GSW WATER HEATING User's Manual
Contents
1. GSW WATER HEATING GSW Bae D A STORAGE BOOSTER TANKS INSTALLATION AND OPERATING INSTRUCTIONS Read and understand these instructions thoroughly before starting TABLE OF CONTENTS I Introduction 0 0 nananana eee 2 I SAIC Wicaec eaadeneudooseeeaouveudoeed ans 2 IMI Installation 2 0 n on cc eee eee 2 IV Operation 0 ee eee 5 V Maintenance 0 0 00 c ee eee 5 MV AIA x ac or eiste oan ee a ee EE 7 PLEASE RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE A WARNING Improper installation adjustment alter ation service or maintenance can cause injury or property damage Refer to this manual For assistance or additional infor mation consult a qualified installer serv ice agency or the electric utility A FOR YOUR SAFETY e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Installation and service must be per formed by a qualified installer service agency or the electric utility A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage per sonal injury or death GSW Water Heating is a division of GSW Water Products Inc PART NO 71772 C 05 02 I INTRODUCTION Thank you for purchasing this storage booster tank Properly installed and maintained it will provide years of trouble free service The warranty on thi2. The boiler or water heating source should be set to pro vide at least 11 C 20 F higher water temperature than the temperature setting of the storage tank 4 Turn power on check for proper operation of boiler and storage tank Temperature Adjustment The setting of 49 C 120 F has been proven to be satis factory from the standpoint of operational costs and safety We recommend the thermostats remain set at 49 C 120 F lf water temperature adjustment is required Turn OFF the electrical supply to the tank Remove lower access door Turn back insulation Adjust thermostat to water temperature desired Replace insulation and access door Turn ON the electrical supply to the tank oa SiS V MAINTENANCE T amp P Valve Check CAUTION The out flowing water is hot Avoid splashing the water on yourself or on the surroundings where it may cause dam age Do not attempt to operate this storage tank with the cold water inlet valve closed The Temperature and Pressure Relief Valve must be manually operated at least once a year This involves opening the valve to check that it is flow ing freely and that there are no blockages WARNING WATER MAY BE HOT and water flow can be forceful Caution should be taken to ensure that 1 No one is in front of or around the outlet of the T amp P valve discharge line 2 The water manually discharged will not cause any bod ily injury or property damage The water may be e
3. is consumed Rapid depletion can leave a heater unprotected causing a premature failure It is good practice to check the anode s annually to see if it needs replacing Operating a storage tank without an actively working anode s will void the warranty Failure to maintain the anode may result in premature failure of the storage tank due to corrosion and leaks Anode Maintenance 1 Turn OFF the electrical supply to the tank 2 Close the cold water supply valve 3 Open a nearby hot water faucet served by the system to depressurize the system 4 Connect a hose to the drain valve and drain 22 litres 6 gal as directed in the Draining and Flushing section NOTE The anode s has been factory installed using a power tool It may be necessary for a second person to sta bilize the tank A few sharp blows on the handle of the sock et wrench should loosen the anode nut If an impact wrench power drive is available this is an easy way to remove an anode 6 Using a1 1 16 socket remove anode s and inspect it The surface may be rough full of pits and crevices but this is normal If it is less than approximately 10mm 3 8 in in diameter or the inner steel core is exposed the anode s should be replaced 7 Apply Teflon tape or sealing compounds approved for use with potable water to the threads of the anode s and install into the tank top 8 Open the cold water supply valve and open a nearby hot water faucet
4. 1 Ensure the storage tank is level before starting installa tion T amp P VALVE SOME MODELS WILL HAVE A SIDE MOUNT FOR THIS VALVE SUPPLY TO BOILER TANKLESS COIL JUNCTION BOX HOT WATER OUTLET ACCESS DOORS THERMOSTAT CONTROL COMBINATION RETURN amp DRAIN VALVE Figure 1 Main Parts and Features THERMOSTAT RETAINER IMPORTANT Do not apply heat directly to tank fittings when making sweat connections They contain non metallic material 2 Install circulation loop as shown using 19mm in copper pipe 3 Install the cold water supply piping into a tee between the circulator discharge and the boiler coil inlet 4 Connect the boiler supply line to the combination return and drain valve 5 Connect hot water supply to top tank fitting 6 Install 19mm in 150 psi Temperature and Pressure Relief Valve into the tank as shown 7 Acheck valve may be installed between the cold water tee connection and the circulator This will force the cold water through the coil first NOTE The check valve can often be noisy and cause reduced supply pressures For multiple storage tank sys PRESSURE REGULATOR OPTIONAL EXPANSION TANK OPTIONAL CIRCULATOR PUMP T amp P VALVE FOR SOME MODELS STORAGE BOOSTER TANK TANKLESS COIL BOILER COMBINATION RETURN amp DRAIN VALVE Figure 2 Single Storage Booster Plumbing Diagram PRESSURE REGULATOR OPTIONAL J4 T amp P VALVE
