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GSW 72090 User's Manual

1. 2 600mm 24 in 450mm 18 in BASEMENT INSTALLATION EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS Figure 5 Combustion Air Supply Openings And Ducts Can Acceptable Round Combined Input Duct Size Diameter of All Appliances Required in Confined Free Area Space 2 75 000 100 000 All appliances refers to and includes those appliances using the same air source e g water heater furnace boiler clothes dryer etc Maximum allowable length of ductwork listed in column Ais 6 1 equivalent metres 20 ft Maximum allowable length of ductwork listed in column B is 15 2 equivalent metres 50 ft Table 1 Air Supply Sizing Can 12 in equals 450mm 18 in as shown in Figure 5 b All exterior vent openings are to be at least 300mm 12 in above the ground and clear of snow levels 0 Confined Space Air Requirements for U S Installations Refer to Figure 6 a b c or d for proper sizing and location of combustion air ducts and openings CHECK LOCAL CODES a Equipment located in confined spaces all air from inside the building Two permanent openings shall be provided connecting the confined space e g closet small room with the unconfined space Each opening shall have a free area of one square inch per 1 000 BTU hour input 22 cm kW of all appliances in the confined space but not less
2. 4 VII COMBO HEATING 21 User Responsibilities 4 System Requirements 21 ll SAFETY ote terete tetes te eee te hed 4 Vill TROUBLESHOOTING GUIDE 22 For Installations in Canada IX REPAIR PARTS ILLUSTRATION 24 For Installations in the United States LIMITED WARRANTY 25 4 4 Safety Warning Flammable Vapours 3 Safety Warning Scalding 5 Safety Warning Carbon Monoxide 3 Relief Valves T amp P 5 Backflow Prevention 5 Ill INSTALLATION 6 Unpacking the Water Heater 6 Location Requirements 6 In Earthquake Zones Clearances and Accessibility 6 Gas Supply 7 Gas Pressure Gas line purging Gas Leak Testing Air Requirements 9 Confined Space Air Requirements for Canadian Installations 9 Confined Space Air Requirements for U S Installations 10 Exhaust Venting 11 Vent Pipe System Drafthood Installation Water Supply 11 Piping Installation Closed System Thermal Expansion Temperature and Pressure T amp P Relief Valve 12 The Temperature And Pressure Relief Valve The Discharge Line Installations Check 13 IV OPERATING INSTRUCTIONS 14 Water Temperature Regulation 14 Temperature Adjustment Lighting Instructions Robertshaw 110R 15 Lighting Instructions Robertshaw 220R 16 Lighting Instructions White Rodgers 37C 17 V OPERATION E 18 Burner Flames 18 Emergency Shut Down 1
3. PERMANENT OPENINGS UNCONFINED SPACE EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM INSIDE THE BUILDING AIR DUCT PERMANENT COMBUSTION 300mm VENTILATION 12 in AIR 300mm 12 in ABOVE GRADE OR _ gt SNOW LINE GRADE FA A BASEMENT INSTALLATION EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS Se N 300mm 12 in OUTDOORS AIR DUCT 300mm 12 in CONFINED SPACE VENTILATION Pat COMBUSTION EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS 300mm 12 in es ATTIC LOUVERS TO OUTDOORS OUTLET CONFINED SPACE Y INLET AIR DUCT 12 in EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC Figure 6 Combustion Air Supply Openings And Ducts U S A Exhaust Venting pmm f EXHAUST FAN Figure 7 Air Moving Devices i REVERSE FLOW OF GASES Vent Pipe System This water heater is a Category 1 non direct vented appli ance The vent pipe must be installed in accordance with all local and provincial or state codes or in the absence of such codes with the latest edition of Natural Gas
4. Gas Control Knob Top View Thermostat Dial Gas Control TO TURN OFF GAS TO APPLIANCE Set thermostat to the lowest setting PILOT LIGHTING Push the gas control knob down slightly and clock wise A to the OFF position Do not force Vue en plong e Gas Control Knob Bouton de commande du gaz lt Igniter Cadran de r glage du thermostat Commande du gaz Lighting Instructions White Rodgers 37C POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT Quiconque ne respecte pas la lettre les instructions dans la pr sente notice risque de d clencher un incendie ou une explosion entrai nant des dommages des blessures ou la mort A L allumage de la veilleuse de cet appareil est assur par un syst me d allumage pi zo lectrique tincelles Ne tentez pas d ouvrir la porte d acc s interne et d allumer la veilleuse manuellement AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour d celer une odeur de gaz Reniflez pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur appelez le service
5. This warranty is limited to one replacement water heater at the original installation site 2 Component Part If any component part other than the inner tank proves to Manufacturer s satisfaction to be defec tive in material or workmanship within one 1 year the Manufacturer will furnish the Owner with a replacement for the defective part s This warranty is limited to one replacement component part for each original part 3 Return of Defective Water Heater and Component Parts Manufacturer reserves the right to examine the alleged defect in the water heater or component part s and it will be the Owner s obligation See paragraph D 5 to return the water heater and or component part s to the Manufacturer a When returning a water heater it must include all component parts and the data plate label b When returning component part s they must be individually tagged and identified with the water heater s product number model number serial number date of purchase and date of installation c 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 THE MANUFACTURER OF ANY NATURE OR KIND EXPRESS OR IMPLIED HOWEVER ARISING WHETHER BY CONTRACT CONDUCT STATEMENT STATUTE NEGLIGENCE PRINCIPLES OF MANUFAC TURER S LIABILITY OPERATION
6. 1 as necessary to completion ARRESTER Figure 16 Flame Arrester External View Resetting and Replacing the Safety TCO Switch The water heater safety system includes a door mount manual resettable safety switch which is designed to dis able the gas control thermostat in the event of excessive combustion chamber temperatures The excessive combus tion chamber temperatures may be generated by accumu lation of lint and dust on the flame arrester located under neath the combustion chamber 1 Follow first the procedure outlined in External Cleaning of the Flame arrester 2 Remove the outer door and locate the TCO switch on the right side of the combustion chamber door 3 Manually press the contact located on the front right side of the TCO switch Figure 17 until a click sound is generated Do not use a metal tool or a screwdriver to press the TCO switch contact 4 Verify if the quick connects are firmly inserted in the TCO switch contacts 5 Replace the outer door 6 Restart the water heater following the Operating Instructions 7 Ifthe pilot burner does not stay lit after several attempts it is possible that the TCO embedded in the safety switch opened due to a flammable vapor incident or the TCO switch was severely damaged Do not attempt to further operate the water heater Call a qualified service technician THERMAL CONTACT Figure 17 TCO Switch Temperature and Pressure Relief V
