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7. INS euipni i6Buo au z s d OL 1nBi3 d L 31S dednos dde jusAnos uolss id aas dednos e 29 9 ju uu noo p ne n d91 ins dednos d91 l ins p dednos jenuew seq l SJA qe PIS dednos ap juejos 491 91S dednos UOHENIEAD P 150 sieuue 1nej 5 EI E Ju uj no5 p NeAn np zawad mb BUN lioduuo2 82 n u Jul ed e7 50190 s asi Nb Jue osi un p l Ano5 1 s ne Jjneu5 491 058 dednos ET suojesijeued s p 19 dq 3 sns adednos uoheqosi nbiuu u 10 Saul s uu ls s SUOHO S S uuolsu uuIp yuswa 110 un p 5500 eg mne ui s s un Suep u wou yd s qe Beuuuop s JJ s Jo 1nq l sueq nbiuui u uoisuedx p u ulou ud np nunuo u l oJ uo2 inod anduod sed 199 dal 5 dednos oun ne yney np JIOAJ S 1 l SUED A SS X uolss 1d un p no lult
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41. 16 Water Rum pe Shu FA dey eae ds 16 Space Heating And Potable Water Systems 16 Combo Heating 17 System Requirements Installation Closed Water Systems 18 Thermal Expansion 18 Temperature Pressure Relief Valve 19 T amp P Valve Discharge Pipe Requirements Temperature Pressure Relief Valve And Pipe Insulation High Altitude Installation 20 Gas PIPING DEER 20 Sediment Traps 21 Filling The Water Heater 22 Venting Seperti dal ede a OS pA abu aed 23 Termination Clearances Sidevvall 24 Side Wall Vent Terminal Installation Roof Vent Terminal Installation Concentric Vent Termination Kit Installation Multiple Concentric Vent Installations Vent Pipe Length Vent Pipe Termination Venting Terminations And Sizing Vent Screen Installation Vent Pipe Material Vent Pipe Installation Vent Pipe Runs Vent Terminal Installations 2 www gsw wh com Blower Assembly Installation 30 Vent Intake Pipe Connections To Blower Air Duct Coupling Installations According To Vent Sizes Sound Suppressor 33 Side Wall Vent Installation Vertical Vent Installation Installation Checklist 34 LIGHTING INSTRUCT ONS 35 OPERATING THE TEMPERATURE CONTROL SYSTEM
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51. 328765 000 Make sure the gas supplied is the same type listed on the model rating plate The inlet gas pressure must not exceed 14 w c for natural gas and propane gas The minimum inlet gas pressure shown on the rating plate is that which will permit firing at rated input All gas piping must comply with local codes and ordinances or with the Natural Gas and Propane Installation Code B149 1 Copper or brass tubing and fittings except tin lined copper tubing should not be used If the gas control valve thermostat is subjected to pressures exceeding 1 2 psi the damage to the gas control valve thermostat could result in a fire or explosion from leaking gas If the main gas line shut off serving all gas appliances is used also turn OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of Natural Gas and Propane Installation Code B149 1 and your gas supplier concerning pipe size There must be Areadily accessible manual shut off valve in the gas supply line serving the water heater and Asediment trap ahead of gas control valve thermostat to help prevent dirt and foreign materials from entering the gas control valve thermostat A ground joint union or other means to disconnect between the shut off valve and gas control valve thermostat to perm
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58. Figure 36 328765 000 EXHAUST VENT TERMINAL INTAKE VENT TERMINAL RODENT SCREEN INSTALL INTO TERMINATION Figure 37 Vertical Vent Installation If the venting installation is vertical directly from the blower through the roof the Sound Suppressor may be used as the vent termination In such an installation the Vent Termination Screen see Vent Pipe Termination section must be installed in the straight through end of the Sound Suppressor see Figure 38 SOUND SUPPRESSOR WITH K EXHAUST VENT TERMINAL Figure 38 www gsw wh com 33 INSTALLATION CHECKLIST Note Use and complete this checklist before lighting the heater Correct any conditions that do not meet these instructions Water Heater Location Centrally located with the water piping system Located as close to gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures L Proper clearances from combustible surfaces main tained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Installation area free of corrosive elements and flam mable material L Sufficient room to service the water heater Gas Supply And Piping Gas supply is the same type as listed on the water heater data plate Gas line equipped with shut off valve un
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68. 36 Gas Control Valve Thermostat 37 FOR YOUR INFORMATION 38 Start Up Conditions 38 Condensate Smoke Odour Strange Sounds Operational Conditions 38 Smelly VVater Air In Hot VVater Faucets 38 PERIODIC MAINTENANCE 39 General Upkeep 39 Venting System nspection 39 Burner Operation And Inspection 39 Combustion Chamber And Burner Cleaning 40 Housekeeping 40 Temperature Pressure Relief Valve Test 40 Draining And Flushing 41 To Drain The Water Heater Storage Tank To Flush The VVater Heater Storage Tank Anode Rod Maintenance 42 LEAKAGE CHECKPOINTS 43 SERVICE ete 000 43 REFERENCE PARTS LISTING 44 TROUBLESHOOTING GUIDELINES 46 Oekoutse 46 Soft Lockout Hard Lockout Resetting The Heater Control 46 Ignition State And Timing 46 System Status And Error Codes 47 Reading The LED Flash Sequence 47 Corrective Actions 48 Other Symptoms 50 Moy 51 328765 000 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extrem
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72. MAX eed 2 RUBBER COUPLING SUPPLIED BLOWER An DUCT ADAPTER d 11 CONFIGURATION FOR 40 50 GALLON LO INPUT HEATERS CONNECTED TO 3 VENTING FOR 3 DIRECT CONNECTION TO THE BLOWER ORDER COUPLING Kit 9008311005 SEE ALSO Figure 33 Figure 31 4 VENT PIPE 4 INLET PIPE 3 4 ADAPTER FIELD SUPPLIED 3 VENT PIPE 75mm 3 MAX LENGTH 3 RUBBER 3 PIPE COUPLING ng SUPPLIED ORDER COUPLING Kit 9008311005 TO REPLACE 2 RUBBER COUPLING SUPPLIED AIR DUCT ADAPTER VENTING LOVV INPUT HEATERS ARE SUPPLIED WITH A 2 RUBBER COUPLING Figure 32 32 www gsw wh com AVENT 3 INLET PIPE PIPE 3 RUBBER COUPLING SUPPLIED BLOWER AIR DUCT ADAPTER 4 5 CONFIGURATION FOR HI INPUT HEATERS CONNECTED TO 3 VENTING OPTIONAL CONFIGURATION FOR LO INPUT HEATERS CONNECTED TO 3 VENTING Figure 33 4 VENT PIPE 4 INLET PIPE 3 4 ADAPTER FIELD SUPPLIED 3 VENT PIPE 75mm 3 MAX LENGTH 3 PIPE 3 RUBBER FIELD COUPLING SUPPLIED SUPPLIED CONFIGURATION FOR HI INPUT HEATERS CONNECTED TO 4 VENTI
73. addition each system requires a 45 long sweep elbow termination with a restrictive screen Minimum pipe length is 0 914m 3 with a minimum of one 90 elbow per side intake and exhaust 1 Determine termination type and pipe size 2 Determine number of elbows in vent system Do not include termination elbow Calculate the maximum equivalent length of the exhaust and air intake system 90 SHORT SWEEP ELBOW 90 LONG SWEEP ELBOW MORE RESTRICTIVE LESS RESTRICTIVE Figure 26 26 www gsw wh com 328765 000 VENT WATER HEATER SIZE Inside Diam INPUT Btu hr 75 gal 58 000 58 000 72 000 E 76 76 000 see Figure 27 and Figure 8 Equivalent lengths of straight pipe for various elbows using Notes Schedule 40 PVC CPVC ABS and polypropylene Vent Pipe Elbow Short Sweep Long Sweep Size Type Radius Radius 2 PIPE MAX EQUIV VENT LENGTH 15m term SCH 7 screen 125 38m term b and screen 50 15m term elbovv and screen K 55m term K and screen 125 38m term elbow and screen Vent Pipe Termination This water heater includes one 1 pair of more restrictive Vent Termination Screens and one 1 pair of less restrictive Vent Termination Screens For safety and optimum efficiency performance ensure the correct Vent Termination Screen is installed for the vent length in your installation Note Before installing the
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84. Flame Out Of Sequence 7 Soft Lockout Retry Limit Failed Trial For Ignition Soft Lockout Recycle Limit Pressure Switch High Limit opened Soft Lockout Recycle Limit Flame Lost Soft Lockout Six Four Flash three second pause Flame out of Sequence Sensed Five Flash three second pause Six One Flash three second pause Six Two Flash three second pause Six Three Flash three second pause Seven Flash three second pause N A Flammable Vapour Sensor Lockout Eight One Flash three second pause N A Flammable Vapour Sensor Fault Detected Eight Two Flash three second pause Temperature Sensor Fault Detected 1 Eight Three Flash three second pause Electronics Fault Detected 1 Eight Four Flash three second pause Valve Fault Detected 1 11 12 13 4 5 6 17 Hard Lockout LED continuously ON 328765 000 www gsw wh com 47 CORRECTIVE ACTIONS See the table below for corrective actions corresponding to the Corrective Action Number in the System Status And Error Codes section above If following those corrective actions does not resolve the error refer to Other Symptoms table later in this manual Corrective Action Corrective Action Normal operation no action necessary Normal operation no action necessary Flame rod not properly seated in flame reposition rod 2 Clean flame sensor rod with fine steel wood to avoid lock out Check that blower operates and does not have
85. JU IA 1d q s dednos oun JON uuolsu uuip dednos un Jed q aas dednos e z 5 duu 1 1 ne uneu np Sanel s insu z Ains ne jjneuo np nes uone u uule p NeAn 9 ins ONS JOUIGOI l Ju uu leIp uuuu 20 E nunuo je 149 sed s ou dednos s Np lins ej R IS pneyo ul ul nNx n 00 enod senders nbsind sjaisayeu lu 559 0 501 ap sed ulenu u ne p Ju uu noo5 nb 556 5 mne Z 3 uBioj s HOP q 5 dednos EI Ju uu noo5 p ne n np liuu nx Seid don JUBASP as uuosi d no i p 5oid lueAV uue sed eo un sulow ne dal 5 dednos Ju uu jl nueui spUeWWODA 199 9 1QS dednos e p abieuep E SDOA Z U L pneuo ne p 3u ul lnoozi onbsiy gt J youejd ulejp l 19 q 1 aale dednos p amue L n ulqol un ne 19 N 4016 np in u lul 6 uluuj S Ju uj no5 p neAn np yul nx l nb
86. PVC ABS CPVC or polypropylene Check local codes to determine which materials are allowed in your area and only use approved material All venting material and components must be joined with the approved primer cleaner and solvent cement Do not cement the venting system to the heater Note Plastic pipe and fittings are available through most plumbing suppliers Always check the marking on the pipe to make sure you are using the correct material 328765 000 Vent Pipe Installation The following guidelines should be followed when installing the air intake and exhaust vent system Venting should be as direct as possible with a minimum number of pipe fittings Ventdiameter must not be reduced unless specifically noted in the installation instructions Support all horizontal pipe runs every 1 2m 4 and all vertical pipe runs every 1 52m 5 or according to local codes or venting manufacturer s instructions Vents run through unconditioned spaces where below freezing temperatures are expected are not recommended Vents run through unconditioned spaces inside a building may result in the condensation of flue gases during the winter season The rubber coupling joined to the blower includes a nipple with a cap In installations such as this connect a condensation trap to this nipple The combustion air intake and exhaust vent system and termination may be installed in one of the following type terminations 1 H
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101. SUPPLIED VENT LENGTH GREATER THAN 6 EQUIVALENT METRES 20 EQUIVALENT FT USE THIS SCREEN SUPPLIED with 4 venting VENT LENGTH GREATER THAN 38 EQUIVALENT METRES 125 EQUIVALENT FT USE THIS SCREEN SUPPLIED Figure 27 28 www gsw wh com Note The same screens should be installed in the intake and the exhaust piping These screens are supplied in the vent kit In the concentric vent application screen is to be installed in the exhaust piping only Important Failure to install the appropriate screen in the vent termination elbows could result in improper heater operation with attendant risk of property damage personal injury or death by fire or carbon monoxide poisoning For heater models 50 58 50 62 75 72 amp 75 76 with 3 venting short with 3 venting long VENT LENGTH LESS THAN OR EQUAL TO 6 EQUIVALENT METRES 20 EQUIVALENT FT USE THIS SCREEN SUPPLIED with 4 venting VENT LENGTH GREATER THAN 6 EQUIVALENT METRES 20 EQUIVALENT FT USE THIS SCREEN SUPPLIED VENT LENGTH GREATER THAN 15 2 EQUIVALENT METRES 50 EQUIVALENT FT USE THIS SCREEN SUPPLIED Figure 28 328765 000 Vent Pipe Material This heater is certified to be installed using Schedule 40 PVC or CPVC or polypropylene plastic vent material for the exhaust All jurisdictions in Canada require that the material used to exhaust combustion products is approved to ULC S636 The combustion air intake material may be
102. T HIGH LIMIT SWITCH YELLOW e BLACK BLUE BLACK dp CAPACITOR 8 n BLACK WHITE GREEN HONEYWELL GAS VALVE Figure 10 328765 000 BLACK RIBBED NEUTRAL 120Vac 60Hz Wall Plug BLACK MIDDLE GND i BLOWER BLACK SMOOTH LINE 1 I JUNCTION BOX www gsw wh com 11 SAFETY LOCKOUTS This water heater has several lockout features designed to prevent the heater from operating in unsafe conditions HIGH LIMIT CONTROLS ENERGY CUT OFF Thermostat Water Temperature This feature is a part of the gas control valve thermostat see Figure 1 item 10 and limits the maximum water temperature In the event of the water overheating this safety feature shuts off the fuel supply to the burner Blower High Limit Switch This device is located on the blower see Figure 5 item 45 and limits the maximum temperature of the blower If the blower temperature rises above the temperature setting the switch opens causing the heater to shut down The switch will auto reset once the temperature drops sufficiently BLOWER AIR PRESSURE SWITCHES The blower heater is equiped with two air pressure switches located in the junction box see Figure 5 item 46 and item 49 Th
