GSW 73992 User's Manual
Contents
1. REPLACE FUSES WITH SAME SIZE TYPE AND RATING ONLY INPUT L1 L2 TERMINAL BLOCK 3 PHASE BLACK FUSE HOLDER WITH FUSES CENTER ELEMENTS LOWER ELEMENTS FIGURE 14 6 Element Power Circuit USA only 15 HIGH LIMIT INPUT CONTROL THERMOSTAT TERMINAL TRANSFORMER BLOCK 3A FUSE PRIMARY SECONDARY X1 THERMOSTAT CONTACTORS 6 E 6 C6 FIGURE 15 9 Element Control Circuit USA only Da gt A oF 71 I I L1 t L2 i L3 TERMINAL L CHEESE NER er ett BLOCK n d SINGLE PHASE BLACKBLUE RED YELLOW 2 5 corn CAES ox Cod ub sap o NC fea Jar ue A REPLACE FUSES WITH SAME SIZE TYPE AND RATING ONLY TERMINAL BLACK BLUE YELLOW FUSE HOLDER WITH FUSES UPPER ELEMENTS CENTER ELEMENTS LOWER ELEMENTS FIGURE 16 9 Element Power Circuit USA only i5 460V H4 230V H3 3 208V H2 2 SECONDARY SECONDARY 115V 0 65 120V 0 63A H1 H1 2 FIGURE 17 Transformer PT75MLI USA only FIGURE 18 Transformer PT75MGJ USA only SECONDARY 0 63A FIGURE 19 Transformer PT75MRMA USA only ud OPERATION General CAUTION NEVER APPLY ELECTRICAL POWER TO THIS WATER HEATER UNLESS IT IS COMPLETELY FULL OF WATER TO PREVENT DAMAGE TO THE TANK AND HEATING ELEMENTS THE TANK MUST BE FILLED WITH WATER BEFORE USE WATER M2. Capacity litres USG 184 50 280 80 Nipple Size meters inches inches 0 57 22 25 1 5 1 56 61 5 0 62 24 25 1 5 1 65 64 75 0 73 28 5 1 5 FIGURE 2 Rough in Dimensions tion of listed equipment or materials as meeting the require ments for Relief Valves and Automatic Shut off Devices for Hot Water Supply Systems ANSI 221 22 meters inches 1 31 51 5 420 119 Important Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The T amp P Valve e Must be connected an adequate discharge line e Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line e Must terminate a maximum of 152mm 6 in above floor drain or external to the building e Must be capable of withstanding 121 C 250 without distortion 2 e Must be installed to allow complete drainage of both the valve and discharge line e Must not discharge so a
3. No of Element Full Load in Amperes KW Input Elements Wattage Single Phase Three Phase 208V 240V 277V 347 480V 600V 208V 240V 480V 600V 6 2000 28 8 25 0 21 7 17 3 12 5 10 0 16 7 14 4 7 2 5 8 9 3000 43 3 94 5 32 5 25 9 18 8 15 0 25 0 21 7 10 8 8 7 12 3 4000 57 7 50 0 43 3 34 6 25 0 20 0 33 3 28 9 14 4 11 5 13 5 4500 64 9 56 3 48 7 38 9 28 1 22 5 37 5 32 5 16 2 13 0 15 5000 72 1 62 5 54 2 43 2 31 3 25 0 41 6 36 1 18 0 14 4 18 6000 86 5 79 0 65 0 51 9 37 5 30 0 50 0 43 3 21 7 17 3 18 3000 86 5 79 0 65 0 51 9 37 5 30 0 50 0 43 0 21 7 17 3 24 4000 115 4 100 0 86 6 69 2 50 0 40 0 66 6 57 7 28 9 23 1 27 6 4500 129 8 112 5 97 5 77 8 56 3 45 0 74 9 65 0 32 5 26 0 30 5000 1442 125 0 108 3 86 5 62 5 50 0 83 3 72 2 36 1 28 9 36 6000 173 1 150 0 130 0 103 7 75 0 60 0 99 9 86 6 43 3 34 6 36 4000 173 1 150 0 130 0 103 7 75 0 60 0 99 9 86 6 43 3 34 6 40 5 9 4500 194 7 168 8 146 2 116 7 84 4 67 5 112 4 97 4 48 7 39 0 45 5000 216 3 187 5 162 5 129 7 93 8 75 0 124 9 108 3 54 1 43 3 54 6000 N A 225 0 194 9 155 2 112 5 90 0 150 0 129 9 65 0 52 0 TABLE 2 Load Currents Minimum Field Wiring Size AWG 75 C No of Element KW Input Elements Wattage Single Phase Three Phase 208V 240V 277V 347 480V 600V 208V 240V 480V 600V 6 2000 10 10 10 12 14 14 12 12 14 14 9 3000 8 8 8 10 12 14 10 10 14 14 12 3 4000 6 6 8 8 10 12 8 10 14 14 13 5 4500 6 6 6 8 8 10 8 8 12 14 15 5000 4 6 6 8 8 10 8 8 12 14 18 6000 3 4 6 6 8 10 6 8 10 12 18 3000 3 4 6 6 8
4. p Vy FIGURE 3 Drain WARNING Closets without drains and carpeted areas are examples of unsuitable locations for any water heater Select a location as centralized within the piping system as possible The heater should be located in an area not subject to freezing temperatures If this heater is to be installed directly on car peting the carpeting must be protected by a metal or wood panel beneath the heater extending beyond the full width and depth of the heater by a minimum 80mm 3 in If the heater is installed in a closet or alcove the entire floor must be covered by the panel This panel must be strong enough to support the weight of the heater full of water without breaking Failure to heed this warning may result in a fire hazard Closed System Thermal Expansion During the heating cycle of the water heater the water expands causing pressure inside the water heater to increase The water utility supply meter may contain a check valve This will create a closed water system If the pressure in a closed water system exceeds 1034kPa 150 PSI water will discharge from the temperature and pres sure T amp P relief valve This is the normal safety function of a relief valve and indicates the proper functioning of the valve Only if the discharge from the relief valve is continu ous or for an extended period of time does this indicate a malfunction of some sort Should this occur have the ope
5. GSW WATER HEATING SW 599 Hill Street West Fergus ON Canada 2X1 COMMERCIAL ELECTRIC WATER HEATER INSTALLATION AND OPERATING INSTRUCTIONS Read and understand these instructions thoroughly before attempting any installation or service TABLE OF CONTENTS D Introduction 2 Il Component Identification 3 Il Recovery Rates 4 IV Installation 5 9 Electrical uu raies 10 17 VI Operation 18 VII Maintenance 19 21 VIII Leakage Checkpoints 22 IX Floor Sealing 23 MA HI mace oe ee 200 24 PLEASE RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE A WARNING Improper installation adjustment alter ation service or maintenance can cause injury or property damage Refer to this manual For assistance or additional infor mation consult a qualified installer serv ice agency or the electric utility FOR YOUR SAFETY e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Installation and service must be per formed by a qualified installer service agency or the electric utility A WARNING If the information in these instructions 15 not followed exactly a fire or explosion may result causing pro