7. C 200 F e Excessive combustion chamber temperatures e The ignition of flammable vapors A thermocouple is used to determine if a pilot flame is pres ent and will shut off the gas supply to the main burner and the pilot burner if the flame is absent A dual safety switch is part of the water heater safety sys tem The gas control is connected to a door mount manual ly resettable safety switch which is designed to disable the gas control thermostat in the event of excessive combustion chamber temperatures or a flammable vapor incident If the thermal switch opens the water heater cannot be used unless this thermal switch is reset by a qualified service technician The gas control has a high temperature limit switch or ECO Energy Cut Off which is used to shut off the unit if the water temperature exceeds 93 C 200 F The ECO is a single use switch and requires complete replacement of the entire gas control thermostat If the ECO should function the water heater cannot be used until the gas control ther mostat is replaced by a qualified service technician Contact your local dealer for service information Anode Water Odour Each water heater contains at least one anode which will slowly deplete while protecting the glass lined tank prolong ing the life of the water heater Certain water conditions may cause a reaction between the anode and the water The most common complaint associated with the anode is a rot ten egg smel
8. Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS 1 STOP Read all safety labels on the water heater before operation 2 Remove the outer door 3 Turn the temperature dial counterclockwise to its low ROBERTSHAW 220R GAS CONTROL R GULATEUR DE GAZ ROBERTSHAW 220R GAS CONTROL KNOB SHOWN IN OFF POSITION PRESSURE REGULATOR IGNITER TEMPERATURE DIAL 4 Turn gas control knob clockwise to the OFF position SS 5 To clear any gas that may have accumulated wait 00 lt gt O ten 10 minutes If you then smell gas STOP Follow instruction B described above 6 Turn the gas control knob counterclockwise 4 to PILOT 7 Depress the gas control knob all the way in and IMMEDIATELY depress the igniter button until you hear a loud click Observe the pilot through the view port Do not release the knob Repeat immediately if pilot does not light on the first try If the pilot does not light by the fourth attempt with the igniter repeat steps 3 6 Continue to hold the control knob for about 1 minute
9. OF LAW OR OTHERWISE WITH RESPECT TO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY INSTALLATION OPERATION REPAIR OR REPLACE MENT THE MANUFACTURER EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES IN NO EVENT WILL THE MANUFACTURER S LIABILITIES EXCEED THE COST OF THE DEFECTIVE PART S OR UNIT D WHAT THIS WARRANTY DOES NOT COVER 1 The Unit must not be installed where water damage can result from a leak while provision s shall be made for direct ing any water escaping from the Unit to a properly operating drainpipe As all units of this type may eventually leak you must protect against any potential water damage The Manufacturer accepts no responsibility for such damage nor any incidental or consequential loss nor damage s related thereto suffered by the Owner of the Unit nor by any third party 2 Manufacturer shall not be liable under this warranty and this warranty shall be void and have no effect if the following events occur a The water heater or any of its component parts have been subject to misuse alteration neglect or accident or b The water heater has not been installed in accordance with the applicable local plumbing and or building code s and or regulations or in their absence with the latest edition of the Natural Gas and Propane Installation Code and or the Canadian Electrical Code or c The water heater is not installed operated and maintained in accordance with the Manufacturer s instruc
10. exceed 550 kPa 80psi If this occurs a pressure reducing valve and or an expansion tank may be required The pressure reducing valve should be placed on the sup ply to the entire house in order to maintain equal hot and cold water pressures Important Heat must not be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings Install the water piping and fittings as shown in Figure 10 Connect the cold water supply to the fitting 3 4 NPT marked COLD or C Connect the hot water supply to the fitting 3 4 NPT marked HOT or H INA CLOSED SYSTEM USE EITHER 1 THERMAL EXPANSION TANK HOT WATER OUTLET 2 PRESSURE RELIEF VALVE COLD WATER INLET VALVE La i PRESSURE REDUCING VALVE WITH BYPASS COLD WATER INLET De AND PRESSURE RELIEF VALVE DISCHARGE LINE 300mm 12 in MAX CANADA OR 150mm 6 in MAX U S A ABOVE DRAIN MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19MGL 142 DRAIN LINE 19mm p in ID MIN Figure 10 Example Of Water Piping Installation FOLLOW THE TEMPERING VALVE MANUFACTURER S INSTRUCTIONS PIPE rs HOT WATER COLD WATER OUTLET TEMPERED WATER TO FIXTURE TEMPERING 120 F Figure 11 Typical Tempering Valve Installation Important Always
11. from the outside of the water heater or on the inside of panels 1 Move the water heater to the location of installation before removing the exterior packaging 2 Remove exterior packaging and place installation com ponents aside 3 Inspect all parts for damage prior to installation and start up 4 Completely read and understand all instructions before attempting to assemble and install this product If you observe damage to the water heater or any of its com ponents DO NOT ASSEMBLE OR INSTALL IT OR MAKE ANY ATTEMPT TO FIX THE DAMAGED PART S Contact the place of purchase for further instructions 5 After installation dispose of packaging material in the proper manner Location Requirements 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