103. The water heater must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater see Figure 11 the wiring diagram g Close the panel on the junction box Make sure that the access panel is secured shut The blower discharge has a rubber coupling made to accept only straight sections of 2 or 3 pipe To start off with an elbow a short section of the straight pipe must be cut and glued into the end of the elbow that will mount in the rubber coupling 328765 000 Vent Intake Pipe Connections To Blower Air Duct 1 The plastic vent piping connects into the rubber coupling located on the top of the blower assembly This coupling includes gear clamps to connect the venting to the blower Important These connections must be properly seated and tightened to prevent the leakage of flue gases into the area See Figure 30 thru Figure 34 2 The 40 and 50 gallon heaters with rated inputs of 45k Btu hr or less are designed and supplied with a 2 rubber coupling to accept the vent pipe 3 The 50 and 75 gallon models with rated inputs of 58k Btu hr or more are supplied with a 3 rubber coupling to accept the vent pipe Note Polypropylene vent systems require separate adaptor field supplied 4 Before installing clean and lightly sand the end of the PVC CPVC plastic vent piping tha
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105. and are considered suitable for combination Water Potable Heating and Space Heating but not space heating only applications The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures TEMPERED SHUT OFF POTABLE WATER Q 1 VALVE NON TEMPERED WATER SUPPLY gt Tl COLD WATER INLET NON TEMPERED SUGGESTED PIPING WATER RETURN ARRANGEMENT FOR TOP CONNECTIONS MIXING VALVE TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG NOTE THE T amp P VALVE DISCHARGE PIPE MUST BE PIPED DIRECTLY TO THE DRAIN OR EXTERNAL TO THE BUILDING METAL DRAIN PAN 45mm 1 75 MAX DEPTH AT LEAST 50mm 2 GREATER THAN THE DIAMETER OF THE WATER HEATER Figure 8 www gsw wh com 9 Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm and the physically mentally disabled Table 1 published by U S Government Memorandum 1978 shows the approximate time to burn relationship for normal adult skin If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precau
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107. burner operation through the viewport on the inner door see Figure 40 The main burner should provide complete combustion of gas ignite rapidly give reasonably quiet operation and cause no excessive flame lifting from the burner ports If the proper flame characteristics are not evident see Figure 41 make sure that the flow of combustion and ventilation air is not blocked Inspection of exhaust air intake termination is needed to ensure there is no blockage there You should also check for sooting Soot is not normal and will impair proper combustion A visual inspection of the main burner and hot surface igniter should also be done at least once a year see Figure 40 Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater by unplugging the power cord and leave off until repairs are made Failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage IGNITER m AND FLAME URNER VIEWPORT Figure 40 www gsw wh com 39 BLUE TIPS Q INCORRECT LIGHT BLUE INNER CONES ARE FLAME LAZY SATISFACTORY ATN ELLON CORRECT FLAME SOFT BLUE Figure 41 COMBUSTION CHAMBER AND BURNER CLEANING In the event your burner or burner air openings require cleaning Call your service agency to remove and clean the burner and correct the problem that required the burner to be cleaned HOUSEKEEPING DAN
108. dance with B149 1 Asediment trap should be installed as close to the inlet of the water heater as practical at the time of water heater installation The sediment trap should be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap If a tee fitting is used it should be installed in conformance with the method of installation shown in Figure 17 Contaminants in the gas lines may cause improper operation of the gas control valve thermostat that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a sediment trap must be incorporated in the piping The sediment trap must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the Natural Gas and Propane Installation Code B149 1 www gsw wh com 21 SHUT OFF VALVE HOT WATER Vir COLD OUTLET w 5 WATER UNION INLET SIDE TAP ee OUTLET SOME COMPONENTS NOT SHOWN FOR CLARITY PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG SIDE TAP 305mm 12 MAX AIR GAP BELOW DISCHARGE PIPE Figure 18 FILLING THE WATER HEATER CAUTION e Avoid water heater damage Fill tank with water before operating Do not insert the power cord into the electrical receptacle until the heater has been fully ins
109. ensure the effectiveness and safety of the installation System Requirements The following requirements must be met for the installation of Combo Heating Systems 1 All components used for the distribution of water in the heating loop must be suitable for potable water These include all piping fittings solder and fluxes pumps for circulation of water valves etc 2 The water heater must not be connected to a hydronic heating system that has been used previously 3 No boiler treatment chemicals of any kind shall be introduced into the system 4 The Combo System components must be selected and sized to meet and maintain the total calculated demands for both domestic service hot water and space heating requirement The sizing and installation must be performed in accordance with good engineering practice such as ASHRAE Handbooks HRAI s Unified Combo Guidelines Hydronics Institute Manuals ANSI Z223 1 CSA F280 National Provincial Building Codes ANSI and or codes having jurisdiction 5 The air handler fan coil and or the circulating pump in a baseboard hydronic loop will require a dedicated 120V circuit This must be provided and identified for this purpose 6 All piping between the water heater and the air handler or hydronic baseboard loop must be adequately insulated to reduce heat loss 7 Ifthe local jurisdiction requires a back flow preventer in the cold water line an expansion tank of adequate size
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111. must be installed 8 Combo Heating Systems require higher water temperatures than other applications When the system is used to supply water for Combo Heating applications a means such as mixing valve must be installed to temper the water in order to reduce scald hazard potential see Figure 13 amp Figure 14 Installation The heating mode may be one of the following options A A fan coil air handler Figure 13 B Ahydronic baseboard finned tube loop In floor heating Figure 14 The following is a list of requirements for the installation of option A or B 1 Install shut off valves and unions so that the water heater can be isolated from the heating module should servicing of the water heater become necessary 2 Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating module without affecting the water heater 3 If the air handler does not have a venting means at the highest point of the piping arrangement install an air bleed at the highest point of the plumbing arrangement HOT WATER OPTIONAL knee also TO HOUSE COLD SUPPLY Massachusetts FIXTURE code requirements CHECK VALVE IF USED on pg 8 REQUIRES EXPANSION TANK CHECK COLD INLET VALVE EXTERNAL FLOW CIRCULATOR CONTROL DRAIN WATER PURGE HEATER L Ka VALVE J lt INTERNAL I CIRCULATOR Figure 13 HOT WATER EE AS see also TO HOUSE N COLD SUPPLY Massachusetts F
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113. of oil from metal parts and will disappear in a short while Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal 38 www gsw wh com OPERATIONAL CONDITIONS Smelly Water Each water heater contains at least one anode rod for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smell is a result of four factors which must all be present for the odour to develop a Aconcentration of sulfate in the supply water b Little or no dissolved oxygen in the water c A sulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans d An excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or service agency for further information concerning an Anode Replacement Kit and this
114. properly connected and not kinked or damaged Check continuity of the vent temperature limit switch replace switch if contacts remain open Check continuity of the air pressure switch N C replace switch if contacts remain open Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded Ensure there are no obstructions in the exhaust and air intake pipes If there are excessive restrictions in the air intake pipe the air pressure switch NC will open Check air pressure switch performance Check blower vacuum with a manometer Compare with air pressure switch N O setting If the air pressure switch proves defective replace the air pressure switch N O If the air pressure switch N O performance test results prove the air pressure switch is working properly and all other steps are followed and fault code persist replace the control Gas supply is turned OFF or gas pressure is too low Ensure supply pressure and manifold gas pressures are within requirements Manifold pressure is nonadjustable If supply pressure proves correct and manifold pressure is off by more than 0 3 WC replace the control Low supply voltage should be 115 125 VAC Ensure flame sensor is making good contact with the burner flame and flame is steady Ensure the flame sensor is clean us
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117. the lighting instructions on the label or see Lighting Instructions to restart the water heater 328765 000 To Flush The Water Heater Storage Tank 1 Turn OFF the electrical supply to the water heater 2 Ensure the cold water inlet valve is open 3 Connect a hose to the drain valve and terminate it to an adequate drain 4 Ensure the drain hose is secured before and during the entire flushing procedure Flushing is performed with system water pressure applied to the water heater 5 Open the water heater drain valve to flush the storage tank Caution Water will be hot 6 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 7 Close the water heater drain valve when flushing is completed 8 Remove the drain hose Ensure the heater is full of water 10 Turn ON electrical supply to place water heater back in operation and follow the lighting instructions 11 Allow the water heater to complete several heating cycles to ensure it is operating properly Caution Do not turn on power to the water heater unless the tank is full Open a hot water faucet and allow the water to run until the air is purged and the water flows uninterrupted from the faucet Important When operating a cold tank condensation can occur and drip on the burner This should not be confused with a tank leak www gsw wh com 41 ANODE ROD MAINTENANCE CAUTION Avoid wa
118. the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater and drain the water heater see Draining And Flushing section Replace the T amp P valve with a properly rated sized new one see Temperature Pressure Relief Valve for instructions on replacement TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE Figure 42 If the Temperature Pressure Relief Valve on the water heater weeps or discharges periodically it may be due to thermal expansion Note Excessive water pressure is the most common cause of temperature pressure relief valve leakage Excessive water system pressure is most often caused by thermal expansion in a closed system See Closed Water Systems and Thermal Expansion sections of this manual The T amp P valve is not intended for the constant relief of thermal expansion Temperature pressure relief valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the Limited Warranty Thermal expansion tanks must be installed on all closed water systems AA WARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Do not plug block or cap the discharge line Failure to follow this warning can result
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121. use isolation pads between the pipe hangers and the vent pipe broken or not properly connected 328765 000 Most power vent installations develop some condensation in the vent piping When using long runs of venting or when the venting passes through cold or unheated areas considerable amounts of condensate from the flue gases can develop Provision must be made for the condensate to drain freely from the system or to be collected in a condensate trap s that can be drained Damage or fracture of the vent piping may occur if the condensate is allowed to collect and freeze Pooling of condensate can restrict airflow and can cause nuisance failures of the system AIR REQUIREMENTS For safe operation an adequate supply of fresh uncontaminated air for combustion dilution and ventilation must be provided Note Contaminated or dusty air may cause build up on the blower wheel resulting in nuisance shut downs 328765 000 www gsw wh com 15 INSTALLING THE NEW WATER HEATER WATER PIPING A DANGER 125 F 62 can cause severe burns instantly resulting in severe injury or death Children the elderly and the disabled and are at highest risk of scald injury Feel water before bathing or showering Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures The water supply pressure should not exceed 80 psi If this occurs a pressure reducing val
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128. 450mm 18 MIN ABOVE ROOF EXHAUST VENT TERMINAL Figure 21 328765 000 4 The air intake termination and the exhaust vent termination must penetrate the same side of roof 5 The centerline of the air intake termination and the centerline of the exhaust vent termination must not be closer than 203mm 8 and not farther avvay than 610mm 24 6 The air intake terminal and the exhaust vent terminal must be oriented facing downward and the same direction Concentric Vent Termination Kit Installation A concentric vent termination kit see Table 2 may be used for vertical or horizontal terminations 45 ELBOW SEE LOCAL CODES PIPE NIPPLE SCREEN INSIDE COMBUSTION ABOVE SNOW AIR ACCUMULATION LEVEL OR 450mm FLASHING FIELD SUPPLIED STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR EXHAUST Figure 22 Figure 22 illustrates the concentric vent termination kit in a vertical roof installation Ensure the combustion air intake location is above the anticipated snow level www gsw wh com 25 ORIENTATION OF EXHAUST PIPING AND COMBUSTION AIR PIPING RELATIVE TO EACH OTHER MAY BE VERTICAL AS SHOWN OR AT ANY OTHER ANGLE TO SUIT THE INSTALLATION STRAP FIELD SUPPLIED EXHAUST SLOPE 6mm 1 4 OVER 1 5m 5 Figure 23 VENT DIA PIN 9008586005 9006328005 Table 2 Figure 23 illustrates the concentric vent kit for