6. Startup when heater is ready to be put back into serv ice Flushing NOTE If the water heater is going to be shut down for an extended period drain the tank as directed in Draining Flushing and Sediment Removal Ensure that the cold water supply valve is closed and the drain valve left open Temperature and Pressure T amp P Relief Valve Check CAUTION THE WATER COMING FROM THE VALVE MAY BE EXTREMELY HOT Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connect ed to a discharge line which terminates at an adequate drain Stand clear of the outlet discharged water may be hot and slowly lift and release the lever handle on the temperature and pressure relief valve see Figure 20 to allow the valve to operate freely and return to its closed position If the valve fails to completely reset and continues to release water immediately turn OFF the power and close the cold water inlet and call a qualified service techni cian Temperature and Pressure Relief Valve Manual Relief 7 Valve Discharge line to drain FIGURE 20 T amp P Valve Test Cathodic Protection Your water heater has been equipped with one or more anodes that protect the glass lined tank from corrosion and prolong the life of the water heater Over time as the anode s works it slowly dissolves exposing the
7. Water tempera ture adjustments can be made to the surface mounted ther mostat by first turning off the electric power supply to the water heater and removing the bottom control panel cover Using a screwdriver turn the thermostat dial to the desired temperature setting The water heater is equipped with a surface mounted high limit control located under insulating material in the top control panel If for any reason the water temperature becomes excessive the high limit will de ener gize the heating element circuit Once the high limit has been activated it must be manually reset by pushing in the red reset button located on the high limit The cause of the excessive temperature should be determined and correct ed A WARNING Hot water produced by this appliance can cause severe burns due to scalding The hazard is increased for young children the aged or the disabled where water tempera tures exceed 52 C 125 F Use tempering valves in the hot water system to reduce the risk of scalding at point of use such as lavatories sinks and bathing facilities Such precautions must be followed when this heater is operat ed in combination with dishwashing or space heating applications A WARNING 20 Py HOT IM i Water temperature over 52 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded Feel water before bathing or showering Temperatu
8. packed shall domestic use be returned transportation pre paid to the address designated by GSW in 6 All repairs must be made by a competent and qualified person who is cer the written request All claims are subject to validation by GSW tified by GSW or one of its authorized dealers to work on the Unit using factory approved replacement parts and the Unit shall not be otherwise modified altered or improperly repaired 24
9. steel inner core Once the anode s is depleted the tank will start to corrode eventually developing a leak Depending on water conditions an anode s can last from one to ten years Many localities treat their water and this can have a signifi cant effect on the life of your heater Water conditioning such as over softening can accelerate the rate at which the anode s is consumed As with any water heater it is good practice to check the anode s annually to see if it needs replacing Do not remove this anode s permanently as it will void any warranties stated or implied Rapid depletion or failure to maintain the anode can leave a heater unprotected and may result in premature failure of the heater due to corrosion and leaks Hot Water Odour On occasion and depending on your location hot water may develop a strong odour This can be especially prob lematic in regions where the water contains sulphur which results in hot water having a rotten egg odour If this occurs drain the system completely flush thoroughly and refill the tank If the water odour or discoloration persists the anode s may need to be changed from magnesium to one made of aluminum Aluminum anodes may reduce but not eliminate water odour problems The water supply system may require special filtration equipment from a water condi tioning company to successfully eliminate all water odour problems In certain cases chlorinating and flushing of the water
10. 0 46 43 401 15 51 195 205 154 123 102 88 77 68 61 56 51 47 44 18 61 434 246 184 148 123 105 92 82 74 67 61 57 53 24 81 912 328 246 197 164 140 123 109 98 89 82 76 70 27 92 151 369 276 221 184 158 138 123 111 101 92 85 79 30 102 390 410 307 246 205 176 154 137 123 112 102 95 88 36 122 868 492 369 295 246 211 184 164 148 134 123 113 105 40 5 138 226 554 418 332 277 237 208 185 166 151 138 128 119 45 153 585 615 461 369 307 263 230 205 184 168 154 142 132 54 184 302 738 553 443 369 316 277 246 221 201 184 170 158 TABLE 1 Recovery Rates IV INSTALLATION General Applicable Codes In addition to the installation instructions found in this man ual the water heater must be installed in accordance with all local and provincial or state codes or in the absence of local and provincial or state codes with the latest edition of Canadian Electrical Code in Canada or NFPA 70 National Electrical Code in USA The requirements of these documents must be carefully fol lowed in all cases Authorities having jurisdiction shall be consulted before installations are made Check your phone listings for the local authorities having jurisdiction over your installation Important Installation and service must be performed by a qualified service technician State of California Note The water heater must be braced anchored or strapped to avoid moving dur ing an earthquake Contact local u
11. 10 6 8 10 12 24 4000 2 3 3 4 6 8 4 6 10 10 27 6 4500 1 2 3 4 6 8 4 6 8 10 30 5000 0 1 2 3 6 6 4 4 8 10 36 6000 00 0 1 2 4 6 3 3 8 8 36 4000 00 0 1 2 4 6 3 3 8 8 40 5 9 4500 000 00 0 1 4 4 2 3 6 8 45 5000 0000 000 00 1 3 4 1 2 6 8 54 6000 0000 000 00 2 3 0 1 6 6 TABLE 3 Wiring Requirements Note Table 3 is for reference only All branch circuit wiring must comply with local and provincial or state codes or in the absence of local and provincial or state codes with the latest edition of the applicable Electrical Code 102 HIGH LIMIT THERMOSTAT INPUT OPTIONAL CONTROL TERMINAL TRANSFORMER USED ON 480 OR 600V ONLY BLOCK SECONDARY o 3A FUSE FOR 3 ELEMENTS CONFIGURATION ONLY C1 WITH CORRESPONDING WIRING APPLIES CONTACTORS 6 FOR 6 ELEMENTS CONFIGURATION ONLY C1 C2 WITH CORRESPONDING WIRING APPLIES FOR 9 ELEMENTS CONFIGURATION CIRCUIT IS AS SHOWN C3 C2 IF APPLICABLE IF APPLICABLE FIGURE 5 Control Circuit Canada YELLOW AMIN TERMINAL TERMINAL BLOCK BLOCK 1 PHASE 3 PHASE CONTACTOR CONTACTOR LOWER ELEMENTS LOWER ELEMENTS FIGURE 6 3 Element Power Circuits Canada THERMOSTAT INPUT TERMINAL CONTACTORS BLACK LOWER ELEMENTS CENTER ELEMENTS FIGURE 7 6 Element 1 Phase Power Circuit Canada INPUT TERMINAL BLOCK CONTACTORS CENTER ELEMENTS LOWER ELEMENTS FIGURE 8 6 Elemen
