Service Manual Model: GSWH-1 LP Gas
Contents
1. Correct Power Supply Minimum 10 5 VDC b Check for Flow of Water c Check Relay d Check ECO e Check for Flow of Power OUT of Sail Switch to Circuit Board f Dirty edge connector on circuit board Clean edge connector g Defective circuit board Confirm with Approved Board Tester such as Fenwal part 05 080224 009 Replace 3 Water Heater Lockout Spark present but no gas a Check Gas Pressure Set inlet pressure at a Minimum 11eW C with Two or More Gas Appliances Running b No or Low Voltage Correct power supply 10 5 VDC Minimum c Loose Wire Connections on Gas Valve Confirm Connections d Test Resistance of Coils Confirm 30 50 ohms e Defective gas valve Replace Coils or Gas Valve f Dirty connector on Circuit Board Clean Edge Connector g Defective circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace Page 14 4 Water Heater Lockout 1 Gas present but no Spark a High Tension Lead Wire Loose Secure Wire Connection on Circuit Board b Poor Ground Connection at Burner Secure Ground Connection to Main Burner c Improper Electrode Gapping Re position Spark Gap Between Electrode Tip and Burner Blade to 1 8 and into Path of Flame Dirty Electrode Clean Electrode Wires Loose in Electrode Porcelain Replace Electrode Cracked Porcelain on Electrode Replace Electrode Defective circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 002. DC Voltage applied is greater than 11 5 and less that 14 VDC ON OFF Switch Figure 2 Page 4 NORMAL OPERATION A tankless water heater also referred to as an fon demandowater heater rapidly heats water as it flows around and through the heat exchanger The output water temperature depends on the temperature of the input water and the flow established at the faucet by the user the faster the flow the cooler the water the slower the flow the hotter the water The gas control valve of the GSWH 1 and the GSWHAF 1 features a dual BTU solenoid that can operate in Highdmode 34 000 BTUs or ow mode 27 000 BTUs depending on the input temperature of the cold water Colder water 65 F or less causes the burner to operate in CHighO Warmer water 70 F or more causes the burner to operate in owQ NOTE When the input water temperature is between 65 70 F the unit may operate in HighOor CLowOdepending upon precise thermostat settings A thermostat setting may vary 5 F Prior to normal operation the user must ensure that all air has been purged from the water lines the Water Heater Power Switch is in the CONOposition and the REMOTE Mode Switch see below is set in the desired position AUTO or LO The 12VDC power is normally left ON while the RVis in use with no use of LP gas In many cases the switch may be set to On the entire camping season This will not harm the unit in any way To start the water heater the user should
3. but no Spark a Misaligned Electrode Ensure Gap Between Electrode Tip and Burner Blade is 1 80 and into Path of Flame b Check for Continuity on Electrode High Voltage Cable c Check for Coil on Circuit Board d Bad circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace 5 Spark present but no Gas a Check Gas Supply b Check Valve Connections c Check for Proper Voltage Minimum of 10 5 VDC d Check Edge Connectors for oxidation Clean and Replace e Check Resistance ohms Draw on Coils Should be 30 50 ohms Page 13 6 Flame okay during trial for ignition TFI no flame sense after TFI a Check Electrode and High Voltage Wire for Continuity b Poor ground at burner c Bad circuit board check flame current CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace GENERAL FAILURES AND POSSIBLE CAUSES AND REMEDIES 1 No Blower no Spark and no Gas a No or Low Voltage Correct Power Supply Minimum 10 5 VDC b Defective ON OFF switch Check for Power Coming into Switch If no Power Replace Switch c Defective or Stuck Flow Switch Tap with Wrench if Problem not Solved Replace Flow Switch d Check Relay e Check ECO f Dirty Edge Connector on Circuit Board Clean Edge Connector g Defective circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace 2 No Spark and No Gas Blower Operating a Low voltage