12. front clearance shall be provided for inspection and service We recommend that 0 9m 36 in above be maintained for serviceability Locate the water heater such that all controls are easily accessible Clearance to combustibles varies by model Refer to rating plate to confirm clearances Heaters with a volume of 19 gallons through 50 gallons and 60 gallon standard input must have the following minimum clearances to combustibles Front 102mm 4 in Sides and Rear 25mm 1 in Top 203mm 8 in Flue 152mm 6 in JW6058 and G6058 high input series heaters must have the following minimum clearances to combustibles Front 127mm 5 in Sides and Rear 25mm 1 in Top 203mm 8 in Flue 152mm 6 in PIPE TO ADEQUATE AT LEAST 50mm 2 in GREATER THAN THE DIAMETER OF THE WATER HEATER Figure 1 Typical Drain Pan Installation The 60 gallon heater is equipped with a Heat Reflector Shield see Figure 2 This Shield reflects heat from the High input heaters to prevent damage to combustible floors The Shield is held in place by three 3 tabs that rest on the inside of the legs of the water heater Ensure the Shield is positioned horizontally parallel to the bottom of the heater and in the designated position of 38mm 1 5 in below the flame arrester HEAT SHIELD ARRESTER Figure 2 Heat Shield Installation 60 gallon only WARNING Do not install directly on carpet Instead place the water heater on a me
13. increase This may cause the temperature and pressure relief valve to dis charge small quantities of hot water To prevent this from happening there are two recommendations 1 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 5 7 litres 1 5 US gallons for every 190 litres 50 US gal lons of stored water and be rated for 150 psi or the working pressure of the water heater 2 Install a pressure relief valve rated at max 125 psi in the cold water supply line Make sure the discharge of this valve is directed to an open drain and protected from freezing Contact the local water supplier or plumbing inspector for information on how to control this situation Important Do not plug the temperature and pressure relief valve Temperature and Pressure T amp P Relief Valve WARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a licensed plumber repair it Do not plug valve Do not remove valve Failure to follow these instructions can result in death or an explosion Refer to Figure 12 for a typical T amp P valve installation 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 betw
14. is installed with a back flow preventer on the incoming water line or in a closed system a diaphragm type expansion tank must always be installed in the system to prevent the T amp P from relieving due to thermal expansion 6 Proper sizing of the water heater for the given space and potable heating application is essential to ensure adequate heating capacity The sizing and installation of such combination system must be performed by quali fied personnel and be in accordance with public utility requirements and or codes having jurisdiction The sizing of the water heater should be based on the design heat loss of the structure to be heated plus the potable water requirements IT IS IMPORTANT THAT THE WATER HEATER USED BE OVERSIZED TO ALLOW ADEQUATE HEATING AND POTABLE WATER HEATING CAPACITY VIII TROUBLESHOOTING GUIDE Note Troubleshooting must be done by qualified service personnel familiar with the start up and check out procedure Note The latest version of the installation and operating instructions manual can be found at www johnwoodwater heaters com PROBLEM POSSIBLE CAUSE S CORRECTION BURNER WILL NOT IGNITE Pilot not lit Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged Defective thermocouple Defective gas control thermostat Heater installed in a confined area Light pilot Turn temp dial to desired temperature Check with gas utility company Notify utility
15. than 100 square inches 645 cm The top open ing shall commence within 300mm 12 in of the top of space and the bottom opening shall commence within 300mm 12 in of the bottom of the enclosure b Basement installation equipment located in con fined spaces all air from outdoors When supplying air directly from the outdoors each opening shall have a minimum free area of one square inch per 4 000 BTU hour input 5 5 cm kW of total input rating of all appliances in the confined space The inlets shall be a minimum of 300mm 12 in above the grade snow line The top opening shall commence within 300mm 12 in of the top of the confined space c Equipment located in confined spaces all air from outdoors When supplying air directly from the outdoors using hor izontal ducting each opening shall have a free mini mum area of one square inch per 2 000 BTU hour 11 cm kW of total input rating of all appliances in the con fined space d Equipment located in confined spaces all air from outdoors through ventilated attic When supplying air directly through vertical ducting each opening shall have a free minimum area of one square inch per 4 000 BTU hour 5 5 cm kW of total input rating of all appliances in the confined space WARNING Burn Hazard Do not touch vent Doing so can result in burns RU F7 CONFINED SPACE CONFINED SPACE 1
16. to eliminate air from the piping system Purging should be performed by persons experi enced in this type of gas service in compliance with the code having jurisdiction Do not purge in confined areas or space where ignition may occur To avoid risk of fire or explosion ensure the area is well ventilated and all sources of ignition are de activated Contact your local gas authority for local requirements Gas Leak Testing Important This water heater and its gas connection must be tested for leaks before placing the appliance in opera tion Perform a leak test at normal gas pressure If the appli cable code s require the gas lines to be tested at a pres sure of 14 in w c 3 5 kPa or greater the water heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped Test all connec tions of the gas system with a chloride free soap and water solution or equivalent leak test liquid Bubbles will indicate leaks Never use a match or open flame to test for gas leaks A fire or explosion could result If leaks exist repair as required and retest DO NOT light the burner before the tank is filled with water and you have confirmed that there are no leaks in the pip ing and connections Air Requirements Important Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to cor rosive elements in the atmosphere is excluded from war ranty coverage Install