12. TROL COMPARTMENT MAY VARY DEPENDING ON CONFIGURATION Ill RECOVERY RATES RECOVERY RATE IN LITRES PER HOUR Standard BTU Hr Temperature rise in KW Input 179 22 28 33 39 44 50 56 61 67 72 78 6 20 478 310 235 185 155 132 117 102 95 83 79 72 68 9 30 717 466 348 280 235 201 174 155 140 129 117 106 98 12 40 956 621 466 371 310 265 231 208 185 170 155 144 132 13 5 46 075 697 522 420 348 299 261 235 208 189 174 163 1518 15 51 195 776 583 466 386 333 291 257 231 212 193 178 167 18 61 434 931 697 560 466 397 348 310 280 254 231 216 201 24 81 912 1242 931 746 621 530 466 413 371 337 310 288 265 27 92 151 1397 1045 837 697 598 522 466 420 382 348 322 299 30 102 390 1552 1162 931 776 666 583 519 466 424 386 360 333 36 122 868 1862 1397 1117 931 799 697 621 560 507 466 428 397 40 5 138 226 2097 1582 1257 1049 897 787 700 628 572 522 485 450 45 153 585 2328 1745 1397 1162 996 871 776 697 636 583 538 500 54 184 302 2794 2093 1677 1397 1196 1049 931 837 761 697 644 598 RECOVERY RATE IN GALLONS PER HOUR Standard BTU Hr Temperature rise in F KW Input 30 40 50 60 70 80 90 100 110 120 130 140 6 20 478 82 62 49 41 35 31 27 25 22 21 19 18 9 30 717 123 92 74 62 53 46 41 37 34 31 28 26 12 40 956 164 123 98 82 70 61 55 49 45 41 38 35 13 5 46 075 184 138 111 92 79 69 62 55 5
13. USE NON COMPLIANCE TO NSF SPECIFICATIONS ONLY A QUALIFIED INSTALLER SERVICE AGENT OR CER TIFIED FACTORY REPRESENTATIVE SHALL INSTALL THE NSF CONSTRUCTION COMPONENTS General The installation of the floor sealant is a requirement for NSF construction compliance Tools And Materials Required 1 Floor sealant Dow Corning RTV Sealant 732 2 Standard caulk gun WARNING THE MANUFACTURER OF THIS WATER HEATER FIGURE 23 NSF Caulking Floor WILL NOT ASSUME ANY LIABILITY FOR ANY DAM AGE RESULTING FROM FAILURE TO COMPLY WITH THESE INSTRUCTIONS READ THESE INSTRUC TIONS THOROUGHLY BEFORE STARTING Installation Procedure Before proceeding with the sealing of this heater to comply with NSF requirements ensure this water heater has been installed in accordance with local and provincial or state codes or in the absence of local and provincial or state codes with the latest edition of Canadian Electrical Code in Canada or NFPA 70 National Electrical Code in USA Refer to the installation instructions pro vided with this water heater 1 Thoroughly read and understand the floor sealant instructions 2 Thoroughly read and understand the installation instruc tion manual supplied with the heater before beginning the installation 3 Ensure the water heater has been installed in accor dance with the installation instructions for this water heater and or with local codes and ordinances 4 Seal
14. UST FLOW FROM THE HOT WATER FAUCET BEFORE APPLYING POWER Filling the Water Heater 1 Do not turn the power on until all the following steps including Startup steps have been completed 2 Make sure the drain valve is closed 3 Open a hot water faucet associated with the system 4 Open the cold water supply valve NOTE When filling avoid water leakage Do not allow the insulation of the water heater to get wet as water can cause electrical malfunction 5 When water runs out of the hot water faucet in a steady stream the tank is full 6 Close the hot water faucet and check the system for leaks Repair as required and retest 7 Connect a hose to the drain valve and route to a suitable drain Open the drain valve and let water run to flush out any foreign matter that may have entered the system Once flushed close the drain valve and disconnect hose Repeat steps 4 6 Startup Perform the following checks when the heater is placed into operation for the first time Voltage Check Verify that the supply voltage and the rating plate voltage are the same 1 Open the upper component panel cover and check all electrical connections 2 Remove the lower cover and the insulation for the ele ment compartment and check all electrical connections 3 Turn ON the electrical supply to the heater 4 Carefully watch all the components for one complete cycle of operation to see that they function properly DANGER Hazardous
15. ain valve and drain 22 litres 6 USG as directed in Draining Flushing and Sediment Removal CAUTION The water being drained can be extremely hot The drain hose should be rated for at least 94 C 200 F If the hose does not have this rating open the cold water supply valve and a nearby hot water faucet served by the system until the water flow is no longer hot Close the cold water supply valve and resume 5 Using a 1 5 16 socket remove the anode s and inspect it The surface may be rough full of pits and crevices but this is normal If it is less than approximately 10mm 3 8 in in diameter or the inner steel core exposed the anode s should be replaced NOTE The anode s has been factory installed using a power tool It may be necessary for a second person to sta bilize the heater A few sharp blows on the handle of the socket wrench should loosen the anode nut If an impact wrench power drive is available this is an easier way to remove an anode 6 Apply Teflon tape or sealing compounds approved for use with potable water to the threads of the anode s and install into the tank top 7 Open the cold water supply valve and open a nearby hot water faucet to purge air from the water tank as directed in Filling the Water Heater 8 Check for leaks repair as required and re test 9 Turn the electrical supply to the heater ON Lime Scale Over time all immersion type elements accumulate li
16. al leakage points 1 Make sure the heater drain valve is fully closed 2 Discharge from the outlet of the T amp P relief valve may indicate e Faulty relief valve e Excessive water temperature e Excessive water pressure A common cause of relief valve leakage is excessive water pressure This condition is often caused by a closed sys tem A closed system has a check valve in the inlet system that prevents the expanded hot water volume to equalize pressure with the main system If a relief valve does not release this pressure it will damage the water heater or plumbing system 3 Remove the cover and insulation from the element com partment e Examine the area around the element gasket for leak age e Tighten the elements if necessary If tightening the ele ments does not stop the leak it may be necessary to replace the gaskets IF YOU CANNOT IDENTIFY OR CORRECT THE SOURCE OF MALFUNCTION 1 Turn the electrical supply to the heater OFF 2 Close the cold water supply valve 3 Call a qualified service technician 91 AKAGE CHECKPOINTS HOT WATER ANODE UNDER OUTLET PLASTIC CAP i neon T amp P VALVE PLUGS FOR ELEMENTS ELEMENT LOCATIONS CLEANOUT PORT BEHIND ACCESS COLD WATER DOOR INLET DRAIN VALVE FIGURE 21 Possible leakage points 22 IX FLOOR SEALING Installation Instructions WARNING IMPROPER INSTALLATION ADJUSTMENT OR ALTERATION OF THESE COMPONENTS CAN CA