5. FOR SOME MODELS EXPANSION TANK OPTIONAL CIRCULATOR PUMP N 4 a BS STORAGE BOOSTER TANK STORAGE BOOSTER TANK TANKLESS COIL BOILER COMBINATION RETURN amp DRAIN VALVE Figure 3 Multiple Storage Booster Plumbing Diagram tem check valves must be installed to prevent the circulator from pumping hot water into another tank and overheating it 8 The use of a pressure regulator is optional but recom mended when the cold supply pressure is over 80 psi Reducing the inlet pressure to 45 60 psi will reduce probability of relief valve discharge by thermal expan sion 9 The water utility supply meter may contain a check valve back flow preventer or water pressure reducing valve This will create a closed water system During the heating cycle the water expands creating a pressure build up in the water system A Temperature and Pressure T amp P Relief Valve must be installed 150 psi maximum pressure See preceding section If the T amp P valve discharges periodically this may be due to ther mal expansion in a closed system To prevent this con dition and to reduce the possible build up of lime on the Temperature and Pressure Relief Valve seat either one of the following installations is required i Install a 125 psi pressure relief valve in the cold water supply line Make sure that the discharge of this valve is protected from freezing and directed to an open drain ii Install an expansion tank on
6. faucet be opened for several minutes at the kitchen sink before using any electrical appliance con nected to the hot water system Use caution in opening faucets When hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open Local Codes The installation of this storage tank must be In accordance with these Instructions and all applicable local codes Location IMPORTANT This storage booster tank must be installed strictly in accordance with the instructions enclosed and local elec trical fuel and building codes It is possible that connec tions to the tank or the tank itself may develop leaks IT IS THEREFORE IMPERATIVE that the storage booster tank be installed so that any leakage of the tank or relat ed water piping is directed to an adequate drain in sucha manner that it cannot damage the building furniture floor covering adjacent areas lower floors of the structure or other property subject to water damage This is particular ly important if the tank is installed in a multi story building on finished flooring or carpeted surfaces GSW WILL NOT ASSUME ANY LIABILITY for damage caused by water leaking from the storage booster tank pressure relief valve or related fittings Select a location as centralized within the piping system as possible In any location selected it i
7. make available to the extent supplied by the manufacturer without recourse to GSW THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS EXPRESS WARRANTY IS WHERE PERMITTED BY LAW IN LIEU OF AND EXCLUDES AND REPLACES ALL OTHER CONDITIONS WARRANTIES GUARANTEES REPRESENTATIONS OBLIGATIONS OR LIABILITIES OF GSW OF ANY NATURE OR KIND EXPRESS OR IMPLIED HOWEVER ARISING WHETHER BY CONTRACT CONDUCT STATEMENT STATUTE NEGLI GENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW OR OTHERWISE WITH RESPECT TO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY INSTALLATION OPERATION REPAIR OR REPLACEMENT GSW EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES IN NO EVENT WILL GSW S LIA BILITIES EXCEED THE COST OF THE DEFECTIVE PART S OR UNIT GSW WILL NOT PAY FOR ANY TRANSPORTATION LABOUR INSTALLATION OR OTHER INCIDENTAL COSTS ASSOCIATED WITH THE REPAIR OR REPLACEMENT OF A DEFECTIVE PART OR UNIT This warranty and GSW s obligations shall be construed and determined in accordance with the laws of both the Province of Ontario and of Canada in force therein This Warranty does not affect specific legal rights of a consumer under applicable law except to the extent that such rights may be waived or replaced and the provisions hereof are deemed to be amended to the extent necessary The unenforceability of any provision in whole or in part of this Certificate shall not affect the remaining p