17. use a good grade of joint compound approved for use with potable water systems and be certain that all fittings are drawn up tight Important Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove modify or tamper with the heat traps or any inserts within the heat traps Please note the following DO NOT install this water heater with iron piping The sys tem should be installed only with new 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 com patible with potable water DO NOT use valves that may cause excessive restriction to water flow Use full flow ball or gate valves only DO NOT use any lead based solder in potable water lines Use appropriate tin antimony or other equivalent material 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 Closed System Thermal Expansion Periodic discharge from the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system The water utility supply meter may contain a check valve This will create a closed water system During the heating cycle of the water heater the water expands causing pressure inside the water heater to
18. warranty entitlement B WHEN IT IS COVERED The water heater is warranted only when it is installed operated and maintained in accordance with the printed instruc tions accompanying the water heater The water heater shall must be installed in such a manner that if the tank or any connection thereto should leak the resulting flow of water will not cause damage to the area in which it is installed The water heater s temperature and pressure relief valve must be piped to the nearest drain to avoid damage in the event the valve is actuated For detailed instructions read the manual accompanying the water heater and review drawings in the manual C WHAT THE MANUFACTURER WILL DO AND THE PERIOD OF COVERAGE 1 The Inner Tank If the inner tank leaks within the warranty period shown in the table at the top of this page after the original installation Manufacturer will furnish a new water heater of Manufacturer s then prevailing comparable model If industry standards regulatory changes product improvements or product obsolescence prohibits Manufacturer from furnishing an identical model replacement water heater under this warranty the Owner will be furnished with a new water heater of comparable capacity however the Owner will be charged for the additional value of the item s which Manufacturer has incorporated in the replacement water heater A prior authorization number must be obtained from the Manufacturer before replacing the water heater
19. with dishwashing or space heating applications Safety Warning Carbon Monoxide As with all fuel burning equipment this heater requires an adequate supply of air for combustion and ventilation An insufficient air supply can result in poor combustion or the re circulation of the exhaust flue gases Such a condition can cause soot build up or present a fire hazard and may result in serious bodily harm or death from asphyxiation MAKE SURE THE FLOW OF COMBUSTION AND VENTI LATION AIR IS NOT RESTRICTED A DANGER Carbon Monoxide Warning Follow all vent system requirements by the local authorities having jurisdiction over your installation Failure to do so can result in death explo sion or carbon monoxide poisoning Relief Valves T amp P All water heaters must be installed with a proper tempera ture and pressure relief valve These valves must be certi fied as meeting the requirements of the Standard for Temperature Pressure Temperature and Pressure Relief and Vacuum Relief CSA 4 4 in Canada In the United States Relief Valves and Automatic Gas Shut Off Devices for Hot Water Supply Systems ANSI 221 22 is applicable If this water heater has been exposed to flooding freezing fire or any unusual condition do not put it into operation until it has been inspected and approved by a qualified profes sional THESE CONDITIONS CAN RESULT IN UNSEEN INTERNAL DAMAGE which is not subject to warranty cov er
20. 8 Checking the Draft 18 Operating Conditions 18 Condensation Water Heater Sounds Safety Shut off Anode Water Odour VI MAINTENANCE 19 Draining and Flushing 19 Periodic Inspection 19 External Cleaning of the Flame arrester 20 Resetting and Replacing the Safety TCO Switch20 Temperature and Pressure Relief Valve 20 RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE Le 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 A This is the safety alert symbol DANGER or WARNING 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 You can be killed or seriously injured if you don t immediately follow instructions 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 We thank you for choosing a Flammable Vapor Resistant Water Heater Your satisfaction with this product is very important to us This gas fired water heater has been developed to produce domestic hot water and may also be used in combination with
21. DOOR IGNITER TCO SWITCH FLEXIBLE MANIFOLD TUBE HEAT SHIELD 60 GALLON ONLY QUICK CONNECT LEADS Figure 20 Repair Parts TCO SWITCH PILOT THERMOCOUPLE ASSEMBLY VIEWPORT TWO PIECE GROMMET WITH CLIP MANIFOLD DOOR GAS MANIFOLD PILOT TUBE GAS ORIFICE MANIFOLD DOOR GASKET BURNER Figure 21 Manifold Door Assembly LIMITED WARRANTY See Rating Label Serial Number prefix for Warranty Code P R S T U VW Y Warranty Code Reduced warranty period Standard Warranty Years 3 5 6 7 8 9 10 12 applies to Newfoundland Reduced Warranty Years 3 3 3 5 5 5 5 7 RESIDENTIAL STORAGE TANK TYPE WATER HEATER FOR INSTALLATION IN A SINGLE FAMILY DWELLING A WHO IS COVERED GSW WATER HEATING AND ITS SUPPLIERS herein collectively referred to as Manufacturer warrants only to the original consumer purchaser hereinafter Owner of the water heater within the boundaries of continental United States or Canada or their territories so long as he or she continuously occupies the single family dwelling in which this water heater is initially installed for the period specified below This warranty is not transferable This warranty is reduced to one year if the water heater is used in a commercial or industrial application or if the water heater is used to supply more than one dwelling unit Consumers must retain point of sale proof of purchase to validate
22. GSW WATER HEATING G SW 599 Hill Street West Fergus ON Canada N1M 2X1 FLAMMABLE VAPOR RESISTANT WATER HEATER INSTALLATION AND OPERATING INSTRUCTIONS Read these instructions thoroughly before starting 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 gas utility FOR YOUR SAFETY e Do not store or use gasoline or other flammable vapours 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 gas utility A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage per sonal injury or death WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department GSW Water Heating is a division of A O Smith Enterprises Ltd G CERTIFIED PART NO 72090 REV D 07 11 This page intentionally left blank May be used for notes or to record other installation information 59 TABLE OF CONTENTS 1 INTRODUCTION
