American Water Heater NonCondensing Outdoor Natural Gas GT110NE user manual

							21  Page
-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 110 (T-KJr2) model, 190,000 BTU/h for 
the 310 (T-K4) model, and 199,000 BTU/h for the 510 (T-D2) model.
•	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.
•	Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in. 
(152 mm) 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.
ELECTRICAL CONNECTIONS
All indoor models come with a power plug instead of a junction box.  The following procedure is for 
outdoor models only.
1. The water heater must be electrically grounded.  Do not attach the ground wire to either the gas or 
the water piping.
2. The water heater requires 120 VAC, 60 Hz electrical power supply that is properly grounded.
•	A proper disconnect (i.e. on/off switch, power plug, etc.) controlling the main power to the water 
heater must be provided for service reasons. (Must comply with local codes.)
•	Connect the power supply to the water heater exactly as shown in the wiring diagram.
3. A green screw is provided in the junction box to ground the connection.
4. Can be hardwired or wired to a plug-in.
5. The use of a surge protector is recommended in order to protect the unit from power surges.
Follow the electrical code requirements of the local authority having jurisdiction. 
In the absence of such requirements, follow the current edition of the National 
Electrical Code ANSI/NFPA 70 in the U.S. or the current edition of CSA C22.1 
Canadian Electrical Code Part 1 in CanadaWARNING
When servicing or replacing parts within the water heater, label all wires prior to 
disconnection to facilitate an easy and error-free reconnection.  Wiring errors can 
cause improper and dangerous operation.  Verify proper operation after servicing.CAUTION
Outdoor models only
Bottom	view	of	water	heaterView of electrical 
connections	of	water	heater
Ground
Connect
power supply
120VAC, 60HzGreen screw
Indoor models only
Installation
Installation Manual  
						

							22  Page
REMOTE CONTROLLER CONNECTIONS

1.  Disconnect power supply from the water heater.
2.  Take off the water heater’s front cover.
3.  Wires used for the remote controller connection must be:
•	Minimum 20 AWG wire (No polarity)
•	9007666005 (TK-RE02) for 110 (T-KJr2) & 310 (T-K4) models
Maximum 150 ft. long
9007603005 (TM-RE30) for 510 (T-D2) model
Maximum 400 ft. long
* For detailed connection to the remote controller, refer to the instructions that are packaged with 
the remote controller.
4.  Pick location of install for the remote controller.
5.  Cut enough two pair wire.
6.  Crimp on supplied fork connectors.
7.  Locate the remote controller terminals, pictured below (located around the lower right-hand side
of the computer board).
8.  Open the plastic cover 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 termi-
nals 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-circuit the wires, or the computer board will be damaged.
11.  Replace the plastic computer board cover and then replace the front cover securely.
Installation
Installation Manual
Connect to these terminals
9007666005(TK-RE02)
Front of  remote controller
110 (T-KJr2) & 310 (T-K4) models
Back of  remote
Connect to these terminals
510 (T-D2) model9007603005(TM-RE30)
Front of  remote controllerBack of  remote
Connect to these terminalsConnect to these terminals  
						

							23    Page
Installation
Installation Manual
PUMP CONTROL CONNECTIONS
Available on the 510 (T-D2) model only
The 510 (T-D2) model water heater can be used to control a recirculation pump.  Proper pump control 
helps to preserve the life of the system and saves energy as well.
The water heater pump control port is a “normally-open dry contact”, and therefore needs additional 
components to properly control a recirculation pump, such as a relay.  To control a recirculation pump, 
connect the pump to a relay and the relay to the “Pump connector” in the water heater as shown in the 
diagram below.  (In an Easy-Link System, connect the pump ONLY to the “PARENT” unit.) The pump is to 
be connected using suitable relays shown in the diagram below.
Please make sure the relays are properly rated for the recirculation pump.
Using the water heater’s internal thermistors as a temperature control, the recirculation pump will only 
turn on when recirculation is needed.
CAUTION
In an Easy-Link System, the pump must be connected to the “Pump 
connector” in the only “PARENT” unit using an suitable relay.  If the 
pump is connected to any of the “CHILD” units, the pump will not 
work.
Connect to this “Pump connector”
Recirculation 
pump
Power supply for relay
Power supply for pump120 VAC220 VAC etc
120 VAC220 VAC etc for relay
Thermal relay for	additional	safety
These components are NOT included with the water heater and are external to the unit.  They must be acquired separately.  
						