8. the cold water supply line 10 A vacuum relief valve may be installed to provide vent ing of a closed system Check local code requirements Electrical Wiring 120 VOLT SUPPLY CIRCULATOR L1 PUMP JUNCTION BOX AT CASING TOP BOOSTER TANK WIRE CONNECTORS MUST BE GROUNDED TO THE ELECTRICAL SUPPLY SERVICE THERMOSTAT IF WIRE HAS TO BE REPLACED IN THE FIELD USE ONLY TYPE TEW 105 C WIRE Figure 4 Wiring Diagram Electrical wiring must be in accordance with local codes or in the absence of local codes with the National Electrical code ANSI NFPA 70 or The Canadian Electrical Code as applicable 1 Supply 110 120 volt 60Hz power to the junction box located at the top of the tank 2 Connect the circulator pump in series with the thermo stat as shown in Figure 4 3 A ground wire must be supplied from the ground con nection at the service panel to the ground screw at the junction box 4 The thermostat is rated for a maximum inductive current of 7 FLA at 120 VAC Do not exceed this rating for the circuit 5 Do not install or connect electrical heating elements to this tank Filling NOTE When filling avoid water leakage Do not allow the insulation of the tank to get wet as water can cause electri cal malfunction or reduce the effectiveness of the insulation 1 To insure complete filling of the tank allow air to exit by opening a hot water faucet that is served by the tank and is some distan
9. W authorized dealer point of purchase or GSW itself at 5 The Unit must be carefully inspected maintained and operated in accor GSW Water Heating dance with the manufacturer s instructions No warranty extends for GSW Water Heating is a division of GSW Water Products Inc example and without limitation of the foregoing to any Unit operated 599 Hill Street West without the tank being completely filled with water without an operating Fergus ON Canada NIM 2X1 anode with levels of sediment or lime precipitate which cause failure in Should you have questions please call our Technical Support Line at 1 connection to any attachment s energy saving device s or other means 888 479 8324 of heating except as approved by GSW for the Unit other than with 9 Ifrequested by GSW information relating to the purchase transportation potable water without any additives such as salts chlorine or chemicals operation and installation of the Unit must be supplied The defective except those added for the sole purpose of rendering the water fit for part s or Unit with all components properly and securely packed shall domestic use be returned transportation pre paid to the address designated by GSW in 6 All repairs must be made by a competent and qualified person who is cer the written request All claims are subject to validation by GSW tified by GSW or one of its authorized dealers to work on the Unit using factory approved replacement parts
10. and the Unit shall not be otherwise modified altered or improperly repaired war ae
11. ce away from the heater 2 Ensure the storage tank drain valve is closed 3 Open the cold water supply valve and fill the tank and piping system with water When an uninterrupted stream of water without apparent air bubbles flows from the open hot water faucet the system is full 4 Close the open hot water faucet Check the system for leaks repair aS necessary and retest 5 Connect a hose to the drain valve and route to a suit able drain Open the drain valve and let water run to flush out any foreign matter that may have entered the system Once flushed close the drain valve and dis connect hose Temperature Regulation A DANGER N Pue HOT MA i In order to reduce the risk of scald injury the thermostat is factory set to 49 C 120 F The thermostat operates auto matically and can be adjusted to provide higher or lower water temperature as needed A mixing valve in connection with a higher temperature setting should be used to reduce risk of scald injury CAUTION Increasing the thermostat setting above the pre set tem perature may cause severe burns and consume exces sive energy Hotter water increases the risk of scald injury IMPORTANT RISK OF SCALDING Hot water will cause third degree burns in 6 seconds at 60 C 140 F in 30 seconds at 54 130 F IV OPERATION 1 Follow boiler or heat source installation and operating instructions 2 Fill the tank see FILLING section 3
12. f the storage tank The T amp P valve shall be rated for the BTU INPUT of the entire system This T amp P valve may be in addition to any T amp P valve that is required on the boiler or other energy supply system Install the valve into the opening provided on the storage tank or other approved system location Provide tubing so that any discharge from the valve will exit within 152mm 6 in above or any distance below the structur al floor and cannot contact any live electrical part The end of the relief pipe opening should terminate near the floor drain or other suitable location Do not place a valve s or any other blockage or restrictions between the tank and the T amp P valve T amp P Valve Check Inspect the relief valve annually to ensure proper operation This involves opening the valve to check that it is flowing freely and that there are no blockages and letting it snap shut see MAINTENANCE section lil INSTALLATION A WARNING Excessive Weight Hazard Use two or more people to move and install storage booster tank Failure to do so can result in back or other injury CAUTION Hydrogen gas can be produced in a hot water system served by this storage tank that has not been used for a long period of time generally two 2 weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To reduce the risk of injury under these conditions it is recommended that the hot water