129. 49 41 Manifold Door see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 42 Two Piece Grommet With Clip see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 43 Viewport see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 44 Air Tubing Intake see Figure 5 see also Figure 50 45 Blower High Limit Switch see Figure 5 see Figure 50 46 Intake Air Pressure Switch NC inside box see Figure 5 see also Figure 50 47 Capacitor see Figure 5 see also Figure 50 48 Air Tubing Exhaust see Figure 5 see also Figure 50 49 Exhaust Air Pressure Switch NO inside box see Figure 5 see also Figure 50 x see notes on following page EXHAUST OUTLET PIPING Rear Vievv Figure 47 328765 000 Natural gas and Propane LP main burner with igniter assembly for 40k and 45k Btu hr models Figure 48 Natural gas and Propane LP main burner with igniter assembly for 58k 62k 72k amp 76k Btu hr models Figure 49 328765 000 Shown with Junction Box Cover removed for clarity Notes Items not supplied with the water heater The side recirculation loop connections may not be used as the primary water inlet and outlet connections See Combo Heating Inlet And Outlet Side Taps Caution harness has 120 VAC In operation See Vent Pipe Installation for more information kk T The orifice on Natural gas models has
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137. GER Do not place chemical vapour emitting products near air intake and exhaust terminations Do not use or store flammable vapour products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance e Can cause serious injury or death INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Locating The New Water Heater section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater which can cause a fire TEMPERATURE PRESSURE RELIEF VALVE TEST A DANGER e Burn hazard e Hot water discharge e Keep clear of temperature pressure relief valve discharge It is recommended that the temperature pressure relief valve be checked to ensure it is in operating condition at least once a year When checking the temperature pressure relief valve 40 www gsw wh com operation make sure that 1 no one is in front of or around the outlet of the T amp P valve discharge line and 2 that water discharge will not cause any property damage as water may be extremely hot Use care when operating valve as the valve may be hot To check the relief valve lift lever at the end of valve several times see Figure 42 The valve should seat properly and operate freely If after manually operating
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141. IXTURE O code requirements CHECK VALVE IF USED on pg 8 REQUIRES EXPANSION TANK CHECK COLD INLET VALVE EXTERNAL CIRCULATOR SUPPLY I Li l 1 WATER HEATER l I I it HYDRONIC BASEBOARDS Al H SERIES CONNECTED SHOWN Figure 14 328765 000 www gsw wh com 17 CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will increase As the volume of water increases there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbin
142. Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED MOBILE HOMES GR LLC x ENERGY STAR GSW A CERTIFIED d WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personalinjury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT DOIF YOU SMELL GAS e Donotfry to light any appliance AWA RNING e Do not touch any electrical switch do Bead and deen iRetrasian not use any phone in your building manual and safety messages before installing operating or e Immediately call your gas supplier servicing thisvvater heater from a neighbor s phone Follovv the Failure to follow instructions and gas supplier s instructions safety messages could result in death or serious injury o If you cannot reach your gas supplier Instruction manual must remain with call the fire department water heater Installation and service must be 2 performed by a qualified installer For Your Safety service agency or the gas supplier AN ODOURANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF
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144. NG Figure 34 328765 000 SOUND SUPPRESSOR Included with this water heater is a Tee fitting configured as a sound suppressor Depending on the configuration of the water heater this will be either a 2 or a 3 fitting The sound suppressor can be fitted to the venting near the blower assembly or used as the exhaust termination see Figure 35 thru Figure 38 Side Wall Vent Installation The preferred location for the Sound Suppressor is 12 away from the blower as shown in Figure 35 and Figure 36 and serves as the first 90 elbow Alternatively it can be used as the termination for the venting If the Sound Suppressor is used as the vent termination the Vent Termination Screen see Vent Pipe Termination section must be installed in the straight through end of the Sound Suppressor see Figure 37 1 2 VENT PIPE 305mm 12 ee PREFERRED LENGTH BLOWER SUPPRESSOR 2 SOUND je amm lt AIR DUCT ADAPTER Ek CONFIGURATION FOR CONNECTED TO 2 VENTING Figure 35 3 SOUND lt lt SUPPRESSOR 3 VENT PIPE 305mm 12 PREFERRED LENGTH BLOWER EN AIR DUCT ADAPTER ney ALL CONFIGURATION FOR HI INPUT HEATERS CONNECTED TO 3 VENTING WITH SOUND SUPPRESSION TEE FITTING
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148. Power Direct Vent Water Heater it is recommended that the location of the pipe terminations air intake and exhaust vent be determined Use the Vent Termination Screen as shown in Figure 27 amp Figure 28 Install the Vent Termination Screen in the Termination Elbow on both the air intake pipe and the exhaust pipe 2 PIPE MIN EQUIV VENT LENGTH T 2m term elbow and screen T 2m term elbow and screen 125 38m term elbow and screen 50 15m term elbow and screen CONC VENT MAX EQUIV VENT LENGTH 50 15m term elbow and screen 100 30m term elbow and screen 30 9m term elbow and screen CONC VENT MIN EQUIV VENT LENGTH T 2m term elbow and screen T 2m term elbow and screen Ventlengths shown do not include vent termination elbow A horizontal vent must have a 45 vent termination elbow to direct the vent pipe downward A vertical vent must have a 90 elbow to direct the vent pipe horizontally followed by a vent termination 45 elbow to direct the vent pipe downward If additional elbows are used in the vent system the allowable vent lengths are reduced see chart below Two 45 elbows are considered the equivalent of one 90 elbow The equivalent length of the sound suppressor is similar to that of a short sweep 90 elbow 4 0 Table 3 328765 000 www gsw wh com 27 Venting Terminations And Sizin
149. Prove Period Pressure Switch PS Fault Delay failed 2 minutes open closed Soft Lockout Energy Cut Off ECO Limit Lockout Indefinite 328765 000 SYSTEM STATUS AND ERROR CODES The micro controller inside the gas control monitors the ignition sequence temperature settings and overall operation of the heater If any of these parameters does not operate properly the controller will shut down the water heater diagnose the failure and flash an error code The table below lists the System Status Codes for the Honeywell control Refer to it and to the Ignition State And Timing to diagnose the problem before attempting corrective action READING THE LED FLASH SEQUENCE The LED indicator light is active when the gas valve thermostat is in operation The light will normally show a flash sequence of a short flash once every four seconds or a Heartbeat of alternating bright dim Multiple flash codes indicate an error and can be read as follows Example Corrective Action Number 9 Six Two Flash three second pause For this code the LED indicator light will make six bright flashes pause for one second and then make two more bright flashes The LED will pause for three seconds and repeat the six two cycle of flashes Corrective Action Number Heartbeat alternates bright dim LED Flash Sequence Control Status ECO Energy Cut Off Limit Lockout thermostat temperature limit was exceeded
150. Right hand thread the orifice on Propane LP models has Left hand thread tt For Natural gas models the Flare Nut has Right hand thread For Propane LP models the Flare Nut has Left hand thread www gsw wh com 45 TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent LOCKOUTS Soft Lockout Occurs when a system safety device trips to break the sequence of operation The control will try to start the system in a timed basis but will not reinstate operation until the failure is corrected Hard Lockout Occurs when the main controller fails and must be replaced RESETTING THE HEATER CONTROL Softlockouts as diagnosed by the system error codes require the gas control to be reset To reset the control slide the ON OFF switch to the OFF position Wait for 10 seconds and move the switch back to the ON position If the problem that caused the control to lock out has not been corrected the control will remain or again go back into lockout 46 www gsw wh com IGNITION STATE AND TIMING IGNITION STATE TIMING 5 seconds NG models 15 seconds LP models 10 seconds Pre purge Hot Surface Igniter HSI Warmup Ignition Activation Period IAP Flame Recognition Period FRP Trial For Ignition IAP FRP Flame Stabilization Flame Failure 2 seconds max Q 1uA flame current Response Time Post purge Pressure Svvitch PS 2 minutes
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152. STAT IGNITER IS ENERGIZED CALLS FOR AND GAS VALVE IS HEAT OPENED BURNER COMES ON AND THE FLAME IS HEATER CONTROL SENSED BY CONTROL CHECKS TO ENSURE BLOWER EXHAUST PRESSURE SWITCH IS OPEN BLOWER 5 ENERGIZED CONTROL CHECKS GAS VALVE IS CLOSED TO ENSURE AND BURNER SHUTS EXHAUST PRESSURE OFF SWITCH CLOSES AND INTAKE PRESSURE SWITCH REMAINS CLOSED INDICATING BLOWER IS OPERATING AND THERE ARE NO BLOCKAGES INTAKE OR EXHAUST BURNER CONTINUES TILL THE WATER IN THE TANK REACHES THER MOSTAT SETTING BLOWER CONTINUES FOR A POST PURGE TIME TEMPERATURE SWITCH REMAINS CLOSED INDICATING VENT TEMPARATURE IS NOT ABOVE THE HEATER REMAINS ON STANDBY UNTIL NEXT CALL FOR ALLOWEBLE LIMIT HEAT Figure 9 328765 000 ELECTRICAL REQUIREMENTS amp WIRING DIAGRAM AWARNING Electric Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock 77 plugging in the vvater heater alvvays make sure The voltage and frequency correspond to that specified on the vvater heater vviring diagram The electrical outlet has the proper overload fuse or breaker protection 1 The unit must be connected to a dedicated povver supply 2 The unit must be connected to a 120VAC power supply 3 The water heater must be properly grounded 4 This water heater is a polarity sensitive appliance and will not operate if the power s
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155. YOU ARE UNSUCCESSFUL PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED 1410 328765 000 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 GENERAL SAFETY 4 INTRODUCTION 6 Qualified Installer Or Service Agency 6 Preparing For The Installation 6 TYPICAL INSTALLATION 7 Get To Know Your Water Heater Gas Models List Referencing Figures 1 5 7 Replacement Parts And Deliming Products 8 Combo Heating Inlet And Outlet Side Taps 8 Water Piping Mixing Valve Usage 9 Mixing Valves Water Heater Operation 10 Electrical Requirements amp Wiring Diagram 11 SAFETY LOCKOUTS 42 High Limit Controls Energy Cut Off 12 Thermostat VVater Temperature Blovver High Limit Svvitch Blower Air Pressure SvvitchEs 12 LOCATING THE NEVV VVATER HEATER 13 Facts To Consider About The Location 13 Clearances To Combustibles Floors VVith Carpeting Clearances For Servicing High Ambient Temperature Installations 14 Important Notes and Warnings Air Requirements 15 INSTALLING THE NEW WATER HEATER
156. a horizontal side wall installation To prevent rain water from entering the exhaust outlet slope the vent kit at a downward pitch of 6mm 1 4 per 1 5m 5 away from the inside wall Ensure the combustion air intake location is above the anticipated snow level Multiple Concentric Vent Installations When two concentric vent kits are being installed the vent hood centers shall be either less than 240mm 9 5 apart or more than 1 1m 43 5 apart Spacings between 240mm 9 5 and 1 1m 43 5 are not allowed due to the possibility of exhaust cross circulation see Figure 24 When more than 2 kits are installed only 2 of them shall be less than 240mm 9 5 apart Never install 3 termination kits together less than 240mm 9 5 apart see Figure 25 240mm 9 5 SC 4 1m 43 5 Ml NOTE IF AN ELBOW IS REQUIRED BY LOCAL CODES INSTALL SCREEN IN ELBOW INSTEAD OF CONCENTRIC VENT EXHAUST Figure 24 PIPE NIPPLE USE WITH ELBOW 90 ELBOW SEE LOCAL CODES COMBUSTION mM 25mm 1 MAXIMUM ALL SCREEN INSIDE NOTE IF AN ELBOW IS REQUIRED BY LOCAL CODES INSTALL SCREEN IN ELBOW INSTEAD OF CONCENTRIC VENT EXHAUST SCREEN Figure 25 Vent Pipe Length The maximum allowable pipe lengths for air intake and exhaust are listed in Table 3 The specified maximum lengths are for each of the intake and exhaust systems and not for the combined lengths of both systems In
157. after extended period of non use Read instruction manual before installing using or servicing water heater 4 www gsw wh com 328765 000 GENERAL SAFETY CAUTION A WARNING Improper Installation use and service may result in property damage Before servicing the water heater make sure the blower assembly is unplugged or the electrical supply to the heater OFF Do not operate water heater if flood damaged m O Inspect anode rods regularly replace when significantly depleted Label all wires prior to disconnection when servicing controls Wiring error can cause improper and dangerous Install in location with drainage z n operation Verify proper operation after servicing Fill tank with water before operation Properly sized thermal expansion tanks are required on all Failure to do this could result in death serious bodiy closed water systems injury or property damage Refer to this manual for installation and service AA WARNING ADANGER Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged For operation above 3 079 m 10 100 a high altitude orifice must be installed Do not operate if soot buildup is present e Do not obstruct water heater air intake with insulating jacket P Flammable Vapours Do not obstruct blower air intake Do not place chemical vapour e