17. and flushed on a regular basis to remove any sediment that may buildup during operation Some maintenance and service procedures require that the heater be drained and empty The water heater should also be drained if being shut down for an extended period of time To drain and remove the sediment from the tank 1 Turn the electrical supply to the heater OFF 2 Close the cold water supply valve 3 Attach hose to the drain valve and route to an adequate drain CAUTION The water being drained can be extremely hot The drain hose should be rated for at least 93 C 200 F If the drain hose does not have this rating open the cold water supply valve and a nearby hot water faucet served by the system until the water flow is no longer hot Close the cold water supply valve and resume 4 Open the drain valve using a flat blade screwdriver A nearby hot water faucet must be opened to allow the tank to be fully drained 5 Open the cold water supply valve and flush the tank as needed to remove sediment and any other foreign mat ter that may have entered the system Close the cold water supply valve when clean water flows 6 If the heater is to remain empty for an extended period of time it is suggested the drain valve be left open When draining is complete the hose may be removed 7 Perform any other servicing as required Close the drain valve disconnect hose Follow instructions for Filling the Water Heater and
18. d on the heater for the correct voltage DO NOT connect this water heater to any voltage supply other than that indicated on the rating plate Failure to use the correct voltage may result in unsafe operation and personal injury or property damage If you have any questions or doubts consult your electric company Electrical Connections CAUTION TO PREVENT DAMAGE TO THE TANK AND HEATING ELEMENT S THE TANK MUST BE FILLED WITH WATER BEFORE TURNING ON POWER SEE FILLING THE WATER HEATER The information in Table 3 may be used as a guide to deter mine the wire size of the branch circuit It is recommended the branch circuit wiring be 12596 of the amperage rating of the water heater If the heater is located a long distance Installation Check List away from the electrical supply the wire size of the branch Check Here circuit should be increased The voltage measured at the heater should not be less than 3 lower than what is meas ured at the supply If your calculated value does not appear 3 in the table substitute the next highest rating listed in the table A 1 Ensure the element marking and rating plate data corre spond with the electric service available 5 2 Install a branch circuit directly from the main service 6 panel to the water heater The wiring of this circuit must 7 be of adequate size for the length of run and the load see Table 3 3 A ground wire must run from the green ground screw provided at the e
19. es that may cause excessive restriction to water flow Use full flow ball or gate valves only DO NOT use 50 50 tin lead solder or any lead based sol der in potable water lines Use 95 5 tin antimony or other equivalent material DO NOT tamper with the temperature and pressure relief valve Tampering voids all warranties Only qualified service technicians should service these components DO NOT use with piping that has been treated with chro mates boiler seal or other chemicals DO NOT add any chemicals to the system piping that will contaminate the potable water supply DO NOT apply electrical power before the tank is filled with water and you have confirmed that there are no leaks in the piping and connections A WARNING TO REDUCE RISK OF ELECTRIC SHOCK OR POSSI BLE ELECTROCUTION THE WATER HEATER MUST BE ELECTRICALLY GROUNDED The electrical supply to the water heater should be a separately grounded branch circuit having overcurrent protection and a discon nect switch Refer to the rating plate attached to the heater to determine the correct ratings for voltage and amperage To ensure proper operation the supply voltage should be within 5 and 10 of the rated voltage of the heater The water heater should be grounded in accor dance with national and local codes A WARNING WATER HEATER EQUIPPED FOR LIMITED VOLTAGE RANGE This water heater is designed to operate within a specific voltage range Check rating plate mounte
20. fore installations are made Check your phone WARNING THE ELECTRICAL SUPPLY TO THE WATER HEATER MUST BE TURNED OFF WHEN WORKING ON OR NEAR THE ELECTRICAL SYSTEM OF THE HEATER NEVER TOUCH THE ELECTRICAL COMPONENTS WITH WET HANDS OR WHILE STANDING IN WATER TO ENSURE CONTINUED SAFETY PROTECTION REPLACE FUSES WITH SAME SIZE TYPE AND RAT ING ONLY listings for the local authorities having jurisdiction over your installation Important All supply equipment installation approvals permits inspections etc are the responsibility of the owner of this water heater Consult your local authorities for regu lations specific to your area Refer to Figure 1 to identify the major components and the optional equipment installed on this water heater Familiarize yourself with all the controls and components identified to help with checking the operation of this heater De 1 COMPONENT IDENTIFICATION ANODE UNDER PLASTIC CAP POWER TRANSFORMER IF APPLICABLE FUSES CONTROL CIRCUIT FUSES POWER CIRCUIT IF APPLICABLE CONTACTORS PLUGS HEATING ELEMENTS 7 M COLD WATER INLET FIGURE 1 Parts Locations HOT WATER OUTLET CONTROL COMPARTMENT T amp P VALVE INPUT TERMINAL BLOCK MANUAL HIGH LIMIT RESET CONTROL THERMOSTAT CLEANOUT DRAIN VALVE ELEMENT COMPARTMENT NOTES 1 COVERS REMOVED FOR CLARITY 2 3 ELEMENT CONFIGURATION SHOWN 3 COMPONENT LOCATION IN CON