4. chafing or cracks on the wire insulation Note that the spark ignition cable between the Circuit Board and the igniter is securely in place and not shorted to any metal component At least once a year activate the Relief Valve by lifting the lever on top of the valve MAKE SURE THAT THE WATER HEATER HAS NOT BEEN ON RECENTLY AND THE HOT WATER OUTLET IS COLD Turn on the power to the water heater and open a hot water faucet to inspect the flame of the burner The flame should be of the normal bluish appearance that indicates proper combustion This can be accomplished by observing the flames through the sight hole and looking at the burner under the edge of the heat exchanger See Figure 9 Figure 9 Page 16 WINTERIZATION Freezing of the water heater and its plumbing components will result in severe damage that is not covered by warranty For this reason it is not advisable to use the standard unit Part 1GWH in the winter without installing the Winter Use Device See below for Winter Use Device option At the start of the winter season or before traveling to a location where freezing conditions are likely the unit must be winterized The very small amount of water present in the heat exchanger does not require the installation of a bypass kit Winterization can be accomplished using one of the two common methods of winterization used for RV water systems ACompressed Air Method Drain all water from the system opening o
5. fully open the hot water faucet wait for hot water to flow and decrease the flow which results in hotter water to obtain the temperature desired Note although the Girard tankless water heater is instantaneous the water in the system pipes must be purged before the user will feel hot water at the faucet Thus the further the water heater is located from the faucet shower the longer it will take for the user to feel hot water The ideal location for any water heater is in the center of the coach During normal operation the hot water faucet behaves somewhat like a typical mixing valve it faucet increases the water temperature when turned clockwise reducing the water flow and decreases the water temperature when turned counterclockwise opening and increasing the water flow The user may mix the hot water with cold water but normally this is not recommended The increased total flow Hot plus Cold will reduce the inlet pressure which in turn reduces the flow of water through the heat exchanger of the water heater this will cause the hot water output temperature to increase defeating the effect of the cold water In some cases adding cold water may result in limiting See last paragraph this section When the Mode switch is set to AUTO a thermostat will cause the burner to switch automatically from High to Low when the inlet water temperature goes above 70 F and from Low to High when it goes below 65 F Note A thermostat setting
6. igniter If the Circuit Board does not sense flame at the spark igniter the gas valve is de energized and an internal post purge of 15 seconds will occur before a second try is attempted Two additional tries will be attempted and if no flame is detected in the process the Circuit Board goes into LOCKOUT mode and will make no further attempt to light Once the system has entered lockout mode it must be reset To reset the water heater turn OFF power to the water heater OR close the faucet removing the demand for hot water for a period of five 5 seconds 123486 A WARNING The 35 53 uses voltages of shock hazard potertial Viding and inital operabon must be done by a qualiied senice technician Terminal Designations TERMINAL DESCRIPTION TERMINAL TYPE TION pw a S106 Temina Blower VF QC Terminal AIR Aiow Switch f6 Pin Edge Connector Gas Valve 6 Pin Edge Connector TESTISENSE Remote Sense 6 Pin Edge Connector 3 Figure 6 SFin Edge Comodo 6 R m EE INCLED NC Contact 6 Pin Edos Comes 3 m 7H _ Thenncstet___ 6 Pin Exige Connector Page 10 Whenever the Circuit Board senses flame during the ignition trials sparking stops and the Gas Valve remains energized The Water Flow Switch the Sail Switch and the Burner flame are constantly monitored to assure that the system continues to operate properly When the Hot Water faucet is closed and the Flow Switch opens the demand for heat ends and the G