158. ailing provisions of local codes or in the absence of such the latest edition of Canadian Electrical Code CAN CSA C22 1 Part I After all actions on checklist are checked completed read the Lighting Instructions and proceed with lighting the heater 328765 000 LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater Make sure the burner viewport is not missing or damaged Make sure the tank is completely filled with water before operating the water heater The gas control valve thermostat has an On Off Switch and must be turned on before the water heater is operational Check the label on the front of the water heater near the gas control valve thermostat for the correct gas Do not start this water heater with any gas other than the one listed on the label If you have any questions or doubts consult the gas supplier or gas utility company The following Lighting Instruction label appears on the front of the water heater CH AES injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do NOT try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not t
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160. any blockages Check that all wiring is correct Ensure the air pressure sensing tubes are properly connected and not kinked or damaged Ensure the air pressure switch is correct and the air pressure switch N O is not bypassed jumpered Turn power to the unit OFF check for continuity of the air pressure switch N O with wires disconnected a If the pressure switch contacts show continuity closed circuit replace the pressure switch b If the pressure switch contacts are open and all wiring is correct replace the Gas Control Ensure the blower is running check for 120 VAC to the blower when the heating cycle begins a If the Gas Control does not energize the blower replace the Gas Control b If the blower fails to start when energized i Turn power to the heater OFF check if the capacitor is connected ii Turn power to the heater OFF check the capacitor rating 3uF 5 iii Turn power to the heater OFF replace the blower assembly Ensure the air pressure sensing tubes are properly connected and not kinked or damaged Check continuity of the vent temperature limit switch replace switch if contact remain open Check continuity of the air pressure switch N C replace switch if contact remain open Ensure the correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure maximum number of elbows or equivalent feet of b
161. arge line Failure to follow this warning can result in excessive tank pressure serious injury or death This water heater is provided with a properly rated sized and certified combination Temperature Pressure Relief Valve T amp P valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 and the code requirements of ASME Ifreplaced the new T amp P valve must meet the requirements oflocal codes but notless than a combination temperature pressure relief valve rated sized and certified as indicated in the above paragraph The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi and a discharge capacity not less than the water heater Btu hr input rate as shown on the water heater s model rating plate For safe operation of the water heater the temperature pressure relief valve must not be removed from its designated opening nor plugged The T amp P valve must be installed directly into the fitting of the water heater designed for the relief valve Install discharge piping so that any discharge will exit the pipe within 305mm 12 above an adequate floor drain or external to the building In cold climates it is recommended that it be
162. by insulation to minimize heat loss The insulation has a hole on the bottom side to accommodate the valve outlet and allow for the piping connection Do not restrict the outlet opening of the T amp P valve T amp P Relief Valve Insulation Outlet opening on underside T amp P Relief Valve Line Figure 16 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 16 1 Locate the slit running the length of the T amp P relief valve insulation 2 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 16 Apply gentle pressure to the insulation to ensure it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape electrical tape or equivalent Important The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 16 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this manual 3 Locate the hot water outlet amp cold water inlet pipes to the water heater 4 Locate the slit running the length of a section of pipe insulation 5 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure it is fully seated around the pipe Also ensure the base of the insulation is flush with the water heater O
163. ce with local installation codes and the requirements of the gas supplier 328765 000 Side Wall Vent Terminal Installation Important When terminating the vent on a side wall the following specifications pertaining to terminal location must be followed see Figure 20 1 The air intake terminal and the exhaust vent terminal must terminate on the same exterior wall 2 The vertical centerline of the air intake terminal must be located at a minimum of 203mm 8 and not more than 610mm 24 from the vertical centerline of the exhaust vent terminal 3 The horizontal centerline of the air intake terminal may not be located more than 100mm 4 below the horizontal centerline of the exhaust vent terminal 4 To avoid exhaust recirculation the air intake terminal may be rotated away from the exhaust vent terminal see Figure 20 100mm 4 MAX Figure 20 Roof Vent Terminal Installation Important When terminating the vents through a roof the follovving specifications pertaining to terminal location must be follovved see Figure 21 1 The air intake termination and the exhaust vent termination shall extend above anticipated snovv level or at least 450mm 18 above the roof 2 Must provide proper support for all pipes protruding through roof 3 The vertical roof terminations should be sealed with a plumbing roof boot or equivalent flashing A amp B ABOVE SNOW ACCUMULATION LEVEL OR
164. chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR IN HOT WATER FAUCETS A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions it is recommended that the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open 328765 000 PERIODIC MAINTENANCE GENERAL UPKEEP Make it a habit to look around the heater the vent piping and the hot and cold water pipes Do not allow any material to be piled up against the heater Do not place any object on top of
165. d be as long as 0 89m 35 Refer to the current edition of the Natural Gas and Propane Installation Code B149 1 for detailed requirements TOP VIEW OF CLOSET WITHOUT DOOR A gt TOP VIEW OF CLOSET WITH DOOR 5 5 MIN Figure 12 AA WARNING Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the instruction manual and B149 1 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapour emitting products near water heater 14 www gsw wh com HIGH AMBIENT TEMPERATURE INSTALLATIONS As the room temperature rises the water heater venting is exposed to high temperatures from the inside and the outside In these situations attention to the choice of venting material is necessary Establishing the ambient temperatures where the heater and the venting are installed is very important Areas that can experience high ambient environments include closets alcoves areas under staircases attics especially in metal roofed buildings areas with restricted air movement rooms with large solar gains metal sheds industrial or commercial enterprises and venting systems exposed to direct sunlight Water heater installations in ambient conditions hotter than 43 C 110 F require the installation of a high ambient limit switch kit number 9009024015 and use of CPVC or polypropylene venting material Failure to install the proper ve
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168. dition of the anode rod dictates its replacement see Figure 43 42 www gsw wh com Note Artificially softened water requires the anode rod to be inspected annually The following are typical but not all signs of a depleted anode rod The majority of the rods diameter is less than 10mm 3 8 Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of either prtep or both it should be replaced Note Whether re installing or replacing the anode rod check for any leaks and immediately correct if found Figure 43 To replace the anode 1 Turn off gas supply to the water heater 2 Shut off the water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 191 5 gallons of water from tank Refer to Draining And Flushing for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open a nearby hot water faucet to purge air from water system Check for any leaks and immediately correct any if found 7 Restart the water heater as directed in this manual See the Reference Parts Listing for anode rod location Figure 44 328765 000 LEAKAGE CHECKPOINTS SERVICE If a condition persists or you are uncertain about the operation of the water heater co
169. e is too low Ensure supply pressure and manifold gas pressures are within requirements Manifold pressure is nonadjustable if gas supply pressure proves correct and manifold pressure is off by more than 0 3 WC replace the control Low supply voltage should be 115 125 VAC Ensure flame sensor is making good contact with the burner flame and flame is steady Ensure flame sensor is clean use ultra fine steel wool to clean flame sensor Ensure the Hot Surface Igniter is positioned properly to provide consistent ignition Check for any cracks in igniter assembly ceramic insulators replace igniter assembly if damaged Check resistance of igniter at room temperature at the plug Replace the igniter if resistance is not within 42 76 ohms at room temperature Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded Ensure the blower is running check for 120 VAC to the blower when the heating cycle begins a If the Gas Control does not energize the blower replace the Gas Control b If the blower fails to start when energized i Turn power to the unit OFF check if the capacitor is connected ii Turn power to the unit OFF check the capacitor rating 3uF 5 iii Turn power to the unit OFF replace the blower assembly Ensure the air pressure sensing tubes are
170. e ultra fine steel wool to clean flame sensor Ensure the Hot Surface Igniter is positioned properly to provide consistent ignition Check for any cracks in igniter assembly ceramic insulators replace igniter assembly if damaged Check resistance of igniter at room temperature at the plug Replace the igniter if resistance is not within 42 76 ohms at room temperature Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded 1 Turn the power OFF for 10 20 seconds then ONT again to clear the fault code 2 Replace the control if fault code persists 12 N A If this happens replace the gas control N A If this happens replace the gas control 1 Tum the power OFF for 10 20 seconds then ON again to clear the fault code 1 2 Replace the control if the fault code persist 1 Turn the power OFF for 10 20 seconds then ON again to clear the fault code 2 Replace the control if the fault code persist 16 1 Turn the power OFF for 10 20 seconds then ON again to clear the fault code 2 Replace the control if the fault code persist 1 Control has failed If resetting the control does not clear the fault code replace the control 328765 000 www gsw wh com 49 15 OTHER SYMPTOMS Possible Cause S Corrective Action Insufficient Hot Water Wa
171. ead and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for Obstructions which could cause improper venting The combustion dilution and ventilation air flow must not be obstructed Damage or deterioration which could cause improper venting or leakage of combustion products Be sure the vent piping is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiation 328765 000 Chemical vapour corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapours Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If after inspection of the vent system you found sooting or deterioration something is wrong Call the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater BURNER OPERATION AND INSPECTION At least once a year a visual inspection should be made of the main burner and the hot surface igniter assembly for proper flame characteristics and ignition sequences This can be done by removing the outer door and viewing the main
172. ely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury WARNING indicates a potentially A AAN ANNE hazardous situation which if not avoided could result in death or injury CAUTION indicates a potentially A 07 I hazardous situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert CAUTI ON symbol indicates a potentially hazardous situation which if not avoided could result in property damage DANGER All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury This product is certified to comply with a maximum weighted average of 0 25 lead co
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174. er restrictive screens were used 1 Turn temperature knob to higher setting 2 Correct piping dip tube must be in cold inlet 3 Advise customer 4 Install adequate heater 1 Ensure the correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure the proper restrictive screens were used 2 See thermal expansion section 3 Use a pressure reducing valve and relief valve 4 Check Relief valve for proper operation 5 Do Not plug T amp P valve 1 Chlorination procedure 2 Chlorination procedure 3 Replace with anode appropriate for water conditions 1 Normal operation the condensation should disappear after heater warms up 2 Install condensate hose to drain port on the rubber coupling 1 Ensure the correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded 2 Ensure that the proper restrictive screens were used 3 Replace blower high limit switch 328765 000 NOTES 328765 000 www gsw wh com 51 NOTES 52 www gsw wh com 328765 000 NOTES 328765 000 www gsw wh com 53 NOTES 54 www gsw wh com 328765 000 NOTES 328765 000 www gsw wh com 55 GSW 599 Hill St West Fergus ON N1M 2X1 Phone 888 479 8324 Fax 519 787 5500 Email info gsw wh com www gsw wh com 2 UA ASB AWAN 566 Oyu