							24   Page
EASY-LINK SYSTEM
(Available on the 510 (T-D2) model only)
The 510 (T-D2) model water heaters can be connected with other allowable heaters (see the 
table below) with communication cables to work as a multiple-unit manifold system.
•	The Easy-Link System allows up to 4 units to manifold together.
•	A communication cable (gray color) comes with each 510 (T-D2) 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.
 
-Easy-Link Connection Procedures-
1. Make sure the power to the heaters are off.
2. Verify the DIPswitch set temperatures of all units within the system.  Every single water heater must 
be set to the same set temperature.  If an TM-RE30 remote controller is used, it should be installed to 
the “PARENT” unit.  The remote will set the temperature for the entire system.
3. Select one unit to be the “PARENT” unit.  The “PARENT” unit should be one of the end units.
4. “PARENT” unit:
 Locate the two banks of DIPswitches to the right of the 7-seg. LED on the computer board of the unit 
that you select to be the “PARENT” unit.  Change DIPswitch No. 1 on the right bank of DIPswitches 
to the ON position.  See the computer board diagram as shown in the next page.  Do not change any 
DIPswitches on any of the “CHILD” units.
Gas In
Hot Out
Cold In
•	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-Link System.  The other additional units 
will not work.
•	Only listed models on the table above can be combined together as an Easy-Link 
System.  These models cannot be combined together with other models not listed 
on the table above.
CAUTION
-General-
Easy-Link connection
with allowable heaters
T-K3
T-K3-Pro
510 model (T-D2-IN / T-D2-OS)
510U model (T-D2U-IN / T-D2U-OS)*
510U model (T-D3U-IN / T-D3U-OS)*
200 series
Installation
Installation Manual
*If the 510U (T-D2U) model or 510U (T-D3U) model is incorporated in an Easy-Link Sytem with the other 
models in the table above, the DIP switch of all the 510U (T-D2U) and the 510U (T-D3U) computer 
boards must be changed.  Please refer to the manual of 510U (T-D2U) model or 510U (T-D3U) model 
on Easy-Link System for more detail.  
						

							25    Page
5. Between the “PARENT” and the “CHILD-1” units:
 Connect the “PARENT” connector of the “PARENT” unit to the “1” connector of the “CHILD-1” unit 
using the supplied linking cable.
6. Between the “CHILD-1” and the “CHILD-2” units:
 Connect the “2” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit.
7. Between the “CHILD-2” and the “CHILD-3” units:
 Connect the “2” connector of the “CHILD-2” unit to the “1” connector of the “CHILD-3” unit.
8. Verify that all cables are connected like the diagram below (B).
9. Turn on power to the “PARENT” unit.  The 7-seg LED will display “1”.
 Turn on “CHILD-1”.  When the 7-seg LED displays a number, turn on “CHILD-2”.
 When the 7-seg LED displays a number, turn on “CHILD-3”.
 Make sure the 7-seg LED of all the units' computer boards display the unit #.  The numbering system 
automatically allocates the unit # to each water heater in the Easy-Link System, in accordance with the 
table below.
(A) 510 (T-D2) model Computer board
(B) Basic diagram of connections between the Easy-Link System units
NOTE: The dark squares indicate the direction the DIPswitches should be set to.
Type of unitUnit # of easy-link
Parent1
Child2, 3 or 4
Installation
Installation Manual
Communication cable
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT 
unit
CHILD-1 
unit
CHILD-2 
unit
CHILD-3 
unit
Easy-Link System “Online” LED
Left	bank	of	DIPswitches
7-Seg. LED
Right bank of DIPswitches
Easy-Link connectors are next to the computer board.
To change the DIPswitch 
settings for the Easy-Link 
System, locate the bank of 
DIPswitches to the right of 
the 7-seg LED. 
Do not adjust the left bank 
of DIPswitches.  
						