23. LES gt Flammable Vapours FIRE AND EXPLOSION HAZARD Can result in serious injury or death no not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapours or liquids in the vicinity of this or any other appliance can result in serious injury or death There is a risk in using fuel burning appliances such as water heaters Areas that may not be suitable for water heater installation include those where flammable liquids gasoline solvents adhesives etc or engine driven equip ment or vehicles are stored operated or repaired Due to the nature of air movement flammable vapors can be car ried some distance from the point of storage The gas fired water heater igniter or main burner flame can ignite these vapors causing a flashback fire or explosion which may result in serious personal injury or death as well as severe property damage Safety Warning Scalding DANGER PON HOT an 4 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 see Figure 11 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 operated in combination
24. ONES ARE SATISFACTORY INCORRECT FLAME LAZY LV YELLOW CORRECT FLAME SOFT BLUE Figure 14 Flame Characteristics Emergency Shut Down Important Should overheating occur or the gas supply fail to shut off turn off the water heater s manual gas shut off valve and call a qualified service technician Checking the Draft After successfully lighting the water heater allow the unit to operate for 15 minutes and check the drafthood relief open ing for proper draft Pass a match flame around the relief opening of the drafthood as shown in Figure 15 A steady flame drawn into the opening indicates proper draft If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not oper ate the water heater until proper adjustments or repairs are made to the vent pipe system RELIEF SES Figure 15 Checking The Draft Operating Conditions Condensation Moisture from the products of combustion condenses on the tank surface and forms drops of water which may fall onto the burner or other hot surfaces This will produce a siz zling or frying noise This condensation is normal and should not be confused with a leaking tank Condensation may increase or decrease at different times of the year Highly efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used Once the wate
25. after the pilot is lit Release the control knob and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 3 7 IMPORTANT If the pilot will not stay lit after several tries tum gas control knob to OFF and call your service tech nician or gas supplier IMPORTANT If the gas control knob does not pop up to its original position when released stop and immediately shut off the gas at the line valve or tank Call your service technician or gas supplier C2 AN to ON 4 9 Set the temperature dial to the desired setting 10 Replace the outer door 1 Set the thermostat to lowest setting Turn counterclockwise 4 2 Turn the gas control knob OFF 8 Turn the gas control knob counterclockwise TO TURN OFF GAS TO APPLIANCE Rotate clockwise n 16 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explo sion may result causing property damage personal injury or loss of life This appliance has a pilot that is lit by a piezo electric spark gas ignition system Do not open the inner door of the appliance and try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gases are heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do n
26. age Backflow Prevention Certain jurisdictions may require the installation of a back flow device e g check valve in the water supply line Such a device will require the use of a system expansion tank of adequate size to control the thermal expansion generated during the heating cycle Consult your water supplier or local plumbing authority Important The supply water meter may have a built in check valve device Contact your local water authority 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 If 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 111 INSTALLATION Unpacking the Water Heater 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 Important Do not remove any permanent instructions labels or the rating plate
27. alve 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 Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temper ature and pressure relief valve see Figure 18 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 shut off the manual gas shut off valve and the cold water inlet and call a qualified service techni cian TEMPERATURE AND PRESSURE RELIEF VALVE P MANUAL RELIEF VALVE DISCHARGE LINE TO DRAIN Figure 18 T amp P Relief Valve Test 20 Vil COMBO HEATING This section serves as a guide for the installation and use of Combo heating systems utilizing a domestic water heater which has been specifically approved for such use see Figure 19 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 ensure the effectiveness and safety of the installation System Requirements The following requirements must be met for the installation of Combo Heating Systems 1 The piping and components connected
28. and Propane Installation Code CAN CSA B149 1 in Canada National Fuel Gas Code ANSI Z223 1 NFPA 54 in the U S A The vent pipe must not be obstructed so as to pre vent the removal of exhaust gases to the outside atmos phere Note The horizontal section of the vent must slope up 21mm per metre 1 4 in per foot see Figure 8 U L recognized fuel gas and carbon monoxide CO detec tors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations Important If you lack the necessary skills required to prop erly install this venting system you should not proceed but enlist the help of a qualified service technician Drafthood Installation Hook the tab leg of the drafthood into the slot in the heater s top Align the remaining legs with the hole dimples and secure the drafthood to the top with three screws as shown in Figure 9 Do not alter the drafthood in any way If you are replacing an existing water heater be sure to use the new drafthood supplied with the water heater SLOPE UP 21mm PER METRE 1 4 in PER ft MIN Figure 8 Vent System DRAFTHOOD Water Supply Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 10 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation Water supply pressure should not