175. ermination to raise vent pipe runs the required distance 3 Vertical runs require a support every 1 52m 5 that must provide proper support to prevent stress on the pipes or according to venting manufacturer s instructions Vent Terminal Installations Important The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of Natural Gas and Propane Installation Code B149 1 In addition the manufacturer recommends the vent terminal not to be installed closer than 152mm 6 from an inside or outside corner Plan the vent system layout so that proper clearances are maintained from plumbing and wiring Vent pipes serving power vented appliances are classified by building codes as vent connectors Required clearances from combustible materials must be provided in accordance with information in this manual under Locating The New Water Heater and with the latest edition of Natural Gas and Propane Installation Code B149 1 and local codes 30 www gsw wh com BLOWER ASSEMBLY INSTALLATION 1 2 This power vented water heater comes with blower assembly installed After unit is set in place make sure blower assembly is still mounted securely Make sure there is no damage to blower Make sure there is no packing material in the inlet or discharge of the blower Make sure that the plastic tubing is still attached from the air pressure switch t
176. ese devices are connected in series and monitor the air pressure produced by the blower In the event that the exhaust venting becomes blocked or sufficiently restricted the normally open NO air pressure switch will shut down the heater In the event that the intake pipe becomes sufficiently blocked or restricted the normally closed NC air pressure switch will shut down the heater 12 www gsw wh com 328765 000 LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed 1 Select a location indoors as close as practical to the vent termination or location to which the water heater vent piping is going to be connected and as centralized with the water piping system as possible 2 Selected location must provide adequate clearances for servicing and proper operation of the water heater 3 Avoid locations that could cause the water heater to freeze from outside air 4 Selected location must provide access to a properly grounded electrical branch circuit A dedicated circuit is preferred Do
177. esign certified by CSA International under Water Heater Standard ANSI Z21 10 1 CSA 4 1 or ANSI Z21 10 3 CSA 4 3 current edition as applicable QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this water heater requires ability equivalent to that of a Qualified Agency as defined by ANSI below in the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI Z223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual PREPARING FOR THE INSTALLATION 1 Read the General Safety section of this
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179. g Refer to Table 3 for vent pipe materials and sizing If the installation requires a vent riser suitable drainage must be provided to ensure condensation does not accumulate see Figure 29 Termination through a roof is shown Figure 21 Vent Screen Installation Installed in the vent termination elbow the vent screen is required to keep foreign objects rodents and small birds from entering the venting system These screens have been sized to ensure maximum energy efficiency of the vent system based on the equivalent length of the vent piping CHOOSE ONLY the ONE SCREEN THAT MATCHES YOUR VENTING CONFIGURATION see Figure 27 amp Figure 28 How to determine the equivalent length is shown in Table 3 Supplied with this heater are several vent termination screens see Figure 27 amp Figure 28 Install the appropriate vent screen into the vent termination elbow Gently push the screen into the termination elbow until it sits against the inside shoulder The metal wire screens are self securing Plastic screens must be secured with 2 drops of silicone sealant This will allow for easy removal for inspection and cleaning For heater models 40 40 amp 50 45 with 2 venting short with 2 venting long SSS Eh Zo VENT LENGTH LESS THAN OR EQUAL TO 6 EQUIVALENT METRES 20 EQUIVALENT FT USE THIS SCREEN SUPPLIED with 3 venting FOR ALL LENGTHS OF VENTING USE THIS SCREEN
180. g service agency or your retail supplier regarding the installation of a thermal expansion tank Note To protect against untimely corrosion of hot and cold water fittings it is recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or service agency 18 www gsw wh com SHUT OFF VALVE lt H D HOT WATER OUTLET a gt COLD 8 WATER INLET UNION 3 4 SWEAT FITTING 3 4 SWEAT FITTING TEMPERATURE PRESSURE RELIEF VALVE SOME COMPONENTS NOT SHOWN FOR CLARITY DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN Figure 15 Figure 15 shows typical attachment of water piping to the water heater The water heater is equipped with 3 4 NPT water connections Note If using copper tubing solder tubing to an adapter before attaching the adapter to the water heater connections Do not solder the water lines directly to the water heater connections it will harm the dip tube and heat traps and damage the tank 328765 000 TEMPERATURE PRESSURE RELIEF VALVE A WARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Do not plug block or cap the disch
181. gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death A WARNING For continued protection against risk of fire e Do not install water heater on carpeted floor Do not operate water heater if flood damaged www gsw wh com 13 Clearances To Combustibles Minimum clearances between water heater and combustibles are 0mm 0 at the sides and rear 140mm 5 5 from the front and 305mm 12 from top standard clearance If clearances stated on the heater differ from standard clearances install water heater according to clearances stated on the heater see Figure 12 Floors With Carpeting This water heater must not be installed directly on carpeting Carpeting must be protected by a metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 76mm 3 in every direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard Clearances For Servicing When installing the heater consideration must be given to proper location Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible Servicing this appliance such as changing the anodes etc requires clearances for accesability and replacement of parts The anode coul
182. heater Do not attempt to repair the unit It must be replaced information above on this label Turn off all electric power to the appliance Turn the thermostat STOP Read the safety counter clockvvise f the lovvest setting Set the switch on the control to the OFF position Do not attempt to light manually Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go the next step 10 If the appliance will not operate follow the 7 Turn all electric power to the appliance 8 Set the switch on the control to the ON position 9 Turn thermostat to desired setting Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature instructions To Turn Off Gas To Appliance and call your service technician or gas supplier 1 Turn the thermostat counter clockvvisef the lovvest setting 2 Set the gas control svvitch to the OFF position 3 Turn off electrical povver to the appliance if service is to be performed 323546 000 328765 000 www gsw wh com 35 OPERATING THE TEMPERATURE CONTROL SYSTEM It is recommended that lower water temperatures be used to avoid the risk of scalding t is further recommended in all cases that the water temperature be set for the lowest temperat
183. hin the building 328765 000 www gsw wh com 3 GENERAL SAFETY AWARNING AWARNING Read and understand instruction manual and safety messages For continued protection against before installing operating or risk of fire servicing this water heater Do not install water heater on Failure to follow instructions and carpeted floor safety messages could result in e Do not operate water heater if death or serious injury flood damaged Instruction manual must remain with water heater Water temperature over 52 C 4 DANG ER 125 F can cause severe burns WA RN N G instantly resulting in severe injury or Explosion Hazard death Children the elderly and the physically or mentally disabled are at highest risk for scald injury e Overheated water can cause watertank explosion Feel water before bathing or showering Bl Properly sized temperature Temperature limiting valves are and pressure relief valve available must be installed in opening Read instruction manual for safe provided temperature setting A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets
184. igure 2 Natural gas and Propane main burner with igniter assembly for 40k and 45k Btu hr models Figure 3 Natural gas and Propane LP main burner with igniter assembly for 58k 62k 72k and 76k Btu hr models Shown with Junction Box Cover removed for clarity Vacuum relief valve install per local codes not supplied with heater Figure 6 Notes ltems not supplied with the water heater The side recirculation loop connections may not be used as the primary water inlet and outlet connections See Combo Heating Inlet And Outlet Side Taps below Caution harness has 120 VAC In operation See Vent Pipe Installation for more information kk REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired Standard hardware items may be purchased locally COMBO HEATING INLET AND OUTLET SIDE TAPS Models equipped with Combo Heating capabilities have the two side plumbing taps plugged item 7 and item 10 in Figure 1 and see also Figure 7 amp Figure 8 If the heater is to be installed in a Combo Heating application these plugs must be removed www gsw wh com 328765 000 WATER PIPING MIXING VALVE USAGE Mixing Valves Water temperature over A DAN G E R 125 F 52 C can cause severe burn
185. igure 4 19 Control Harness 20 Sediment Trap 21 Ground Joint Union gas connection 22 Main Manual Gas Shut off Valve 23 Gas Supply 24 Anode under cap 25 Baffle Assembly 26 Hot Water Outlet Nipple Anode 27 Inlet Water Shut off Valve 28 Rubber Coupling see Figure 5 29 Gear Clamp see Figure 5 30 Blower with Power Cord see Figure 5 31 Air Duct Adapter 32 Air Inlet Snorkel 33 Air Duct 34 Thermal Expansion Tank see Closed Water Systems and Thermal Expansion sections 35 Flame Sensor Rod see Figure 3 amp Figure 4 36 Sheet Metal Burner see Figure 3 amp Figure 4 9 9 9 www gsw wh com AIR INLET PIPING Se xy PIPING 37 Gas Orifice see Figure 3 amp Figure 4 38 Gas Manifold see Figure 3 amp Figure 4 39 Hot Surface Igniter see Figure 3 amp Figure 4 40 Manifold Door Gasket see Figure 3 amp Figure 4 41 Manifold Door see Figure 3 amp Figure 4 42 Two Piece Grommet With Clip see Figure 3 amp Figure 4 43 Viewport see Figure 3 amp Figure 4 44 Air Tubing Intake see Figure 5 45 Blower High Limit Switch see Figure 5 46 Intake Air Pressure Switch NC inside box see Figure 5 47 Capacitor see Figure 5 48 Air Tubing Exhaust see Figure 5 49 Exhaust Air Pressure Switch NO inside box see Figure 5 k kk kkk KKKK see notes on following page EXHAUST OUTLET LLC 2 8 Rear View F
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187. in excessive tank pressure serious injury or death 328765 000 DRAINING AND FLUSHING Periodic draining and cleaning of sediment from the tank maybe necessary It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures See Typical Installation section in this manual for location of the water heater components described below A DANGER e Burn hazard Hot water discharge Keep hands clear of drain valve discharge To Drain The Water Heater Storage Tank 1 Turn OFF the electrical supply to the water heater 2 Turn OFF the gas supply at the Main Gas shut off Valve if the water heater is going to be shut down for an extended period 3 CLOSE the cold water inlet valve to the water heater 4 OPEN a nearby hot water faucet and leave open to allow for draining 5 Connect a hose to the drain valve and terminate to an adequate drain Note If the water heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 Close the water heater drain valve when all water in the storage tank has drained 7 Follow instructions in the Filling The Water Heater section 8 Turn ON the gas supply at the main gas shut off valve 9 Follow
188. ing In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the relief valve and the drain A DANGER e Burn hazard Hot water discharge e Keep clear of temperature pressure relief valve discharge It is recommended to manually operate the T amp P valve at least once a year Caution should be taken to ensure 1 no one is in front of or around the outlet of the discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions in this manual and replace the temperature pressure relief valve with a properly rated sized new one www gsw wh com 19 Note The purpose of a temperature pressure relief valve is to prevent excessive temperatures and pressures in the storage tank The T amp P valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion see Closed Water Systems and Thermal Expansion sections Temperature Pressure Relief Valve And Pipe Insulation The T amp P valve installed on this water heater is covered
189. ion and sediment trap L Approved pipe joint compound used Adequate pipe size and of approved material Chloride free soap and water solution or other approved means used to check all connections and fittings for possible gas leaks Vent Pipe System Vent pipe and fittings of approved material Acceptable size length and number of elbows on exhaust vent system Installed in accordance with prevailing provisions of local codes or in the absence of such the latest edition of Natural Gas and Propane Installation Code B149 1 Horizontal piping slopes at an upward pitch of 3mm 1 8 rise per 1 52m 5 away from the water heater U Not obstructed in any way 34 www gsw wh com Vent Termination Horizontal L 305mm 12 min above grade snow level L Away from corners other vents windows etc Vertical Air Intake and Exhaust terminations 450mm 18 min above roof snovv level VVater System Piping Temperature and Pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water D O Closed system pressure build up precautions installed Electrical Connections Unit connected to a dedicated 120V electrical sup ply L Proper polarity L Water heater properly grounded Installed in accordance with prev