13. ion and 3 The Unit shall not be installed where it will be exposed to adverse or Any repair or replacement of any part tank or Unit under this Warranty unusual environmental or corrosive conditions No warranty extends for will not extend the Warranty Period beyond that calculated from the date example and without limitation of the foregoing to Units exposed to of first installation of the original Unit The date of first installation will salts chemicals exhausts pollutants or contaminants Further no war be deemed to be the later of the date indicated by the Unit s serial num ranty extends to Units affected by fire freezing or flood Acts of God ber or if supplied with the Warranty claim the sales receipt or installer s or any other contingency beyond the control of GSW receipt 4 The Unit shall be equipped with a properly operating temperature and 8 A claim under this Warranty must include the model and serial number of pressure relief valve as specified by GSW and applicable standards The the Unit proof of date on which the Unit was first installed and the iden Unit shall be operated at temperatures not exceeding the maximum set tity of the defective part s for which a claim is being made and be sub ting of the thermostat and or high limit control provided by GSW and at mitted within 15 days following discovery of the defect s by personal water pressures not exceeding the pressure reading stated on the Unit delivery to a GS
14. rovisions Any and all repair and or replacement of part s or Unit are the sole and exclusive remedy available against GSW LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING 1 The Unit shall be installed in accordance with all manufacturers instruc 7 A properly documented claim shall be received by GSW or one of its tions all applicable equipment and building codes ordinances and regu authorized dealers or point of purchase within the following Warranty lations hereinafter referred to as the standards Period except as provided otherwise below 2 The Unit must not be installed where water damage can result from a a for any defective part within one 1 year or leak while provision s shall be made for directing any water escaping b for any Unit that develops leaks in the inner tank due to rust corrosion from the Unit to a properly operating drainpipe As all units of this type or other chemical reactions caused by the potable domestic water sup may eventually leak you must protect against any potential water dam plied to your home within the period of time shown in table at the top of age GSW accepts no responsibility for such damage nor any incidental this page or consequential loss nor damage s related thereto suffered by the Residential units installed and used in a commercial application carry a owner of the Unit nor by any third party warranty period of one 1 year from date of installat
15. s recommended that a suitable drain pan be installed under the storage booster tank This pan must limit the water level to a MAXIMUM depth of 45mm 1 3 4 in and have a diameter that is a minimum of 50mm 2 in greater than the diameter of the storage booster tank Suitable piping shall connect the drain pan to a properly operating floor drain Locate the storage tank in a clean dry area close to the water heating source and preferably central to the piping system Adequate clearance for accessibility to permit main ae tenance and service must be provided Water lines and the storage tank should be protected from freezing tempera tures Do not install the storage tank in outdoor unprotected areas It is desirable to have a floor drain nearby to permit easy draining if necessary WARNING The water heating source piping and components con nected to the tank must be suitable for potable water use TOXIC chemicals such as used for boiler treatment must not be introduced into the tank Circulator Pump A circulator pump is not supplied Use only a bronze body model rated for 110 120 volts 60Hz Install in accordance with the pump manufacturer s instructions using standard plumbing practices Plumbing Connections The main parts and features of your storage booster tank are identified in Figure 1 Install plumbing according to Figure 2 for single storage tank and according to Figure 3 for multiple storage tank systems