29. ary or incidental in returning the defective water heater or component part s to a location desig nated by the Manufacturer 4 The terms of this Limited Warranty cannot be modified by any person whether or not he she claims to represent or act on behalf of the Manufacturer E HOW THE ORIGINAL OWNER CAN MAKE A WARRANTY CLAIM 1 The Owner should submit the warranty claim directly to Manufacturer s Service Department at the address or phone number listed below and Manufacturer will arrange for the handling of the claim 2 Whenever any inquiry or request is made be sure to include the water heater s catalogue number model number serial number date of purchase date of installation and location of installation This warranty and the Manufacturer s obligations shall be construed and determined in accordance with the laws of both the Province of Ontario and of Canada in force therein This Warranty does not affect specific legal rights of a consumer under applicable law except to the extent that such rights may be waived or replaced and the provisions hereof are deemed to be amended to the extent necessary The unenforceability of any provision in whole or in part of this Certificate shall not affect the remaining provisions Any and all repair and or replacement of part s or Unit are the sole and exclusive remedy available against the Manufacturer GSW Water Heating 599 Hill Street West Fergus ON Canada N1M 2X1 Should you have any
30. ated input and fuel for which it was factory built or The water heater or any of its component parts fail due to sediment build up or The water heater does not have installed a properly operating temperature and pressure relief valve certified to ANSI Z21 22 CSA Requirements for Relief Valves for Hot Water Supply Systems or The water heater or any of its component parts fail because of fire floods lightening or any other act of God or any other contingency beyond the control of the Manufacturer or The water heater is installed in a closed system without adequate provision for thermal expansion 3 Except when specifically prohibited by the applicable law the Owner and not the Manufacturer shall be liable for and shall pay for all charges for labour or other expenses incurred in the removal repair or replacement of the water heater or any component part s claimed to be defective or any expense incurred to remedy any defect in the product Such charges may include but are not necessarily limited to a b C d All freight shipping handling and delivery costs of forwarding a new water heater or replacement part s to the Owner All costs necessary or incidental in removing the defective water heater or component part s and installing a new water heater or component part s Any material required to complete and or permits required for installation of a new water heater or replacement part s and All costs necess
31. ater Long runs of exposed piping Hot water piping in exposed wall Leaks or cracks in dip tube Pilot line or orifice clogged Low gas pressure Defective pilot OONMAPWNAAARWNHSA 2 CDN BR ZOND PW Bleed the air from the gas line Check with gas utility company Notify utility install dirt trap in gas line Clean locate source and correct Finger tighten then 1 4 turn with wrench Replace thermocouple Locate source and correct Replace gas control thermostat Call a qualified service technician Replace igniter or pilot assembly Replace water heater eliminate flammable vapors source Call a qualified service tech nician Check with gas utility company Reset the TCO switch Check if the quick connects are firmly inserted on TCO switch contacts Set temperature dial to lower setting Drain Flush Provide water treatment if needed Install adequate size heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Check dip tube Replace if faulty Clean locate source and correct Check with gas utility company Replace pilot PROBLEM POSSIBLE CAUSE S CORRECTION 1 Thermostat set too low 1 Turn temperature dial to desired setting 2 Sediment or lime in tank 2 Drain flush provide water treatment if need ed 3 Water heater too small Install adequate size heater 4 Wrong piping connections Correct
32. ater is design certified by CSA International as a Category I non direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside In addition to the installation instructions found in this man ual the heater shall be installed according to all local and provincial or state codes or in the absence of such codes with the latest edition of the following specifications For Installations in Canada Natural Gas and Propane Installation Code CAN CSA B149 1 and Canadian Electrical Code CAN CSA C22 1 Part I available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontario Canada L4W 5N6 For Installations in the United States National Fuel Gas Code ANSI Z223 1 NFPA 54 and National Electrical Code NFPA 70 available from American National Standards Institute 25 West 43rd Street New York NY 10036 Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2 00 and 5 00 Check your phone 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 Safety Warning Flammable Vapours AWARNING ct FLAMMAB
33. ations in or for certain places including but not limited to those listed below will require outdoor air for combustion due to chemical exposure Beauty shops Photo processing labs Buildings with indoor pools Water heaters installed in laundry hobby or craft rooms Water heaters installed near chemical storage areas In such circumstances outdoor combustion air may reduce but will not eliminate the presence of corrosive chemicals in the air Combustion air must be free of acid forming chemi cals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrig erants and many other commercial and household prod ucts When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet The area in which the heater is located is classified as either an unconfined space or a confined space An unconfined space is defined as a space having a vol ume not less than 50 cubic feet per 1000 BTU hour 4 8 cubic metres per kilowatt of combined input rating of all appliances using the space Adjacent open rooms may be included as part of the unconfined space provided there are no closeable doors between these rooms An example of this is an open basement A confined space is one smaller than described above For buildings using tight