							26   Page
(C) Examples of incorrect settings and /or connections
      CASE 1: Wrong DIPswitch setting on the "PARENT" unit
      CASE 2: Wrong connections between the "PARENT" unit and the 
                   "CHILD-1" unit
Installation
Installation Manual
•	Unless you change DIPswitch No. 1 of the “PARENT” unit to the “ON” position, the system will 
not work as an Easy-Link System.  The units will operate as individual units.
Communication cable
Connectors
Right bank of Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT unitCHILD-1 unit
Wrong	setting
Prohibited
Wrong DIPswitch 
setting on the 
“PARENT” unit
•	A remote controller is not required for an Easy-Link System, however, it does 
provide for more temperature options and ease of maintenance.
•	If running the Easy-Link System without a remote controller, please make 
sure the temperature 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.
NOTICE
Communication cable
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT unitCHILD-1 unit
Wrong	connection
Communication cable
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT unitCHILD-1 unit
Wrong	connection
OR
•	If you connect the “1" (or "2") connector of the “PARENT” unit to the “PARENT" (or "1") 
connector of the “CHILD-1” unit, the system will not work as an Easy-Link System.  The units will 
operate as individual units.
Prohibited
Wrong connections between the "PARENT" unit and the "CHILD-1" unit        
						

							27  Page
CASE 3: Wrong connections between the "CHILD-1" unit and the "CHILD-2" unit
CASE 4: Remote controller connected to incorrect unit
Connecting two “PARENT” connectors together from two separate units may 
damage the computer board.  The communication cable has a female end and 
a male end so it’s impossible to have a PARENT-to-PARENT connection with the 
communication cable.  Do not splice or modify connectors.WARNING
Installation
Installation Manual
•	If you connect the “PARENT” connector of the “CHILD-1” unit to the “1” connector of the 
“CHILD-2” unit, the “CHILD-2” unit will operate as an individual unit, and will not be part of the 
Easy-Link System.
Prohibited
Wrong connections between 
the "CHILD-1" unit and the 
"CHILD-2" unitCommunication cable
Connectors
Right bank of Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT unitCHILD-1 unitCHILD-2 unit
Wrong	connection
Communication cable
Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2Connectors
Right bank of 
Dipswitches
OFF ON
12
3 4
56
PARENT
1
2
PARENT unitCHILD-1 unit
Wrong connection
•	If a remote controller is used, it has to be connected to the “PARENT” unit. If the remote 
controller is connected to a “CHILD” unit, it will only control that particular individual “CHILD” 
unit and will not control the Easy-Link System as a whole.
Prohibited
Remote controller 
connected to 
incorrect unit      
						