7. is certified by the Canadian Standards Association CSA to meet these standards for use in recreation vehicles The design of this product differs from the traditional storage tank water heater units found in RVs More specifically Athe Girard Tankless Hot Water System uses a finned copper heat exchanger and nine high efficiency blade burners AThe Motor Aided Induced Draft enhances combustion for increased efficiency and improved wind resistance A Dual BTU Gas Valve optimizes the output temperature range based on the temperature of the input cold water and water flow When properly installed in a Recreation Vehicle the Girard Tankless Water Heater is connected to AThe RV6 cold water system with its water input from a pressurized 45 psi source such as a shore connection or a water storage tank with water pump Athe RV6 hot water system i e faucets and shower AThe RV amp LP Gas system capable of supplying the rated BTU requirement AThe RV6 12VDC Electrical power distribution panel on a 10 amp fused circuit Please refer to the Owners Manual supplied with the unit for further information The Owners Manual will allow you to verify if the unit is properly installed and the connections are within the following recommended parameters AtThe pressure of the water supply is between 40 and 60 psi for normal operation AtThe LP Gas system is operating within the inlet pressure limits indicated on the rating label 10 50 and 140WC Athe
8. may vary 5 F If the output temperature exceeds 123 F an Emergency Cut Off ECO thermostat will shut down the unit to prevent scalding this operation is both normal and desirable and is commonly referred to as imiting Page 5 As a convenience a Mode switch is installed to manually force the burner to operate only in LOW mode Operating the system exclusively in LOW mode allows better temperature control when inlet water flow is minimal and the inlet water temperature is between 70 and 65 F and the automatic control has not yet automatically switched to Low mode The switch must manu ally be reset to Auto in order for the system to operate automatically Important When the inlet water is below 50 F input water is very cold the hot water flow must be reduced to 75gpm or less to reach an output temperature above 100 F If the input water temperature is approximately 60 F or greater the model GSWH 1 will generate output water in the range of 95 F to 120 F depending on the water flow RECOMMENDED TOOLS AND EQUIPMENT No unusual tools and or equipment are needed to service the Girard Tankless Water Heater The following equipment is commonly used for service and is readily available Be sure that all instruments are regularly calibrated U Tube or Dial Type Manometer This device is for measuring the gas pressure If using a dial type manometer please insure that it is regularly calibrated U Tube Mano
9. unit when you open a hot water faucet The Sail Switch is moving freely forward and backward The gas is connected and the gas tank is not empty Page 12 CIRCUIT BOARD TROUBLESHOOTING The Circuit Board is the electronic controller for the Water Heater It is very reliable but it is often diagnosed improperly and replaced Note in all cases the replacement of the Circuit Board is the last ttem We provide here a list of symptoms and their possible causes to help you to determine if the problem is due to a malfunction of the board or other components 1 Dead a Fuse Circuit Breaker Bad b Converter battery bad c Mis wired T Check GOn OffOSwitch for Incoming Power d No voltage POWER or BLOWER connections Check for Broken Wire e Bad circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 1 Replace 2 Flow Valve Activated No Blower Output a Mis wired or Failed Sail Switch Check Wiring b Check Relay c Check ECO d Check Wiring to Board e Defective or Stuck Flow Switch Tap with Wrench If Problem not Solved Replace Flow Switch f Bad circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace 3 Sail Switch Input Okay No Trial for Ignition a Mis wired T Confirm Wiring and Connections b Check Sail Switch for Continuity c Bad circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace 4 Gas present