190. it servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution nota match or open flame Repair and retest as required When finished rinse off soapy solution and wipe dry F WARNING e Use joint compound or tape compatible with natural gas and propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape marked as being resistant to the action of gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual shut off valve should be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in 328765 000 excess of 1 2 psi It should be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi Connecting gas piping to the gas control valve thermostat of water heater can be accomplished by the method shown in Figure 17 BLACK PIPE SEDIMENT TRAP JOINT CONTROL UNION VALVE OPTIONAL Figure 17 SEDIMENT TRAPS AA WARNING Contaminants in gas lines cause fire or explosion e Clean all gas piping before installation Install sediment trap in accor
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195. manual first and then entire manual carefully If you don t follow safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for installation operation and maintenance of the gas fired water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and instructions are essential to proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER 6 www gsw wh com The installation must conform with these instructions and local code authority having jurisdiction In absence of local codes installation must comply with current editions of the Natural Gas and Propane Installation Code B149 1 and Canadian Electrical Code CAN CSA 22 1 Part I All documents are available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontario Canada L4W 5N6 The water heater when installed must be electrically grounded in accordance with the local codes or in the absence of local codes current edition of the Canadian Electrical Code CAN CSA C22 1 Part I If after reading this manual you have any questions or do not understand any portion of the instructions call the local gas utility or the manufacturer whose name appears on the rating pla
196. me states require settings at specific lower temperatures The thermostat settings on the gas control valve are shown in Figure 39 The water temperature setting was factory set at the lowest VAC temperature setting 328765 000 GAS CONTROL VALVEITHERMOSTAT 54 C 60 C 65 C 0 130 F 140 F 150 F 155 F E 1 2 43 C 21 C 49 C ON OFF TEMPERATURE 120 F 110 F 70 F SWITCH SETTING DIAL en t Figure 39 Approximate Time to induce a 2nd Temperature Temperature and 3rd Degree burn Dial Setting i to adult skin VERY HOT 68 155 Less than 1 second 65 150 About 1 5 seconds e Lang Less than 5 seconds HOT Low VAC 21 70 N A Table 4 Note The temperatures indicated are approximate The actual temperature of the heated water may vary The Vacation Setting VAC sets the controller at approximately 21 C 70 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy 328765 000 www gsw wh com 37 FOR YOUR INFORMATION START UP CONDITIONS Condensate Whenever the water heater is filled with cold water some condensate will form while the burner is ON A water heater may appear to be leaking when in fact the water is condensate This usually happe
197. mitting products Vapours from flammable Water heater has a main near water heater Iquids may explode and burner and hot surface igniter Gas and carbon monoxide detectors are catch fire causing death or The hot surface igniter available severe burns 1 can be triggered at any No vent damper installation is compatible with time and this power vented water heater Do not use or store 2 the hot surface will ignite flammable products such as flammable vapours Breathing carbon monoxide can cause brain damage or death gasoline solvents or adhe Alvvays read and understand instruction manual sives in the same room or Vapours area near the water heater 1 cannotbe seen 2 are heavier than air Keep flammable products 3 go a long way on the floor 1 far avvay from heater and 2 in approved containers 4 can be carried from other 3 tightly closed and rooms to the electrodes 4 out of children s reach by air currents nstallation Do not install the vvater heater vvhere flammable products will be stored or used 328765 000 www gsw wh com 5 INTRODUCTION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service Abbreviations found in this Installation and Operating manual e CSA Canadian Standards Association ANSI American National Standards Institute ASME American Society of Mechanical Engineers This gas fired water heater is d
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200. nce seated secure the insulation with duct tape electrical tape or equivalent 6 Repeat steps 4 and 5 for the hot water outlet pipe 7 Add additional sections of pipe insulation as needed 20 www gsw wh com HIGH ALTITUDE INSTALLATION WARNING e For operation above 10 100 ft 3 079 metres a high altitude orifice must be installed Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual This heater is approved for operation up to 3 079m 10 100 without alteration Failure to replace standard orifice with a high altitude orifice when installed above 3 079m 10 100 could result in improper and inefficient operation of the appliance producing carbon monoxide gas in excess of safe limits which could result in serious injury or death Contact your gas supplier for any specific changes which may be required in your area GAS PIPING AA WARNING Do not use water heater with any gas other than the gas shown on the rating plate Excessive pressure to gas control valve can cause serious injury or death e Turn off gas lines during installation Contact qualified installer or service agency AWARNING Explosion Hazard Have a qualified technician make sure that the L P gas operating pressure does not exceed 13 water column Failure to do so can result in death explosion or fire
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203. not use a GFI outlet 5 Avoid locations that expose the water heater to direct sunlight 6 Keep combustibles such as boxes magazines clothes etc away from the water heater area Important Do not use an extension cord to connect the water heater to an electrical outlet CAUTION All water heaters eventually leak Do not install without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow of water will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor In all cases a metal drain pan should be installed under the water heater Metal drain pans are available at your local hardware store Such a metal drain pan must have a clearance of at least 25mm 1 greater than any point on the water heater s outer jacket and must be piped to an adequate drain The pan must have a maximum depth of 45mm 1 75 Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from
204. ns when a A new water heater is filled with cold water for the first time b Burning gas produces water vapour in water heaters particularly high efficiency models where flue temperatures are lower c Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise Because of the suddenness and amount of water condensate water maybe diagnosed as a tank leak After the water in the tank warms up about 1 2 hours the condition should disappear Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up An undersized water heater will cause more condensation The water heater must be sized properly to meet the family s demands for hot water including dishwashers washing machines and shower heads Excessive condensate maybe noticed during the winter and early spring months when incoming water temperatures are at their lowest Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapour see also Condensate section Smoke Odour It is not uncommon to experience a small amount of smoke and odour during the initial start up This is due to burning off
205. nt material will result ina non compliant installation and can result in deformation breakage of the pipe WARNING Flue gases may escape if vent pipe is deformed Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Important Notes and Warnings Thisheateris certified to be installed using Schedule 40 PVC or CPVC or polypropylene plastic vent material All jurisdictions in Canada require that the material used to exhaust combustion products is approved to ULC S636 Only use approved material All venting material and components must be joined with the approved primer cleaner and solvent cement Do not common vent this heater with any other appliance During operation the plastic piping will expand as it heats up and contract as it cools down This is normal for this type of venting Rigidly fastening the vent piping can cause undue stress that may result in the cracking or fracturing the vent piping material A fracture of the venting pipe may pose a serious safety hazard To prevent stressing of the vent system all hangers and supports must allow the vent piping freedom to move Use long sweep elbows wherever possible Closely coupled elbows and short radius elbows can reduce the venting capacity All power vented water heaters generate a certain amount of operational noise In order to minimize noise transmission to the support structure it is recommended to
206. ntact a service agency Use this guide to check a leaking water heater Many suspected leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with gas codes your water heater and safety practices contact your gas supplier or qualified installer to check the water heater Ensure the venting is properly attached and secured Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the blower assembly is water vapour which has condensed out of the combustion products This is caused by a problem in the vent A drainage port is included at the vent pipe connection B Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapour which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner This i
207. ntent as required in some areas IMPORTANT DEFINITIONS Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified installer must also be familiar with the design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this Installation and Operating manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding ofthis Installation and Operating manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances wit
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209. o the port on the blower motor housing Make sure the plastic tubing is not folded anywhere between the pressure switch and the blower motor housing see Figure 30 thru Figure 34 This water heater is a polarity sensitive appliance and will not operate if the power supply polarity is reversed Power to this water heater must be wired properly correct polarity Do not plug in power cord until vent system is completely installed The Power Direct Vent operates on 110 120 VAC therefore a grounded outlet must be within reach of the 6 foot flexible power cord supplied with the heater The power cord supplied may be used ona unit only where local codes permit If local codes do not permit use of flexible power supply cord a Make sure the unit is unplugged from the wall outlet Remove the screw and open panel on the front of the junction box on the blower b Cut the flexible power cord leaving enough to be able to make connections Remove the strain relief fitting from the box c Install a suitable conduit fitting inside the enclosure d Splice field wiring into existing wiring using code authorized method wire nuts etc e Be certain that the neutral and line connections are not reversed when making these connections f Ground heater properly This water heater must be grounded in accordance with the current edition of Canadian Electrical Code CAN CSA 22 1 Part I and or local codes These must be followed in all cases
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214. ony Clearance to window or door that may be opened 15cm 6 for appliances lt 10 000 Btuh 3 kW 30cm 12 for appliances gt 10 000 Btuh 3 kW and lt 100 000 Btuh 30 kW 91cm 36 for appliances gt 100 000 Btuh 30 kW Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 61cm 2 from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above regulator E F G 91cm 3 within a height 15 above the regulator 24 www gsw wh com V vent terminal Air supply inlet Warea where terminal is not permitted H Gas regulator Clearance to service regulator Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 15cm 6 for appliances lt 10 000 Btuh 3 kW 30cm 12 for appliances gt 10 000 Btuh 3 kW and lt 100 000 Btuh 30 kW 91cm 36 for appliances gt 100 000 Btuh 30 kW Clearance above paved sidewalk or paved driveway located on public property 2 13m 7 t A vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Clearance in accordan
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216. orizontal 2 Pipe air intake and exhaust vent 2 Vertical 2 Pipe air intake and exhaust vent 3 Concentric Vent Termination horizontal side wall installation 4 Concentric Vent Termination vertical roof installation This water heater has been design certified by CSA International for use with the specified CSA listed plastic vent pipe WARNING Primers and cements are extremely flammable and must not be stored or used near heat or open flame Also use only in a well venti lated area WARNING Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement They are also very flammable and should be kept away from heat or flame Do not use solvent cement to connect the exhaust vent system to the blower Use the rubber coupling and gear clamps instead This connection must be removable to service the heater All other joints in the air intake and exhaust vent systems must be properly cemented www gsw wh com 29 Vent Pipe Runs 1 The exhaust vent system must not under any circumstances be run downhill then run uphill thus forming a valley It may leave a space to accumulate condensation and block vent pipe 2 Horizontal runs require a minimum 3mm 1 8 rise per 1 52m 5 and a support every 1 2m 4 or according to venting manufacturer s instructions Ensure there is enough height between heater and t