21. heater may be required Contact your dealer or water supplier 49 Discoloured Water e Water rich in iron or other minerals can produce red brown staining Heating water generally worsens this situation e Black water can be an indication of organic contami nates in the water supply This can be problematic in areas where the water is obtained from surface or con taminated sources Organic particles can develop bac terial growth causing potential health hazards e Contact your water supplier for proper filtration or water conditioning equipment bacterial problems contact your local health author ity See also Hot Water Odour e Asudden appearance of rust coloured water may indi cate that the anode s has been depleted Once deplet ed the anode s inner steel core becomes exposed causing it to corrode and release iron particles into the water See also Anode Maintenance Anode Maintenance A new anode is about 20mm 13 16 in to 22mm 7 8 in diameter and has a steel wire core approximately 3mm 1 8 in diameter in the center The anode should be replaced when this wire is visible Operating a water heater without an actively working anode s will void the warranty To check replace the anode 1 Turn OFF the electrical supply to the water heater 2 Close the cold water supply valve 3 Open a nearby hot water faucet served by the system to depressurize the system 4 Connect a hose to the dr
22. ice of the same voltage by making the following changes 1 Disconnect all the blue wires and all the yellow wires from Terminal Block L3 2 Reconnect all the blue wires to Terminal Block L1 with the black wires 3 Reconnect all the yellow wires to Terminal Block L2 with the red wires 4 Connect incoming power to Terminal Blocks L1 and L2 To Three Phase If the heater is shipped for connection to a single phase electrical service it may be connected to a three phase elec trical service of the same voltage by making these changes 1 Disconnect all the blue wires from Terminal Block L1 2 Disconnect all the yellow wires from Terminal Block L2 3 Reconnect the blue wires and the yellow wires to Terminal Block L3 4 Connect incoming power to Terminal Blocks L1 L2 and L3 8 Temperature Control All electric water heaters feature fully automatic controls to regulate the water temperature The thermostat supplied with the water heater may be either an immersion or a sur face mounted type Both types of thermostats use contact relays to energize the electric heating elements The ther mostats are located in the bottom control panel The ther mostats are factory set to 60 C 140 F to reduce the risk of scalding Water temperature adjustments for the immersion type thermostat can be made by turning the temperature adjustment dial located on the outside of the lower control panel to the desired temperature setting
23. ime shown in table at the top of age GSW accepts no responsibility for such damage nor any incidental this page or consequential loss nor damage s related thereto suffered by the Residential units installed and used in a commercial application carry a owner of the Unit nor by any third party warranty period of one 1 year from date of installation and 3 The Unit shall not be installed where it will be exposed to adverse or Any repair or replacement of any part tank or Unit under this Warranty unusual environmental or corrosive conditions No warranty extends for will not extend the Warranty Period beyond that calculated from the date example and without limitation of the foregoing to Units exposed to of first installation of the original Unit The date of first installation will salts chemicals exhausts pollutants or contaminants Further no war be deemed to be the later of the date indicated by the Unit s serial num ranty extends to Units affected by fire freezing or flood Acts of God ber or if supplied with the Warranty claim the sales receipt or installer s or any other contingency beyond the control of GSW receipt 4 Unit shall be equipped with a properly operating temperature and 8 claim under this Warranty must include the model and serial number of pressure relief valve as specified by GSW and applicable standards The the Unit proof of date on which the Unit was first installed and the iden Unit shall be o
24. ion Piping fittings and valves should be installed according to the installation drawing Figure 4 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation Water supply pressure should not exceed 80 of the working pressure stated on the water heater s data plate If the supply pressure is high er than this limit a pressure limiting valve with a bypass must be installed in the cold water inlet line This should be placed on the supply to the entire building in order to main tain equal hot and cold water pressures 6 Important Heat must not be applied to the water fittings on the heater as they may contain nonmetallic parts If sol der connections are used solder the pipe to the adaptor before attaching the adaptor to the hot and cold water fit tings Important Always use a good grade of joint compound that is compatible with potable water and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 4 Connect the cold water supply 1 1 2 in NPT to the fit ting marked Cold Water Inlet Connect the hot water supply 1 1 2 in NPT to the fitting marked Hot Water Outlet 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a tempering va
25. lectrical connection point in the heater junction box to the ground connection at the service panel 4 Final connections are made in the control panel box on the heater 5 The heater you have received is internally wired A spe cific wiring diagram for each heater is located inside the control panel All internal wiring is colour coded and con nections must be made as shown in the wiring diagrams Figures 5 10 for Canada Figures 11 16 for USA Are the fuse and wire sizes correct Is the certified relief valve installed Were steps taken to prevent water damage in case of leaks Has the relief valve been piped to a suitable drain point Is the relief valve discharge unobstructed Is the heater completely filled with water Is the cold water supply valve open D OOO OF OOO If the answer to the above are yes turn on the power and enjoy all the hot water you need all the time Fuses Components in the power circuit are protected by fuses For voltage supplies up to 480V the fuses are rated for 30 amperes class For voltage supplies of 600V the fuses are rated for 15 amperes class G Replace fuses with same size type and rating only Note These fuses are not required or installed in water heaters sold in Canada Phase Conversion USA only To Single Phase If the heater is shipped for connection to a three phase elec trical service it may be connected to a single phase electri cal serv