10. warranty claim the Service Center must be an authorized Girard Products LLC service Center Aduthorized Service Centers must obtain prior approval for work that exceeds the flat rate time allowances AOperational failure caused by improper installation or the use of non GSWH 1 components will result in the warranty claim being denied Page 18
11. 9 Replace aoa hO amp 5 Water Heater Lockout 1 Gas and Spark Present a Check Gas Pressure Set inlet pressure at a Minimum 11eW C with Two or More Gas Appliances Running No or Low Voltage Correct power supply 10 5 VDC Minimum Poor Electrical Ground Secure Electrical Ground Dirty Electrode Clean Electrode Partial Obstruction in Main Burner Check for Complete Ignition of Burner Blades through sight Hole Remove any Obstructions Partially Obstructed Burner Manifold Clean Burner Orifices Replace if Necessary Dirty Connector on Circuit Board Clean Edge Connector Defective circuit board CONFIRM with Approved Board Tester such as Fenwal part 05 080224 009 Replace oD aoo g J Q h 6 Erratic or Uneven Burner Flame a Check Gas Pressure Set inlet pressure at a Minimum 11 W C with Two or More Gas Appliances Running b Partial Obstruction in Main Burner Check for Complete Ignition of Burner Blades through Sight Hole Remove any Obstructions c Obstructed Exhaust Tube Grill Inspect and Remove any Obstruction d Partially Obstructed Burner Manifold Clean Burner Orifices Replace if Necessary 7 Excessive or Insufficient Water Temperatures Water Not Hot or Water Cold a Air is present in water lines Purge Air from Water Lines b Thermostat not Seated Against Sensing Tab Reseat Thermostat and Add Thermal Paste to Insure Good Contact c Defective Thermostat Replace Thermostat d In Case of Excessi
12. D Winter Use Devoce Optional Figure 4 Ladder Diagram Page 8 Please refer to the electrical diagram for a functional understanding of the electrical components and of the Circuit Board control functions Wiring Diagram Cold Hot 12V or Mode SW j l Tiri Flow Switch Heat Exchanger 12VDC Red 12VDC Ground Black Ground Green Gas Valve Brown ED Diagnostics Gas Valve 12VDC Row Limit Air Figure 5 Page 9 CIRCUIT BOARD OPERATION When the user opens a Hot Water faucet water starts flowing through the unit and activates the Flow Switch which in turn activates the Relay this applies 12VDC power to the ECO Emergency Cut Off Thermostat and to the Heat Demando Connection 5 of the Circuit Board see below Change to ECO Emergency Cut Off Thermostat and to the HOConnection 2 of the Circuit Board Power is then applied to the Sail Switch that is open when there is no air flow from the blower The ECO is normally closed The Circuit Board starts the blower and verifies that the Sail Switch closes when this occurs the Circuit Board will sense the 12VDC at the Circuit Board indicating that there is sufficient air flow for combustion The circuit is now complete Try For Ignition TFI The Circuit Board is now ready to try for ignition and applies power to the gas valve through connection 4 and without delay generates a spark of five 5 seconds duration at the
13. GIRARD PRODUCTS LLC Service Manual Model GSWH 1 LP Gas Tankless Water Heater For Recreation Vehicles This manual is intended solely for use by trained personnel who perform service or repairs on the Model GSWH 1 Water Heater on behalf of a Girard Products LLC Authorized Service Center Fd 4 d i TH hy Sp CERTIFIED 9 eae CSA Approved Girard Products LLC 1361 Calle Avanazado San Clemente CA 92673 U S A Service Manual Part No 1GWH9405 40 7 2010 Patent Pending TABLE OF CONTENTS Service Manual Model GSWH 1 Product Identification Description and Features Normal Operation Recommended Tools and Equipment Removing Controls Housing schematics and Diagrams a Ladder Diagram b Wiring Diagram Circuit Board Operation Exploded View Troubleshooting Guide Circuit Board Troubleshooting General Failures and Possible Causes and Remedies Routine Maintenance Winterization Spare Parts List Flat Rate Schedule Page 2 PRODUCT IDENTIFICATION Water Heater Part Number 1GWH IGWHAF w Winter Use Device Door Part Number 1GWHD Serial Number Location On Rating Label affixed on the inside right of the Controls Housing Figure 1 Specifications The main performance specifications of the Model GSWH 1 are 125 PSI Max 125 56 Page 3 DESCRIPTION AND FEATURES The Girard Products GSWH 1 LP Gas Tankless Water Heater is designed to meet ANSI Z21 10 3 2004 and CSA 4 3 2004 and