217. oth pipes was not exceeded Ensure there are no obstructions in the exhaust and air intake pipes If there are excessive restrictions in the air intake pipe the air pressure switch NC will open Check air pressure switch performance Check blower vacuum with a manometer Compare with air pressure switch N O setting If the air pressure switch proves defective replace the air pressure switch N O If the air pressure switch N O performance test results prove the air pressure switch is working properly and all other steps are followed and fault code persist replace the control Resetting the ECO Energy Cut Out requires manual intervention It cannot be reset by cycling power to the control Reset Procedure Manual reset is performed by turning the set point knob to lowest set point position for a minimum of 10 seconds and then return it to the desired set point The manual reset of the ECO can only be performed 2 times after the ECO trips a third time the gas valve will enter a hard lock out where the gas control will need to be replaced Turn the power OFF for 10 20 seconds then ON again to clear the fault code Flame rod not properly seated in flame reposition rod Clean flame sensor rod with fine steel wood to avoid lock out Replace the control if the fault code persists 48 www gsw wh com 328765 000 Corrective Action Corrective Action Gas supply is turned off or gas pressur
218. ouch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES C Use only your hand to turn the gas control D Do not use this appliance if any part has This heater is equipped with a Honeywell gas control thermostat and a hot surface igniter This control is a combination gas valve thermostat and ignition controller for use on this power vented water heater The valve contains a micro controller that supervises the ignition sequence and monitors the temperature settings and operation of the heater The controller also monitors the flammable vapour safety features of this heater This heater is equipped with a hot surface ignition system that automatically ignites the burner Do not attempt to light this heater manually with a match or flame producing device If you cannot reach your gas supplier call the fire department buttons Never use tools If the control buttons will not turn don t try to repair them call a qualified service technician Force or attempted repair may result in a fire or explosion been under water Immediately contact a qualified installer or service agency to replace a flooded water
219. r other chemicals and do not add any chemicals to the water heater piping Ifthe space heating system requires water temperatures in excess of 49 C 120 F steps must be taken to limit temperatures at fixtures in the potable hot water supply for safety and regulatory requirements Pumps valves piping and fittings must be compatible with potable water A properly installed flow control valve is required to prevent thermosiphoning Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle Weeping blow off ofthe temperature pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning The hot water line from the water heater should be vertical past any mixing valve or supply line to the heating system to remove air bubbles from the system Do not connect the water heater to any system or components previously used with non potable water heating appliances when used to supply potable water 328765 000 COMBO HEATING This section serves as a guide for the installation and use of Combo heating systems utilizing a domestic water heater that has been specifically approved for such use It is written for those knowledgeable in the required trades and professionals involved in the design and installation of Combo Heating Systems It is the responsibility of the installer designer to follow all applicable codes to
220. result in property damage This unit includes an air intake terminal and an exhaust vent terminal A WARNING Install vent system In accordance with codes Do not operate water heater if flood damaged Install water heater in accordance with the instruction manual e Do not operate if soot buildup is present e Do not obstruct water heater air intake s with insulating blanket e Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available e Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation fire explosion or asphyxia tion Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Important DO NOT common vent this water heater with any power vented appliance DO NOT vent into a common chimney This water heater has a direct vent system in which all air for combustion is taken from the outside atmosphere and all combustion products are discharged to the outdoors This water heater must be properly vented for removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the safe and efficient operation of thi
221. rtain fixtures to not exceed 49 C 120 F In addition to using lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at hot water taps used by these people or at the water heater see Figure 7 amp Figure 8 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat in this manual see Table 4 36 www gsw wh com The water heater should be located in an area where the general public does not have access If a suitable area is not available a cover should be installed over the thermostat to prevent tampering This water heater is equipped with an adjustable thermostat to control water temperature see Figure 39 Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and or death The temperature at which injury occurs varies with the person s age and time of the exposure The slower response time of children aged or disabled persons increases the hazards to them Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or disabled person unattended in a bathtub or shower The hot setting shown on the dial is approximately 49 C 120 F This is a good starting point to set the temperature Setting the water heater temperature at 49 C 120 F will reduce the risk of scalds So
222. s 4 Sound Suppressor Tee fitting 6 Cold Water Inlet Nipple Diptube 7 Combo Heating System Supply Outlet Optional 8 T amp P Valve 9 Discharge Pipe 10 Combo Heating System Return Inlet Optional 11 Gas Control Valve Thermostat Honeywell 12 Gas Valve Electronic Control Module And Cover Honeywell 13 Drain Valve Front View Figure 46 44 ep 14 Outer Gas Door 15 Manifold Door Assembly behind outer door see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 16 Metal Drain Pan 17 Floor Drain 24 Anode under cap 25 Baffle Assembly 26 Hot Water Outlet Nipple Anode 28 Rubber Coupling see Figure 5 see also Figure 50 29 Gear Clamp see Figure 5 see also Figure 50 30 Blower with Power Cord see Figure 5 see also Figure 50 31 Air Duct Adapter 32 Air Inlet Snorkel 33 Air Duct 35 Flame Sensor Rod see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 36 Sheet Metal Burner see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 37 Gas Orifice see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 38 Gas Manifold see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 AIR INLET PIPING www gsw wh com 39 Hot Surface Igniter see Figure 3 amp Figure 4 see also Figure 48 amp Figure 49 40 Manifold Door Gasket see Figure 3 amp Figure 4 see also Figure 48 amp Figure
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224. s common at the time of start up after installation and when incoming water is cold Water in the water heater bottom may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken 328765 000 Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow the instructions in the Draining And Flushing section and then remove fitting Put pipe dope or Teflon tape on the threads and replace Then follow the instructions in the Filling The Water Heater section AVVARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious iniury Instruction manual mustremain with water heater Figure 45 www gsw wh com 43 REFERENCE PARTS LISTING Replacement parts may be ordered through your plumber or the local distributor When ordering replacement parts always have the following information ready 1 Model Serial and Product number 2 Type of gas 3 Item number 4 Parts description 1 Termination Elbovv vvith Rodent Screen 2 Vent Pipe 3 Vent Pipe Elbow long radiu
225. s instantly resulting in severe injury or death Children the elderly and the disabled and are at highest risk of scald injury Feel water before bathing or showering Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures Water heated to a temperature which satisfies space heating clothes washing dish washing and other sanitizing needs can scald and cause permanent injury upon contact Short repeated heating cycles caused by small hot water uses can cause a temperature increase of the hot water by 116 20F higher than the heater s temperature settings SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS TEMPERED POTABLE WATER MIXING VALVE 5 12 RAT VALVE COLD WATER INLET TEMPERATURE PRESSURE RELIEF VALVE CERTAIN MODELS ARE EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE HEATING THE HOT AND COLD FITTING ASSEMBLIES PART 9001262005 CAN BE ORDERED THROUGH THE MANUFACTURER DISCHARGE PIPE DO NOT CAP OR PLUG NOTE THE T amp P VALVE DISCHARGE PIPE MUST BE PIPED DIRECTLY TO THE DRAIN OR EXTERNAL TO THE BUILDING METAL DRAIN PAN 45mm 1 75 MAX DEPTH AT LEAST 50mm 2 GREATER THAN THE DIAMETER OF THE WATER HEATER RAN 305mm 127 MAX AIR GAP Figure 7 328765 000 This appliance has been design certified as complying with CSA Standard for water heaters
226. s water heater and is an important factor in the life of the unit A Vent Kit included with this water heater consists of 1 Blower outlet adapter rubber coupling and gear clamps Sound Suppressor Two 2 45 Vent Termination Elbows More restrictive Vent Termination Screens Less restrictive Vent Termination Screens Air intake adapter 3 to 2 ABS reducer and 3 pipe nipple 2 venting only Vent pipe must be installed in accordance with all local and provincial or state codes or in the absence of such the latest edition of Natural Gas and Propane Installation Code B149 1 Dm P 328765 000 AA WARNING Install water heater in accordance with the instruction manual and B149 1 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapour emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Important Check to make sure the vent pipe is not blocked in any way Note Do not common vent this water heater with any other appliance Do not install in the same chase or chimney with a metal or high temperature plastic from another gas or fuel burning appliance www gsw wh com 23 TERMINATION CLEARANCES SIDEWALL Figure 19 Vent terminal clearances for Power Direct Vent installations A Clearance above grade veranda porch deck or balc
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228. so uonoy sajqeqoid s sneo ul lqold SAINQLdINAS SAYLNV es WOD UM MS MMM 006 286 puguuuuo2 EI l sed uluul u uj s s np zju w aweg UN IS u jiiej p 266 np puguuuuoo SS sues 16160009 po2 l IS pueuluio2 El z XELdul M p09 Jee INOd NO E ne Anou sind s puoo s QZ 6 0 uepu d 440 e 266 np puewwos unaydnsejul 2955004 SS sues Weseddesdi po l IS SPUBLULUOD EI z vejdw y BPOD s uluul NO 6 ne Anou sind s puoo s QZ 6 0 JUepusd 440 e 266 puewwo EI in dnujlui z ssno i SS sues Weseddesdi po2 l IS Puewwo EI z vejdw y BPOD s uluul NO 6 ne Anou sind s puoo s QZ 6 0 luepu d 440 e 266 np puewwo EI sn dni lull 2958004 286 spueWWOD EI 1 5 duu xi O S zeB np pueuuuuoo EI Jede dwey 58 SS sues yeseddegu p09 l IS El 2006 0 Z p09 Jee inod NO g ne Anou sind s puov S QZ 6 0 uepu d 440 e 266 np unaydnsejul 2955004 sseEd ns sed 159 95 0 9 lu eAinb 6 ej nb no s pno jewixew al
229. some plumbing supply wholesalers and retailers and detect and react to leakage in various ways 328765 000 Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the metal drain pan that turn off the water supply to the entire building when water is detected in the metal drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply AA WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell gas e Do not expose water heater control to excessive gas pressure e Use only gas shown on rating plate e Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater A VVARNING FLAMMABLES Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage or use of
230. sult a Qualified Installer or Service Agency Follow manufacturer s instructions for installation of valves Before changing the factory setting on thermostat read Operating The Temperature Control System section in this manual This water heater should not be connected to any heating systems or components previously used with a non potable water heating appliance Allpiping components connected to this unit for space heating applications should be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into the potable water used for space heating When the system requires water for space heating at temperatures higher than required for domestic water purposes a mixing valve must be installed Please refer to Figure 7 amp Figure 8 for suggested piping arrangement Note Water piping and vent piping occupy the space above the water heater Plan the water piping to ensure it does not cause interference with the vent piping see Planning the Vent System If this water heater is to be used to supply both space heating and potable water the instructions listed below must be followed Be sure to follow the manual s shipped with the air handler or other type heating system This water heater is not to be used as a replacement for an existing boiler installation Do not use with piping that has been treated with chromates boiler seal o
231. t will connect into the rubber coupling For polypropylene vent systems follow manufacturer s instructions 5 Loosen the upper clamp on the rubber coupling and insert the sanded end of the vent piping a full 32mm 1 1 4 Do not use glue or sealant in the rubber coupling Check that there is no stress on the connection or the vent piping that may be caused by twisting or bending 6 Tighten the upper clamp so that the vent piping is firmly secured in the coupling and is gas tight Do not over tighten or cause distortion of any of the parts Ensure the bottom of the rubber coupling is firmly seated on the blower outlet and that the lower gear clamp is also secure Check to ensure there is no distortion or movement of the clamped assembly once it is completed CAUTION Do not overtighten the top and bottom gear clamps of the rubber coupling Do not apply solvent cement or silicone to the rubber coupling connection HOSE CONNECTION PORT FOR CONDENSATE DRAIN Figure 29 328765 000 www gsw wh com 31 Coupling Installations According To Vent Sizes 2 INLET 2 VENT PIPE PIPE 2 3 ADAPTER Le SUPPL ED 2 RUBBER COUPLING SUPPLIED 3 PIPE SUPPLIED BLOWER gt gt AIRDUCT ADAPTER CONFIGURATION FOR 40 AND 50 GALLON LO INPUT HEATERS CONNECTED TO 2 VENTING Figure 30 3 VENT PIPE 3 INLET PIPE ADAPTER I FIELD SUPPLIED 2 VENT 75mm 3