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APPLICATIONS
-Space-Heating Applications-
-Recirculation-
*The recirculation pump is to be controlled by:
-Dual-set aquastat (recommended w/timer) or -"Pump Control Connections" 510 (T-D2) model only. (Refer to p.23.)
*The recirculation pump is to provide no less than 2 GPM and no more than 4 GPM through
  each activated unit in the system.
•	This water heater is suitable for combination water (potable) heating and 
space heating and not suitable for space heating applications only.
•	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 circulation 
flow rates are labeled next to each application diagram.  These flow rate 
requirements must be followed.
•	Toxic chemicals used in boiler treatments such as alcohol, glycerol and glycol 
groups must not be introduced into the system if the system incorporates an 
open-loop potable water system.
•	The water heater can be used to supply potable water and space heating and 
shall not be connected to any heating system or component(s) previously 
used with non-potable water where any chemicals were added to the water 
heating appliances.
•	When the system requires water for space heating at temperatures higher 
than required for other uses, a means such as a mixing valve shall be installed 
to temper the water for those other uses in order to reduce scald hazard 
potential.
•	Water temperature over 125 °F (52 °C) can cause severe burns instantly or 
death from scalding.
WARNING
Air vent
Hot	water	outlet	to	fixtures
Recirculation
pumpAirseparator
SCheck valve
Check valve
Y-Strainer
Cold water inlet
Expansion tank
Gas supply
Ball valves
Unions
Hot water outletCold water inletGas inlet
Pressure relief valve
This is a concept drawing only.
Applications
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•	Priority Control Devices such as a flow switch, an Aquastat or other 
electronic controller can be used to prioritize the domestic water system over 
the heating system.
•	Follow all local codes, or in the absence of local codes, follow the most recent 
edition	of	the	 National	 Standard	 Code,	ANSI	Z21.10.3.
•	This illustration is a concept design only.  The reference to the 1/8th hole 
in check is only for the State of Massachusetts.  There are a wide variety 
of variations to the application of controls and equipment presented.  
Designers must add all necessary safety and auxiliary equipment to conform 
to code requirements and design practice.  For more details, contact the 
manufacturer.
NOTICE
120 VAC switch or outlet
Hot water outlet
Unions
T-handle	gas	shutoff	valve
Check valve
Electronically controlled pump	timer.		Activates	every 6 hours for 60 seconds.  Wire to product approved pump
Heating Coil(used with air-handler)
Cold water supply
4-inch gas exhaust vent (Discharge must comply with local and state codes.)  Cannot be common vented with other appliances
An approved temperature and pressure relief	valve.	Tie	to	location	approved	by	local	codes	and	must	meet	BTU	rating	of	water heater model used
Check valve will have 1/8-inch hole drilling in	clapper	optional
Atmosphericvacuum breaker
Shutoff 	  valve
Pressure gauge
Apply correct thermal expansion tank-size per	application
Shutoff	valves
Shutoff	valves
Check valves
Cold water inletGas inletWater filterDrain plugThermostatic	mixing	valveHot water supply and return to heating	coil
System installed with reverse acting	aquastat	to	shut	off	fan.	Suggested but not required by 248 CMR
50’-0” maximum distance from water heater to fan coil.(Developed length) Not including coil	in	heating	unit
NSF-61 product approved pump
Automatic	tempering	device	must be installed below the top of the water heater as per manufacturer’s recommendations
Piping loop between water heater and fan coil shall be in compliance with 248 CMR
Tempered water to plumbing	fixtures.		Must	meet temperature requirements of 248 CMR
All water piping should be insulated in accordance with 780 CMR (Massachusetts	energy	code)
-Dual-purpose hot water heating-
(Domestic and Space Heating):
Diagrammatic layout of radiant heating and domestic water heater per Mass. code.
     The recirculation pump is to provide no less than 2 GPM (7.5 L/min) and no more than 4 GPM (15 L/min)  
         through each activated unit in the system
Installation
Installation Manual
BallValveIsolationValve  
						

							30   Page
INITIAL OPERATION
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 supplier from a neighbor’s phone.  Follow the gas 
supplier’s instructions.
•	If you cannot reach your gas supplier, call the fire department.
WARNING
Operation
1.Once the above checks have been completed, please clean filter of 
any debris.  Refer to p. 40 for instructions.
2.Fully open the manual water control valve on the water supply 
line.
3.Open a hot water tap to verify that water is flowing to that tap.  
Then close the hot water tap.
4.Fully open the manual gas control valve installed.
5.Turn on the 120 VAC, 60 Hz power supply to the water heater.
6.Now you are ready to enjoy hours of endless hot water.
•	Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time.
•	Open the main gas supply valve to the unit using only your hand to avoid any spark.  Never use 
tools.  If the knob will not turn by hand, do not try to force it; call a qualified service technician.  
Forced repair may result in a fire or explosion due to gas leaks.
•	Be sure to check for the presence of leaking gas toward the bottom of the unit because some 
gases are heavier than air and may settle towards the floor.
•	Check the GAS PRESSURE.  Refer to p. 20.
•	Do not try to light the burner manually.  It is equipped with an electronic ignition device which 
automatically lights the burner.
•	Check for PROPER VENTING and COMBUSTIBLE AIR to the water heater.
•	Purge the GAS and WATER LINES to remove any air pockets.
•	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!
FOR YOUR SAFETY, READ BEFORE OPERATING
Initial operation
Installation Manual