14. as Valve is de energized immediately after the post purge and cool off period of 90 seconds the blower is turned off Flame Failure lf the established flame signal is lost while the burner is operating the control will sense this and respond within 0 8 seconds The gas valve will stay energized and the Ignition Spark will be energized in an attempt to relight the burner trial for ignition lf the burner does not light the control will make two more attempts to relight and then go into lockout See Try for Ignition page 10 If flame is established Combustion Airflow Problems lf the airflow signal is lost or the ECO opens during heat mode the gas valve is immediately de energized and the blower stays on If the switch closes again a normal ignition sequence will resume If not and this condition persists for more than five minutes the control will enter lockout See Try for Ignition page 10 with the blower off Water Heater LED Diagnostics If the water heater stops operating normally check the LED indicator on the user panel located behind the water heater door If the LED is lit or blinking consult the list below to help diagnose the fault detected by the Circuit Board e Steady On Internal Control Fault e 1 Flash Air Fault e 2 Flashes Flame Detection Error e 3 Flashes Lockout e 4 Flashes N A Reserved for future diagnostics e 5 Flashes Low voltage The pattern will be repeated at interva
15. ls of 3 seconds Page 11 TROUBLE SHOOTING GUIDE This section includes the most common symptoms that may be found in a model GSWH 1 that is not operating normally Please refer to the following drawing to locate the components in the unit Exhaust Collector Limit Switch Blower Motor Assembly Support Sail Switch Housin i a g Heat Exchanger Circuit Board Fenwal eon l Diagnostic LED Exhaust Tube i i 7 H i 4 j x Z i 4 e i 3 F ae j Rel a ff i ae i f ie F N ff br j TEE teen LPS N fof eee a so j z i Ne Scat f3 j anonn amp va x Pa l EE i f j 4 hi Si lt a greece f i H A l SA T mess Ere 2 EZ i i ee iiy foe f j p 3 E j T 7 H A 3 1 we jE J A H b Connections gt TAJ et d A i 7 i i y i f j i i rf Das a A ui Hot Water Flow E Switch Cold Water 2i Power Switch Control Panel Housing z Door Flange Gas Burner Gas Control Valve Anti Freeze Thermostat Auto Lo Thermostat Burner Manifold Door EXPLODED VIEW OF MODEL GSWH 1 AND MAJOR COMPONENTS IDENTIFICATION Figure 7 NOTICE Before starting the troubleshooting steps suggested below verify that There is power connected to the water heater The power switch is in the ON position The wiring is not damaged in any way All connectors are plugged in no dangling connectors Water flowing through the
16. meter Dial Type Manometer Gas Leak Test Solution There are many inexpensive solutions on the market that bubble when applied to fittings where a leak is present Multimeter Used for testing Continuity Voltage Current AC DC and Resistance With a good quality Multimeter you can verify voltage problems and defective components The entire electronic system can be tested with this meter Fenwal Board Tester or Similar Approved Tester a Used for testing the Circuit Board This tester will diagnose vave the power circuit sense circuit spark igniter and lock out _ Strona ae mode Fenwal part 05 080224 009 oo Bel Page 6 Hand Tools APhillips and flat head screw drivers A9 160 3 40 and 13 160 S A E open wrenches Avmm and 5 5mm nut drivers and or wrenches ANeedle nose pliers wire crimp and cutter Aeak Test Solution REMOVING CONTROLS HOUSING No unusual tools and or equipment are needed to service the Girard Tankless Water Heater The following equipment is commonly used for service and is readily available Be sure that all instruments are regularly calibrated To gain easy access to the serviceable components of the Water Heater you must first remove the Controls6Housing that shields and supports the following ACircuit Board ANDual BTU Gas Control AMain Gas Line AGround connections AXPower switch with the LED indicator 1 7mm Nuts fasten Us ia 4 the Controls Housing i 34 TH Main Gas Con
