. There is a wire mesh filter within 
the cold inlet to trap debris from 
entering your heater.  This will need 
to be cleaned periodically to maintain 
optimum flow. (Refer to p. 40.)
Pressure port
Cold inletHot outlet
Gas inlet
As Close as 
Possible
Pressure relief valve
Installation
Installation Manual
•	Do not use this appliance if any part has been under water.  Immediately contact 
a qualified installer or service agency to replace a flooded water heater.  Do not 
attempt to repair the unit!  It must be replaced!WARNING