34. ature dial will increase the risk of scald injury Hot water can produce third degree burns in 6 seconds at in 30 seconds at in 5 minutes at 60 C 140 F 54 C 130 F 49 C 120 F Temperature Adjustment The thermostat of this water heater has been factory set at its lowest position It is adjustable and must be set to the desired temperature setting The preferred starting point is 49 C 120 F Turn the water temperature dial clockwise f to decrease the temperature or counterclockwise to increase the temperature Figures 13a amp 13b show the approximate water tempera tures produced at various thermostat settings Short repeat ed heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the ther mostat setting by up to 17 C 30 F 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 fail to shut off turn off the manual gas con trol valve to the appliance Valves for reducing the point of use temperature by mixing cold and hot water are available see Figure 2 Also avail able are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority Note During low demand periods a lower thermostat set ting will reduce energy losses and may satisfy your normal hot water needs If hot water use
35. construction newer and renovated structures the air supply shall be introduced from the out doors regardless of whether the space is confined or unconfined Confined Space Air Requirements for Canadian Installations Refer to Figure 5 a or b and Table 1 for proper sizing and location of combustion air ducts and openings CHECK LOCAL CODES a Two permanent openings shall be provided connecting the confined space e g closet small room with the unconfined space Each opening shall have a free area of one square inch per 1 000 BTU hour input 22 cm kW of all appliances in the confined space The top opening shall be located as close to the ceiling as prac tical but never lower than the top of the heater see Figure 5 a The bottom opening shall be located nei ther more than 450mm 18 in nor less than 150mm 6 in above floor level When using a single air supply the duct shall terminate within 300mm 12 in above and within 600mm 24 in horizontally of the burner level of the appliance having the largest input For example GSW s water heaters burners are 150mm 6 in from the floor plus 300mm b a PERMANENT OPENINGS CONFINED SPACE UNCONFINED SPACE 1 EQUIPMENT LOCATED IN CONFINED SPACES ALL AIR FROM INSIDE THE BUILDING 300mm b a2 in MIN CONFINED 7 SPACE GRADE La conenano TT COMBUSTION VENTILATION AIR DUCT
36. 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 When used with a fuel fired heater this drain pan must not restrict combustion air flow Note Before installing this water heater consideration and planning must be given to the following details e Location and Clearances e Access for gas supply See Gas Supply e How and where to obtain combustion and ventilation air supply See Air Requirements e Routing and support of the vent piping e Position of water supply and placement of water piping for hot and cold water See Water Supply e Floor drain and service In Earthquake Zones Note The water heater must be braced anchored or strapped to avoid moving during an earthquake Contact local utilities for code requirements in your area Note REVIEW SAFETY WARNINGS FOUND IN THE FRONT OF THIS MANUAL BEFORE PROCEEDING Clearances and Accessibility Specific clearance locations are shown in Figure 3 A mini mum of 600mm 24 in of
37. des incendies Ne poussez ou tournez la manette d admission du gaz qu la main ne jamais utiliser d outils Si la manette reste coinc e ne tentez pas de la r parer appelez un technicien qualifi Le fait de forcer la manette ou de la r parer peut d clencher une explosion ou un incendie N utilisez pas cet appareil s il a t plong dans l eau m me par tiellement Faites inspecter l appareil par un technicien qualifi et remplacez toute partie du syst me de contr le et toute commande qui ont t plong s dans l eau DIRECTIVES D ALLUMAGE ET DE MISE EN MARCHE ARRETEZ Lisez les instructions de s curit sur la portion sup rieure de cette tiquette R glez le thermostat la temp rature la plus basse L allumage de la veilleuse de cet appareil est assur par un syst me d allumage tincelles Ne tentez pas d allumer la veilleuse manuellement Enlevez la porte d acc s externe Appuyez sur le bouton de commande du gaz et faites le tourner dans le sens horaire f jusqu OFF Figure A NOTE Il n est PAS POSSIBLE de faire passer le bouton de PILOT a OFF a moins d appuyer dessus Ne le forcez pas 6 Attendre dix 10 minutes pour laisser chapper tout le gaz Reniflez tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz ous sentez une odeur de gaz ARRETEZ Passez l tape B des instructions de s curit sur la portion sup rieure de cette ti
38. een the relief valve and the tank TEMPERATURE AND PRESSURE RELIEF VALVE DISCHARGE LINE 19mm 3 4 in MIN DO NOT CAP OR PLUG Figure 12 Typical Temperature amp Pressure Relief Valve Installation 12 The Temperature And Pressure Relief Valve Must be connected to an adequate discharge line Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line Must terminate a maximum of 300mm 12 in max Canada or 150mm 6 in max U S A above a floor drain or external to the building Must be capable of withstanding 121 C 250 F without distortion Must be installed to allow complete drainage of both the valve and discharge line Must not discharge so as to come in contact with any electrical part or wiring Installations Check 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 13 Have the safety precautions described in the manual been implemented Does the gas piping conform to the recom mendations of your Gas Utility Company Has the gas piping been tested Is the supply pressure correct Is the water heater connected to the correct gas supply a
39. gas supplier IMPORTANT If the pilot button does not pop up to its original position when released stop and immediately shut off the gas at the line valve or tank Call your service technician or gas supplier 8 Turn the gas control knob counter clockwise to ON 9 Set the temperature dial to the desired setting 10 Replace the outer door TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting Turn counterclockwise A 2 Turn the gas control knob OFF Rotate clockwise 44 ONE aha Lighting Instructions Robertshaw 220R FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing proper ty damage personal injury or loss of life A This appliance has a pilot which must be lighted by an igniter When lighting a pilot follow these instructions exactly 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 touch any electric switch do not use any phone in your building o Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions o If you cannot reach your gas supplier call the fire depart ment C Use only your hand to turn the gas control knob