232. talled Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water 1 Close the water heater drain valve by turning handle to the right clockwise The drain valve is on the lower front of water heater see Figure 18 2 Ifthe heater is equipped with plumbing side taps and they are not connected to piping ensure the side taps have been closed with pipe plugs 3 Open all hot water faucets served by the water heater to allow air to escape from the tank and the water piping Ensure any shut off valves between the heater and the faucets are the open position 4 Open the cold water supply valve to the water heater Notes The cold water supply valve must be left open when the water heater is in use Avoid water leakage when filling the tank Do not allow the insulation of the water heater to get wet as water can reduce the effectiveness of the insulation 5 To ensure complete filling of the tank allow air to exit by opening nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping 6 Check all water piping and connections for leaks Repair as needed 22 www gsw wh com 328765 000 VENTING CAUTION Improper Installation use and service may
233. te Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires see Figure 12 Examine the location to ensure the water heater complies with the Locating The New Water Heater section in this manual For installation in areas subject to earthquakes this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake Contact local utilities for code requirements in your area 328765 000 TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS LIST REFERENCING FIGURES 1 5 1 o oR WP 1 12 13 14 15 16 17 Termination Elbow with Rodent Screen Vent Pipe Vent Pipe Elbow long radius Sound Suppressor Tee fitting Union Di electric water connection Cold Water Inlet Nipple Diptube Combo Heating System Supply Outlet Optional T amp P Valve Discharge Pipe Combo Heating System Return Inlet Optional Gas Control Valve Thermostat Honeywell Gas Valve Electronic Control Module And Cover Honeywell Drain Valve Outer Gas Door Manifold Door Assembly behind outer door see Figure 3 amp Figure 4 Metal Drain Pan Floor Drain r 5 S ASAIO Front View Figure 1 328765 000 18 Flexible Manifold Tube see Figure 3 amp F
234. ter 5 Too Hot Slow Hot Water Recovery Drip From Relief Valve Smelly Water Condensation Exhaust Pipe Too Hot 50 Thermostat set too low Leaking faucets Wasted hot water Wrong piping connections Water heater too small Sediment or lime in tank Long runs of exposed piping Hot water piping in outside wall Thermostat setting is too high Heater stacking Failure to install the proper restrictive screens Thermostat set too low Wrong piping connection Wasted hot water Heater too small Heater stacking Failure to install the proper restrictive screens Closed water system Pressure build up Improperly seated valve Sulfides in water supply 2 Bacteria in water supply Incompatible anode Filling the new water heater for the first time Water dripping from blower assembly Failure to use correct size of exhaust and air intake pipes Failure to install the restrictive screens Blower high limit switch fails to open switch defective www gsw wh com 1 Turn temperature knob to higher setting 2 Repair faucets 3 Correct piping dip tube must be in cold inlet 4 Install adequate heater 5 Drain flush provide water treatment if needed 6 Insulate piping 7 Insulate piping 1 Turn temperature knob to lower setting 2 Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent length Ensure prop
235. ter heater damage Inspection and replacement of anode rod required Each water heater contains at least one anode rod which will slowly deplete due to electrolysis prolonging the life of the water heater by protecting the glass lined tank from corrosion Adverse water quality hotter water temperatures high hot water usage hydronic heating devices and water softening methods can increase the rate of anode rod depletion Once the anode rod is depleted the tank will start to corrode eventually developing a leak Certain water conditions will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfi de gas dissolved in the water Important Do not remove this rod permanently as it will void any warranties A special anode rod may be available if water odour or discolouration occurs Note This rod may reduce but not eliminate water odour problems The water supply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odour problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod should be inspected after a maximum of three years and annually thereafter until the con
236. terminated at an adequate drain inside the building Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 9m 30 or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve 328765 000 No valve or other obstruction is to be placed between the T amp P valve and the tank Do not connect discharge piping directly to the drain unless a maximum of 305mm 12 air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage CAUTION Temperature pressure relief valve discharge pipe must terminate at an adequate drain T amp P Valve Discharge Pipe Requirements Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe Must terminate a maximum of 305mm 12 above a floor drain or external to the build
237. the vent pipes Every 3 6 months or as necessary Clean lint from blower top of heater Once per year Inspectthe Vent System Burner Operation and Inspection Combustion Chamber for scaling or sooting Temperature Pressure Relief Valve Test Anode Rod Inspection Flush a pail of water from the heater drain valve once per year If any deficiencies or abnormalities are encountered during these inspections call a qualified service technician Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause death serious bodily injury or property damage Contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced VENTING SYSTEM INSPECTION AA WARNING Flue gases may escape if vent pipe is not properly connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death e Do not store corrosive chemicals in vicinity of water heater e Chemical corrosion of flue and vent system can cause serious injury or death D Analyze the entire vent system to make sure that 4 condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always r
238. tions must be taken Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Water Temperature C F 44 110 47 116 47 116 50 122 Time for 1st Degree Burns Less Severe Burns normal shower temp pain threshold 35 minutes 45 minutes 1 minute 5 minutes 55 131 60 140 65 149 68 154 U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 5 seconds 25 seconds 2 seconds 5 seconds 1 second 2 seconds instantaneous 1 seconds Table 1 In addition to using lowest possible temperature setting that satisfies demand of application a mixing valve should be installed at water heater see Figure 7 amp Figure 8 or at hot water taps to further reduce system water temperature Mixing valves are available at plumbing supply stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Operating The Temperature Control System section in this manual 10 www gsw wh com WATER HEATER OPERATION Figure 9 shows the water heater s sequence of operation when a call for heat is initiated The ignition control module will attempt to light the burner three times If the ignition control does not detect ignition it will enter lockout mode and flash the corresponding error code HEATER THERMO
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240. u sed au SnOA Z MSSV 9 oe po Jed suo ne poul ui un p E uolx uuo ej 2 l suep lidoidde un 5 in o9npuo2o al z l sul ap s nloq suep lqe ap nBeq EI Zoujay onbuelg un ey w d mb ajuesyjns 6 aun Jassie 105 1 u jdnos Zadnoy q j91 Ano2 l 20 u jjnos EI uoljouo s nloq np l Ud n l Inb SIA EI z in M einuu siud uocueiq p 1s nb 201095 5 E 9 uopioo un Jed 1Ju sipi u s po2 s IS 0 l s po s l no EI JUBIAUOD ldnos 9 UOISUS X9 p sed 159 Id 9 uu g ldnos uopio2o np s w 1 u Jed lu uui e n Jju uu nbiun ned VOA 06 0 oun liss 5 u 531Ip uoljenoeA 9 E nes 9D UOHEIEISUL uy lno JUeAe Nes jjneuo np uone u uule p uop109 sed 290060 N 9 woo ym msB MMm 6 slue od 1
241. ul un p I S pow ej no seinss q 0 5 ne lneu2 s sin sed N senei6 Jeujesjue yned esleyinoes gasside aoejins aun ins uones lnn p s Ano Ip s p janueU np seanoaip s p osdseJ uou 6 ne lneu 8 sed N 0 lDU SUL DP D s silmnn p s nbst s p uyy UBAR uonesiln p e S sano jenuew 1u es Jd l u uieA ue ail ZANA 55113 YY INSINASSILYSAV 4 10 5 5 30 3114 239 woo ym msBb MMM 006 206 ne 5 p uoneied uono dsul p s o AJ s s p 1lu uu eB JUSIYO 266 sin ssiuunoj sin isni Ju uui eq np uedoid 195 1 l yu uuneq np siduuoo A u uuneq 266 suonesijeue5 s p uoneqoidde uono dsuli qesuods 1 ej1 u B ua 1s 266 In ssiuinoj a jUeseid suep sep qi snquuo2o e sj sedde s l sed si nn l no jainjyeu 266 oa Juessiuuinoj NO Sol qnd s oS A1 s sud lu 266 ap in ssiuinoj 1UEOUOEL u n n p XNE suoneued
242. uonsnqulo 266 s p JIE JUBLUBUUOISIAOIdde Ll qulold s ulpulop s l suep s oSu duuo2 s p 1 liss o u jlesedde u n nu l 3 ISUIY Snoss p l S UOHlUH P EI SNV Jed s lulJj p 5 nu un 59 6 jue eAIinb s ou l duuo5 s p Ju iss 5 u Neds ayneyo u n nu ASIANAS 20 3311N39 YNALVTIVLSNI P WSO 5701762 ISNV no Ly VSO VOL VZZ ISNV El WSO Jed linl s 266 nes ajjneyo uond uo e si ulBu3g 801 JO anos 482 6 UBOWOWY ISNV spiepue S VSO 40NOv UOIUESIEULIOU 9 UOHE OSSV VSO UOhES n p UOUEIEISULD Ju s id np SUOHeIASIgY S UUB sesneiquiou juepued uoloejsies 5 0 9 0 nu nu 1u uu 1 l n6 i lle su 4014 SO BUA Mneu n SNOA 5001219019 SNOA SNON NOILONGOULNI 9 woo ym msBb MMM s qeuuuuejjui s p seen no 99500000 JUOS no UN nee ayneyo o sed 20
243. upply polarity is reversed Note Always reference the wiring diagram for the correct electrical connections After making all electrical connections completely fill the tank with water and check all connections for leaks Open the nearest hot water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank The electrical power may then be turned on Verify proper operation after servicing See also Installation Checklist CAUTION LABELALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING POWER VENT WIRING SCHEMATIC NOTE REFER TO THE INSTALLATION CHECKLIST BEFORE OPERATING THIS HEATER N N EARTH GND CAPACITOR BLOWER FLAME SENSOR 65 HOT SURFACE IGNITER PRESSURE SWITCH CLOSED PRESSURE SWITCH OPEN PRESSURE SWITCH CLOSED HIGH LIMIT SWITCH CLOSED Circled numbers indicate sequence of operation Figure 11 IF WIRING HAS TO BE REPLACED IN THE FIELD USE ONLY TYPE TEW 105 C WIRE LECTRICAL RATING 120V 5A 60 HZ PRESSURE SWITCH SWITCH PRESSURE NO NC
244. ure which satisfies your hot water needs This will also provide the most energy efficient operation of the water heater Short repeated heating cycles caused by small hot water uses can cause a temperature increase of the hot water by 11C 20F higher than the heater s temperature settings If you experience this type of use you should consider using lower temperature settings to reduce scald hazards Should overheating occur or the gas supply fails to shut off turn off the main manual gas shut off valve to the appliance see Figure 1 125 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the disabled and are at highest risk of scald injury Feel water before bathing or showering Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures HOT WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water fits into one of these groups you must take special precautions The National Plumbing Code requires ce
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246. ve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures HOT WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water fits into one of these groups you must take special precautions The National Plumbing Code requires certain fixtures to not exceed 49 C 120 F In addition to using lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at hot water taps used by these people or at the water heater see Figure 7 amp Figure 8 Valves for reducing point of use temperature by mixing cold and hot water are also available SPACE HEATING AND POTABLE WATER SYSTEMS This appliance has been design certified as complying with CSA Standard for water heaters and is suitable for combination water potable heating and space heating but not space heating only applications WARNING Toxic Chemical Hazard Do not connect to non potable water system 16 www gsw wh com Con
247. w y JUSAIOP sjis upe p sjeidde p slueu luo2 59 gt N IEIAEGGIKEEIWAI 919 u lq n l un suep nb z sili n s N anu uluulEH un p in eu5o oinos un p llulxold e s sin no s sod qu sed u Alop SII s qeuuuue Ju Ju uu uu9nx 59 sJis upe jo s1 idde 1405 VSO el 1ed s Anoidde nbysejd uonel u A slinpuo3 s p s uuonouo anod guol ui lu VSO Jed linl e Nee eyneyo 92 iz ap nbi u Suoo einuu UORE U A Bp 40518011 jel uoziuou zl LA Z UOHeUSWI e 1 1 2 uonen EA UOHe USWI e z S UBA DS S lE SU UOS EU UL suoneinBiJuo2 s an siuiduuo5 uonsnqulo 266 s p uonenoers p 9 ai jueinquio5 jjneuo seo l suep un suep uoneglie su UOU R UOHESUSPUOD un 2900006 0 une uou nde un sed noquu UN p Ju uu dno525 e p UOYOUeW l jjnos El
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249. yuiew Np xneyuozuou suo uon s D L t S uedoid 266 np uonejjezsui p poo np nanfa 9 UOIIP9 DAAC S ILUJOJUOD US S pO S 9009500 ue no xne lluuoJuoO2 egisu D s pnoo 60 wou 19 6 uonsnqulo 266 s p Np enb pe 1u ui uuolsu uiq D Anoidde neweyew un p s nb MqE JUOS S S uonsnquuo 266 sap uonen eEA p 6 Anoidde pou ui nne un eEsilmn ua UO o dsul no ze6 ua ne s i np 5 s l sno INS SUBS uonnios un p uongOuddel sed segjoedsul suongaeue D Anoidde nel yeul s nb luqe 1405 5 s s ne n D nBo ouuou Stall nod eyeyoueje p sodulo uonesinn D sju uuip s in 5 09 un p nb Isule un p uiqou un p lunul 1s 266 np uone u uule p 6 O ne ayneyo np nbi jeuBis nbeid ej ins nbipui injeo nb d4 w w 1s sllnn ajqisnquwoo d D ii ne n ze5 uone u uuiy uye neid
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