26. led within the boundaries of continental United States of Canada or their territories Consumers must retain point of sale proof of purchase to validate warranty entitlement This Warranty does not cover components not manufactured by GSW such as oil burners which carry the warranty given by the manufacturer thereof copy of which warranty GSW will make available to the extent supplied by the manufacturer without recourse to GSW THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS EXPRESS WARRANTY IS WHERE PERMITTED BY LAW IN LIEU OF AND EXCLUDES AND REPLACES ALL OTHER CONDITIONS WARRANTIES GUARANTEES REPRESENTATIONS OBLIGATIONS OR LIABILITIES OF GSW OF ANY NATURE OR KIND EXPRESS OR IMPLIED HOWEVER ARISING WHETHER BY CONTRACT CONDUCT STATEMENT STATUTE NEGLI GENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW OR OTHERWISE WITH RESPECT TO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY INSTALLATION OPERATION REPAIR OR REPLACEMENT GSW EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES IN NO EVENT WILL GSW S LIA BILITIES EXCEED THE COST OF THE DEFECTIVE PART S OR UNIT GSW WILL NOT PAY FOR ANY TRANSPORTATION LABOUR INSTALLATION OR OTHER INCIDENTAL COSTS ASSOCIATED WITH THE REPAIR OR REPLACEMENT OF A DEFECTIVE PART OR UNIT This warranty and GSW s obligations shall be construed and determined in accordance with the laws of both the Province of Ontario and of Canada in fo
27. lve in the domestic hot water line as shown in Figure 4 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use Contact a licensed plumber or the local plumbing supplier 4 f installing the water heater in a closed water system install an expansion tank in the cold water line as speci fied under Closed System Thermal Expansion 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be eas ily accessible Show the user the location of this valve and how use it to shut off the water to the heater 6 Atemperature and pressure relief valve is installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater Add a discharge line to the opening of the T amp P relief valve Follow the instruc tions under Temperature and Pressure T amp P Relief Valve 7 After piping has been properly connected to the water Tempering valve Water meter or anti siphoning device heater close the shut off valve in the cold water inlet line Please note the following DO NOT install this water heater with iron piping The sys tem should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or poly butylene DO NOT use PVC water piping DO NOT use any pumps valves or fittings that are not compatible with potable water DO NOT use valv
28. me scale on their surfaces Various conditions affecting this buildup include e Volume of hot water used as the consumption of hot water increases more scale results e Water temperature the hotter the water the more scale is deposited e Purity of the water supply If it becomes necessary to delime the elements use a non metallic soft tool or scraper to remove the scale taking care not to damage the surface of the element Alternatively use a non muriatic delimer that is approved for use with potable water to dissolve the lime scale DANGER Do not use muriatic or hydrochloric acid based deliming solutions Troubleshooting Checklist Before placing a service call perform the following checks to see if the problem can be identified and corrected easily Correcting a fault identified by this list may eliminate the need for a service call and quickly restore hot water service Refer to Figure 1 to identify the location of all of the heater s major components DANGER BE SURE TO TURN OFF THE POWER TO THE HEATER WHEN CHECKING EQUIPMENT Insufficient or no hot water 1 Ensure the electrical supply to the water heater is in the ON position 2 Check that all the fuses are intact Fuses are usually contained in the electrical disconnect switch There are also fuses in the heater control panel 3 If the water is now cold but was excessively hot the high limit switch may have tripped e To reset open the c
29. omponent panel cover remove the insulation plug to access the high limit switch Depress the red button to manually reset the switch NOTE the high limit switch trips repeatedly the water heater should be inspected by a qualified service techni cian 4 Alarge demand for hot water may have been more than the heater can supply Allow a recovery period to restore water temperature after large demands 5 Check incoming water supply temperature e incoming water temperature is cooler than normal it will lengthen the time required to heat water to the desired temperature 6 Look for leakage in the hot water supply lines 7 Operation of the water heater may be affected by the buildup of sediment or lime scale e Follow the instructions given in Draining Flushing and Sediment Removal 200 Water heater is noisy 1 The heater makes sizzling and hissing noises operating The accumulation of sediment or lime scale may be the cause The sounds are normal however the tank bot tom and elements should be cleaned Follow the instruc tions given in Draining Flushing and Sediment Removal 2 Some of the electrical components of the water heater controls make noises e Most of these are normal Contactors will click or snap as the heater starts and stops transformers and con tacts often hum Water leakage is suspected or apparent Refer to Leakage Checkpoints Figure 21 to locate poten ti
30. perated at temperatures not exceeding the maximum set tity of the defective part s for which a claim is being made and be sub ting of the thermostat and or high limit control provided by GSW and at mitted within 15 days following discovery of the defect s by personal water pressures not exceeding the pressure reading stated on the Unit delivery to a GSW authorized dealer point of purchase or GSW itself at 5 The Unit must be carefully inspected maintained and operated in accor GSW Water Heating dance with the manufacturer s instructions No warranty extends for GSW Water Heating is a division of GSW Water Products Inc example and without limitation of the foregoing to any Unit operated 599 Hill Street West without the tank being completely filled with water without an operating Fergus ON Canada N1M 2X1 anode with levels of sediment or lime precipitate which cause failure in Should you have questions please call our Technical Support Line at 1 connection to any attachment s energy saving device s or other means 888 479 8324 of heating except as approved by GSW for the Unit other than with 9 If requested by GSW information relating to the purchase transportation potable water without any additives such as salts chlorine or chemicals operation and installation of the Unit must be supplied The defective except those added for the sole purpose of rendering the water fit for part s or Unit with all components properly and securely