16. s storage booster tank is in effect only when the tank is installed and operated in accordance with these instructions The manufacturer of this tank will not be liable for any injury or property damage resulting from fail ure to comply with these instructions IMPORTANT Read and understand these instructions before installing and operating your storage booster tank Description The JOHN WOOD series of storage booster tanks avail able in 40 50 or 80 gallon sizes have been designed to supply hot water for domestic use when combined with a tankless coil boiler or other water heating source Each tank is equipped with an adjustable thermostat pre wired and ready for connection to a circulator pump not supplied These tanks are not constructed to ASME requirements and should not be used for such applications Il SAFETY Relief Valve Requirements WARNING For protection against excessive temperatures and pres Sure install temperature and pressure protective equip ment required by local codes but no less than a combi nation Temperature and Pressure T amp P Relief Valve cer tified as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI 221 22 by a nationally recognized test ing laboratory that maintains periodic inspection of pro duction of listed equipment or materials The valve shall be marked with a maximum set pressure not to exceed the maximum working pressure o
17. to purge air from the tank as directed in the Filling section 9 Check for leaks repair as required and re test 10 Turn ON the electrical supply to the tank Certificate of Warranty See Rating Label Serial Number prefix for Warranty Code P R ST U V W Y Warranty Code Reduced warranty period Standard Warranty Year 3 5 6 7 8 9 10 12 applies to Newfoundland Reduced Warranty Year 2 3 3 5 5 5 5 7 For its GSW and John Wood water heaters and storage boosters Unit GSW Water Heating GSW warrants that upon receipt of a properly verified Warranty claim within the Warranty Period it will at its election repair or replace units which leak or parts which are defective in material or workmanship subject to the terms and conditions set forth in this certificate GSW will not assume any expense or liability for unauthorized returns nor repairs made by a person who has not been authorized by GSW or one of its authorized dealers GSW Units parts must be replaced with GSW or John Wood products to be eligible for Warranty This Warranty is available to the original owner of a Unit installed within the boundaries of continental United States of Canada or their territories Consumers must retain point of sale proof of purchase to validate warranty entitlement This Warranty does not cover components not manufactured by GSW such as oil burners which carry the warranty given by the manufacturer thereof copy of which warranty GSW will
18. xtremely hot While standing clear of the outlet discharge water may be hot lift the lever and let it snap shut The water should stop Temperature and Pressure Relief Valve Manual Relief Valve Discharge line to drain Figure 5 T amp P Valve Test immediately If it fails to reset completely and continues to release water the valve is not functioning properly and must be replaced immediately Close the cold water supply valve drain the tank as directed in the Draining and Flushing section and replace the T amp P valve with a new one Failure to install and maintain an approved T amp P valve will release the manufacturer from any claim that might result from excessive temperature or pressure In systems where the relief valve discharges periodically this may be due to ther mal expansion or to a thermostat that is operating at too high a temperature If you suspect a malfunctioning thermo stat contact a qualified service technician for repairs Draining and Flushing Some service work to be performed on the tank requires the tank to be drained It is also recommended that the tank be drained and flushed every 6 months to remove any sedi ment and lime which may build up in the bottom of the tank during operation Such buildup can result in noisy operation To drain the tank 1 Turn OFF the electrical supply to the tank 2 Close the cold water supply valve 3 Open a nearby hot water faucet served by the s
19. ystem 4 Connect a hose to the drain valve and route it to an ade quate drain CAUTION The water being drained can be extremely hot The drain hose should be rated for at least 93 C 200 F If the drain hose does not have this rating open the cold water supply valve and a nearby hot water faucet served by the system until the water flow is no longer hot Close the cold water supply valve and resume 5 Open the drain valve and allow all the water to drain from the tank 6 Open the cold water supply valve and flush the tank as needed to remove sediment and any other foreign mat ter that may have entered the system Close the cold water supply valve when clean water flows 7 Perform any other servicing as required 8 Close the drain valve disconnect hose and refill the tank see FILLING section 9 Turn ON the electrical supply to the tank Cathodic Protection Your storage booster tank has been equipped with one or more anodes that protect the tank from corrosion Over time as the anode works it slowly dissolves and must be replaced If the anode s is less than 10mm 3 8 in in diam eter or has any of the inner steel core exposed it must be replaced Depending on water conditions an anode can last from one to ten years Many localities treat their water and this can have a significant effect on the life of your heater Water conditioning such as over softening can accelerate the rate at which the anode s
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