17. ne tap at a time and using compressed air to purge all remaining water ARV Anti freeze Method Follow the recommendations of the Recreation Vehicle manufacturer and fill the system with a non toxic anti freeze Make sure that the antifreeze flows from each tap to complete the process PARTS BREAKDOWN Item WETU Part P T Relief Valve 1 2 NPT 1GWH7200 Conversion Flange for Atwood or Suburban 10 Gallon Polar White 1GWHDAS10 EE 2 EZ EJ EJ ES EA ES 10 EA 12 14 15 16 18 19 20 Figure 10 Page 17 FLAT RATE SCHEDULE Effective 01 01 2010 TIME ALLOWANCE in hours calculated at 1 10th hour 6 minutes General Trouble Shooting Diagnostic Testing 18 minutes 30 hour Replacement of Component Hours Minutes Complete Water Heater 1 00 60 Door Frame Flange 00 30 Flue Tube 10 6 Exhaust Bracket 20 12 Control Gas Housing Plate 50 30 Circuit Board 40 24 Gas Control Valve w inlet fitting AO 24 LP Gas tube from valve to burner 10 6 Burner 40 24 P T Relief Valve AO 24 Hot Water Outlet Manifold Assembly 20 12 Flow Switch 40 24 Cold Water Inlet Manifold Assembly 30 18 ECO 10 6 Sail Switch 20 12 Relay 30 18 Power On Off Switch 10 6 Mode Switch Hi Low Burner 10 6 Diagnostic LED 10 6 Winter Use Control Unit 30 18 Winter Use Thermostat 10 6 Figure 11 For any component replacement that does not appear on the above list contact Girard Products LLC for authorization and instructions Ato process a
18. nection to the bottom of the E i l from System to Unit Main Housing 3 9 16 Gas Connection Tube from Gas Valve to Burner Wing nut on side wall fastens the Assembly Figure 3 Controls Housing to the Main Housing 1 Loosen the Power Strain Reliever nut at the back of the unit to allow the wiring harness to be pulled into the housing as needed Page 7 2 Remove the Hex Nuts Lock Washers and Washers along the lower edge of the Control Housing and set aside for re assembly 3 Reach inside along the left side of the housing but behind the ControlsOHousing and locate the small Wing Nut along the side wall item 2 Remove and set aside for re assembly 4 Disconnect the Burner Tube from the Burner Assembly item 3 using a 9 160 open end wrench being careful not to damage the tube Set aside for re assembly 5 Lean the ControlsOHousing to the right to slip it out of the wing nut post and lift it to clear the bottom posts 6 Remove the assembly from the Main Housing as far as the wiring harness will allow If necessary cut the wire ties being careful not to cut the wires be sure to replace them wire ties when the job is done SCHEMATICS AND DIAGRAMS The following schematics and diagrams will help to provide a better understanding of the operation of the Model GSWH 1 Water Heater and to trouble shoot the most common malfunctions 7 __ _ i i i i i i s n HiLo TS TS Thermostat ECO Emergency Gut Off WU
19. ve Temperature Verify that the Maximum Flow is not Limited by a Flow Restrictor Page 15 ROUTINE MAINTENANCE We recommend that the GSWH 1 water heater be inspected regularly by the user and at least once a year by a qualified service technician Before an inspection make sure that the LP Gas and Water supply are connected and turned on A routine inspection must include the following items gt INO oo o1 o N co Inspect the integrity of the sealing caulking or tape between the side wall and the door of the water heater and make sure that the unit is solidly mounted to the vehicle Verify that the air inlet openings louvers are completely open and clear of any debris including mud leaves twigs insects etc Remove all obstructions to allow full air flow Inspect the Exhaust tube and make sure that it is also unobstructed and that the Exhaust screen is clean Open the cover and verify that no debris or extraneous combustible materials are present anywhere especially in the area of the burner and the gas controls remove any item present and wipe clean the bottom of the housing Inspect the interior surface of the housing for any cracks or corroded areas that could allow penetration of gases into the interior of the vehicle Check especially around the Hot Water Cold Water Gas and electrical connections Check that all wire connections are firmly in place and there are no signs of
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