31. perty damage per All models are listed sonal injury or death by Underwriters UL Laboratories Inc GSW Water Heating is a division of GSW Water Products Inc INSTALLATION RECORD This water heater is protected by a three 3 year warranty against leaks plus a one 1 year warranty on parts Record key data here for future reference and prompt service Installed By Purchased From Installation Date Location of Electrical Switch or Circuit Protector Model Number Serial Number Volts Volume Watts Element Number of Elements Watts Total Technical Support Line 1 888 479 8324 PART NO 73992 REV A 05 03 Your safety and the safety of others is very important We have provided many important safety messages in this manual and on your appliance Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING DANGER Instructions You can be killed or seriously injured if you don t immediately follow A WARNING You can be killed or seriously injured if you don t follow instructions All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed 1 INTRODUCTION Thank you for pu
32. r ation of the heater checked by a technician qualified to do so Frequent operation of the T amp P valve can result in a build up of natural mineral deposits on the valve seat rendering the valve inoperative Should this happen the valve needs to be replaced To prevent this from happening install a diaphragm type expansion tank that is suitable for potable water on the cold water supply line The expansion tank must have a minimum capacity of 6 litres 1 5 USG for every 190 litres 50 USG of stored water and be rated for 1034kPa 150 PSI or the working pressure of the water heater NEVER PLUG OR REMOVE the T amp P valve Important Do not plug or remove the temperature and pressure relief valve A WARNING Excessive Weight Hazard Use two or more people to move and install water heater Failure to do so can result in back or other injury Unpacking the Water Heater Important Do not remove any permanent instructions labels or the data label from the outside of the water heater or on the inside of panels Remove exterior packaging and place installation components aside Inspect all parts for damage prior to installation and start up Completely read and understand all instructions before attempting to assem ble and install this product After installation dispose of packaging material in the proper manner Important Strictly follow the installation instructions before making electrical connections Piping Installat
33. rce therein This Warranty does not affect specific legal rights of a consumer under applicable law except to the extent that such rights may be waived or replaced and the provisions hereof are deemed to be amended to the extent necessary The unenforceability of any provision in whole or in part of this Certificate shall not affect the remaining provisions Any and all repair and or replacement of part s or Unit are the sole and exclusive remedy available against GSW LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING 1 The Unit shall be installed in accordance with all manufacturers instruc 7 properly documented claim shall be received by GSW or one of its tions all applicable equipment and building codes ordinances and regu authorized dealers or point of purchase within the following Warranty lations hereinafter referred to as standards Period except as provided otherwise below 2 The Unit must not be installed where water damage can result from a a for any defective part within one 1 year or leak while provision s shall be made for directing any water escaping b for any Unit that develops leaks in the inner tank due to rust corrosion from the Unit to a properly operating drainpipe As all units of this type or other chemical reactions caused by the potable domestic water sup may eventually leak you must protect against any potential water dam plied to your home within the period of t
34. rchasing this water heater Properly installed and maintained it will provide years of trouble free service This manual gives instructions for the proper instal lation safe operation and maintenance of this water heater is your responsibility to ensure that your water heater 15 properly installed and cared for Important Consumer Notice The warranty on this water heater is in effect only when the water heater is installed and operated in accordance with these instructions The manufacturer of this water heater will not assume any liability for any injury or property dam age resulting from failure to comply with these instructions Protect your warranty Regularly maintain your water heater as detailed in the service and maintenance section of this manual Installation Code Requirements In addition to the installation instructions found in this man ual the water heater must be installed in accordance with all local and provincial or state codes or in the absence of local and provincial or state codes with the latest edition of Canadian Electrical Code in Canada available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontario Canada L4W 5N6 Or National Electrical Code in USA available from American Standards Institute 1430 Broadway New York NY 10018 The requirements of these documents must be carefully fol lowed in all cases Authorities having jurisdiction shall be consulted be
35. re limiting valves are recommended CAUTION Hydrogen gas can be produced in a hot water system served by this heater that has not been used for a long period of time generally two 2 weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To reduce the risk of injury under these conditions it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance con nected to the hot water system Use caution in opening faucets When hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during the periods of heat up and cool down 2 Sediment build up in the tank bottom will create varying amounts of noise and may cause premature tank failure Drain and flush the tank as directed under Draining Flushing and Sediment Removal V ELECTRICAL
