TK-510U Gas Conversion Guide

Gas Conversion-110U,310U,510U Series 200
This water heater is configured for Natural Gas from the factory. However, if a field conversion to Propane Gas is
necessary, the conversion kit supplied with the water heater must be used and installed by a qualified service agency*.
Before you install the components in this Propane Gas conversion kit, verify the type of gas that will be used to fuel the
unit. WARNING! An improper field conversion could cause potentially dangerous conditions that may cause an
explosion or fire resulting in property damage, bodily injury or both.
• This conversion kit shall be installed by a qualified service agency* or a gas utility service technician in
accordance with Manufacturer’s written instructions and all applicable codes and requirements of the
authority having jurisdiction. The information in these instructions must be followed to minimize the risk
of fire or explosion or to prevent property damage, personal injury or death. The qualified service agency*
is responsible for the proper installation of this kit. The installation is not proper and complete until
the operation of the converted appliance is checked as specified in the manufacturer’s instructions
suppied with the kit.
• If your water heater has been converted to use a different gas type in the past, the manufacturer
does NOT recommend converting it again.
• IN CANADA, THE CONVERSION SHALL BE CARRIED OUT IN ACCORDANCE WITH THE REQUIREMENTS
OF THE PROVINCIAL AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE
REQUIREMENTS OF THE CSA-B149.1, NATURAL GAS AND PROPANE INSTALLATION CODE.
WARNING
* A qualified service agency is any individual, firm, corporation or company which either in person or through a
representative is engaged in and is responsible for the connection, utilization, repair or servicing of gas utilization
equipment or accessories; who is experienced in such work, familiar with all precautions required, and has
complied with all of the requirements of the authority having jurisdiction.
Tools Required:
• Phillips Screwdriver / Manometer / Gas Leak Detector
Included Items: 100270585
LP Gas Manifold Nozzles
with nozzle gaskets
Manifold gasket Gas Conversion Label Spare screws
Qty: 2 Small / 1 Large
Qty: 1
Qty: 1
Qty: 2
Before servicing the water heater, make sure that electrical power and gas service to the
water heater is turned OFF. Failure to do so may result in bodily injury, death, or property
damage.
WARNING
Procedure:
1. Turn off power supply.
2. Turn off both gas and water valves to the water heater.
3. Remove the front cover.
4. Once the front cover is removed, place it in a safe location to prevent accidental
damage. With the internal components exposed, locate the gas manifold near
the center of the unit.
5. Use a Phillips screwdriver to remove the 20 screws on the manifold plate
shown in Figure 1.
6. Remove the manifold plate. (Figure 2)
7. Remove the manifold gasket from the manifold plate. Discard the gasket.
8. Install the new manifold gasket onto the manifold plate. Ensure that the gasket
is in good condition and not compromised in any way. If it is damaged, do not
install the gasket. Replace it with a new one. (Part number: 319143-581)
9. Refer to Figure 3 and identify the proper location for each LP Gas Manifold
Nozzle. The nozzle attachments are of two types: small and large. The smaller
nozzle attachments are for the left two sections and the larger one is for the right
section.
1W1220
100270941
Ensure that each manifold nozzle includes
a gasket prior to installation.
10.Install each LP Gas Manifold Nozzle as shown in Figure 3.
NOTE: The parts are keyed and cannot be installed incorrectly.
11.After making sure that the manifold nozzles are secure, install the
manifold cover using the 20 screws that were removed during
step 5. See Figure 1.
Hand tighten the screws. Do not overtighten as this may damage or crack the components.
Do not use a powered screwdriver.
12. Set the DIP switches on the PCB to the correct position for propane. See the figures below for the proper propane
DIP switch settings.
• Turn off the power before changing the DIP switch settings.
• Only change the DIP switches specified above for the conversion to propane.
• Failure to properly set the DIP switches could cause carbon monoxide
poisoning, resulting in severe personal injury or death.
WARNING
Upper bank of
DIP Switches
<Upper bank of
DIP switches>
Gas type
Propane
OFF
ON
1 2 3 4 5 6 7 8
510U
Change to the above posion.
(No.1 SW : ON No.2 SW : OFF)
Gas type
Propane
OFF
ON
1 2 3 4 5 6 7 8 9 10
110U / 310U
DIP switches
Change to the above posion.
(No.1 SW : ON No.2 SW : OFF)
13. Verify that the gas supply pressure is within an acceptable range. For instructions, see “Gas Supply and Gas Pipe
Sizing for Propane” on the reverse side of this instruction sheet.
14. Turn power ON and turn on the gas supply.
15. Check for gas leaks around the manifold plate as follows:
a. Turn on a nearby hot water faucet.
b. Wait until a consistent flame is seen through the sight
glass.
c. Check for gas leaks by running a gas leak detector
along the edges of the manifold plate. If you find a leak,
stop operating the water heater and turn the gas supply off.
Replace the manifold gasket with a new one. (Part number:
319143-581)
16. Turn the water supply off.
17. After the water heater has completed its post-purge process, turn
off the gas supply and turn off power to the water heater.
18. Verify the static and dynamic gas pressures for the water heater.
Refer to the installation manual for instructions.
19. Check the manifold pressures as described on the reverse side of
this instruction sheet.
20. Install the front cover with four screws for Indoor models and
three screws for Outdoor models.
21. Fill out all items on the gas conversion sticker with a permanent marker. Affix the label on the upper right side of the
front cover of the heater as shown in Figure 4.
22. Restart the water heater according to the Installation Manual and Owner’s Guide. Verify proper operation before
returning the water heater to service.
Remove
the 20 screws.
Figure 1
(continued overleaf)
Part No. : 319143-581
Figure 2
Small LP Gas
Manifold Nozzles
Large LP Gas
Manifold Nozzle
Figure 3
Figure 4
Rang
Plate
Gas Conversion Label
1W1240
This water heater was converted on
/ / (month-day-year)
to Propane gas with kit No. 100270585
by
(name and address of organizaon making this conver-
sion, who accepts the responsibility for the correctness
of this conversion).
Affix the label on the front cover in a conspicuous location
as close as possible to the rating plate on the side case.
Model
110U
Indoor
(AT-KJr3U-IN)
310U
Indoor
(AT-K5U-IN)
510U
Indoor
(AT-D3U-IN)
Inlet Gas Pressure
Min. 8.0” W.C. (1.99 kPa)
Max. 14.0” W.C. (3.48 kPa)
Manifold Gas
Pressure
Min.
inches WC
0.45 0.45 0.45
Max.
inches WC
1.70 2.60 3.10
BTU Input
Min.
BTU/h
15,000 15,000 15,000
Max.
BTU/h
140,000 190,000 199,000
Model
110U
Outdoor
(AT-KJr3U-OS)
310U
Outdoor
(AT-K5U-OS)
510U
Outdoor
(AT-D3U-OS)
Inlet Gas Pressure
Min. 8.0” W.C. (1.99 kPa)
Max. 14.0” W.C. (3.48 kPa)
Manifold Gas
Pressure
Min.
inches WC
0.51 0.51 0.51
Max.
inches WC
1.85 3.20 3.40
BTU Input
Min.
BTU/h
15,000 15,000 15,000
Max.
BTU/h
140,000 190,000 199,000