36. s to come in contact with any electrical part or wiring Under no circumstances is the manufacturer to be held responsible for any water damage in connection with this water heater IMPORTANT This water heater must be installed strictly in accordance with the instructions enclosed and local electrical fuel and building codes It is possible that connections to the water heater or the water heater itself may develop leaks IT IS THEREFORE IMPERATIVE that the water heater be installed so that any leakage of the tank or relat ed water piping is directed to an adequate drain in such a manner that it cannot damage the building furniture floor covering adjacent areas lower floors of the structure or other property subject to water damage This is particular ly important if the water heater is installed in a multi story building on finished flooring or carpeted surfaces GSW WILL NOT ASSUME ANY LIABILITY for damage caused by water leaking from the water heater pressure relief valve or related fittings Select a location as centralized within the piping system as possible In any location selected it is recommended that a suitable drain pan be installed under the water heater This pan must limit the water level to a MAXIMUM depth of 45mm 1 3 4 in and have a diameter that is a minimum of 50mm 2 in greater than the diameter of the water heater Suitable piping shall connect the drain pan to a properly operating floor drain x
37. t 3 Phase Power Circuit Canada me INPUT TERMINAL CONTACTORS LOWER ELEMENTS BLACK CENTER ELEMENTS UPPER ELEMENTS FIGURE 9 9 Element 1 Phase Power Circuit Canada INPUT TERMINAL BLOCK CONTACTORS LOWER ELEMENTS UPPER ELEMENTS CENTER ELEMENTS FIGURE 10 9 Element 3 Phase Power Circuit Canada sige HIGH LIMIT INPUT CONTROL THERMOSTAT TERMINAL TRANSFORMER BLOCK 3A FUSE PRIMARY SECONDARY X1 480V THERMOSTAT CONTACTORS O D G Me A a ee T a T 71 I I L1 L2 3 TERMINAL L d EE E BLOCK 1 E SINGLE PHASE BLACKBLUE RED YELLOW 5 NOV X VAA REPLACE FUSES WITH SAME SIZE TYPE AND RATING ONLY INPUT L2 L3 TERMINAL BLOCK 3 PHASE RED BLUE YELLOW FUSE HOLDER WITH FUSES LOWER ELEMENTS FIGURE 12 3 Element Power Circuit USA only 14 HIGH LIMIT CONTROL THERMOSTAT INPUT TERMINAL TRANSFORMER BLOCK 3A FUSE PRIMARY SECONDARY X1 480V THERMOSTAT CONTACTORS C4 FIGURE 13 6 Element Control Circuit USA only RSS RE a ST O 71 I I L1 t L2 L3 TERMINAL L S ORT ees ee ee BLOCK 1 i E SINGLE PHASE BLACKBLUE RED YELLOW ne de nt nt Ve en ste ent ar nee en cat g CA A lt l f
38. the heater base to the drain pan and the drain pan to the floor with the sealant listed above Be certain that there are no gaps or openings in the seal See Figure 22 5 drain pan is not installed seal the unit base to the floor with the sealant listed above Be certain that there are no gaps or openings in the seal See Figure 23 NOTE The NSF certification requires the heater to be designed constructed and installed to prevent the harbor age of vermin and the accumulation of dirt and debris 987 Certificate of Warranty See Rating Label Serial Number prefix for Warranty Code P R S T UV W Y Warranty Code Reduced warranty period Standard Warranty Years 3 5 6 7 8 9 10 12 applies to Newfoundland Reduced Warranty Years 2 3 3 5 5 5 5 7 For its GSW and John Wood water heaters and storage boosters Unit GSW Water Heating GSW warrants that upon receipt of a properly verified Warranty claim within the Warranty Period it will at its election repair or replace units which leak or parts which are defective in material or workmanship subject to the terms and conditions set forth in this certificate GSW will not assume any expense or liability for unauthorized returns nor repairs made by a person who has not been authorized by GSW or one of its authorized dealers GSW Units parts must be replaced with GSW or John Wood products to be eligible for Warranty This Warranty is available to the original owner of a Unit instal
39. tilities for code requirements in your area FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE THOROUGHLY READ ALL INSTRUCTIONS BEFORE YOU ATTEMPT TO INSTALL OPERATE OR MAINTAIN THIS HEATER Location Requirements Refer to Figure 2 to determine the size of the various mod els of the water heater 1 clear space of 457mm 18 in should be allowed in front of the heater to allow access to the controls and elements 2 clearance of 305mm 12 in is sufficient clearance from the top of the heater to adjacent surfaces is suggested that the heater be located in the center of the water system or close to the point of use requiring the most hot water 4 The water heater should be located in an area not sub ject to freezing temperatures 5 Water heaters located in unconditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing 6 The drain and controls must be easily accessible for operation and service This water heater is not intended for space heating applications Temperature and Pressure T amp P Relief Valve All water heaters must be installed with a proper tempera ture and pressure relief valve In the United States this valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the produc
40. voltages are present in both com partments Be careful not to touch any electrical connec tions 5 To check the operation of the thermostat a operate the thermostat manually and let the heater come to the preset temperature and shut off automatically Turn OFF the electrical supply to the heater Replace all the insulation and close all covers 8 Turn ON the electrical supply to the heater N O High Temperature Limiting Device The heater is equipped with a high temperature cutoff switch If the water temperature exceeds the preset limit this device turns off the power to the heating elements The high temperature switch is set to activate at 88 C 190 F If the switch has been activated allow the water temperature to drop by 17 C 80 F min and reset manually The high temperature switch is not adjustable 18 Vil MAINTENANCE General Do not attempt to repair water heater Call your authorized dealer for service Shut off the electric power whenever the water supply is turned off Before calling for service check that 1 The heater is properly filled 2 The electrical supply has not been interrupted Draining and Sediment Removal Water may contain fine particles of soil and sand which set tle to the bottom of a tank and thus form a layer of sediment If not removed the sediment could reach the heating ele ments and cause them to fail It is recommended that the tank be drained
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