40. i ou votre fournisseur du gaz 10 Faites tourner le bouton de commande du gaz dans le sens antihoraire A jusqu ON Figure A 11 Une fois la veilleuse allum e remettez en place la porte d acc s externe 12 R glez le thermostat la temp rature d sign e 13 Si la veilleuse ne reste pas allum e apr s plusieurs tentatives faites tourner le bouton de commande du gaz dans le sens horaire jusqu OFF Figure A Si l appareil ne se met pas en marche suivez les instructions intitul es Comment couper l admission des gaz de l appareil et appelez un technicien qualifi ou le fournisseur de gaz Button Bouton de l allumeur x COMMENT COUPER L ADMISSION DES GAZ DE L APPAREIL R glez le thermostat a la temp rature la plus basse ALLUMAGE DE LA VEILLEUSE Appuyez sur le bouton de commande du gaz et faites le tourner dans le sens horaire f jusqu OFF Ne le forcez pas V OPERATION Burner Flames Inspect the burner flames through the viewport and com pare them to the drawings in Figure 14 A properly operat ing burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified service technician if the flame is not satisfactory TIPS MAY HAVE A YELLOW TINT YELLOW INNER C
41. install trap in gas line Clean locate source and correct Clean locate source and correct Replace thermocouple Replace gas control thermostat Provide fresh air ventilation SMELLY WATER Sulfur in the water Replace the anode with a special anode BURNER FLAME YELLOW LAZY Insufficient secondary air Low gas pressure Flue clogged Main burner line clogged Heater installed in a confined area Obstruction in main burner orifice Provide ventilation to water heater Check with gas utility company Clean locate source and correct Clean locate source and correct Proper fresh air ventilation Clean or replace orifice PILOT WILL NOT LIGHT OR REMAIN LIT HIGH OPERATION COSTS PILOT FLAME TOO SMALL 4 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 ke 2 3 4 5 6 7 8 9 Air in gas line No gas Dirt in gas lines Pilot line or orifice clogged Thermocouple connection loose Defective thermocouple Cold drafts Gas control thermostat ECO switch open Door mount temperature cut off TCO switch activated Defective igniter or electrode Flammable vapors incident Flame Guard function activated Low gas pressure Improper installation of the quick connects in the TCO switch loose connection or interrupted gas control leads Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot w
42. is expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods e g vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 49 C 120 F BAR 54 C 130 F BAR GAS CONTROL GAS CONTROL 49 C 120 F MARK ES oN Figure 13b White Rodgers Gas Control Thermostat Settings Lighting Instructions Robertshaw 110R FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing proper ty damage personal injury or loss of life A This appliance has a pilot which must be lighted by igniter When lighting a pilot follow these instructions exactly 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 touch any electric switch do not use any phone in your building o Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions o If you cannot reach your gas supplier call the fire depart ment C Use only your hand to turn the gas control knob Never use tools If the knob will not
43. l produced by the presence of sulfur Do not remove this anode permanently as it will void any war ranties stated or implied An aluminum anode may reduce 18 if not eliminate water odour problems The water supply sys tem 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 cal cium ions The use of a water softener may decrease the life of the water heater tank The anode should be inspected periodically If the anode is more than 50 depleted the anode should be replaced VI MAINTENANCE Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup dur ing operation The water heater should be drained if being shut down for extended periods of time To drain the tank perform the following steps 1 Turn off the gas to the water heater with the manual gas shut off valve 2 Close the cold water inlet valve 3 Open a nearby hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate drain Note The drain hose should be rated for at least 94 C 200 F If the drain hose does not have this rating open the cold water inlet valve and nearby hot faucet until the water is no longer hot 5 Open the water heater drain valve and all
44. ner and pilot burner Check for a soft blue flame 3 Leaking or damaged water and gas piping 4 Presence of flammable or corrosive materials in the installation area 5 Presence of combustible materials near the water heater 6 Presence of debris on the outside of the flame arrester See note below Sigs Note Visually inspect the flame arrester by placing a mirror underneath the water heater A flashlight can be used to illu minate the slots in the flame arrester if necessary Routine cleaning of the flame arrester is recommended if inspection shows accumulation of debris on the flame arrester See section titled External Cleaning of the Flame arrester for cleaning instructions Important Verify proper operation after servicing this water heater If you are unsure of this inspection procedure or the proper operation of the water heater and its special safety features enlist the services of a qualified service technician External Cleaning of the Flame arrester Important It is recommended that the flame arrester be visually inspected periodically for accumulation of dust lint and other debris especially if the heater is installed in areas having a high dust and or lint content Any such accumula tion should be cleaned as outlined below 1 Use a vacuum cleaner to remove all loose debris in the flame arrester 2 If necessary a soft bristle brush can be used to dis lodge any remaining debris 3 Repeat step
45. nstalled in a confined area 3 Provide fresh air ventilation COMBUSTION ODOURS Insufficient secondary air 1 Provide ventilation to water heater Check flue way flue baffle burner Low gas pressure Check with gas utility company Flue clogged Clean locate source and correct SMOKING AND CARBON FOR 7 4 Defective gas control thermostat 4 Replace gas control thermostat 5 5 6 6 1 1 MATION SOOTING Heater installed in a confined area Provide fresh air ventilation Burner flame yellow lazy See Burner Flame Yellow Lazy co SATIO Temperature setting too low Increase the temperature setting NDENSATION 2 Water heater too small 2 Install adequate size heater Orifice too large Replace with correct orifice High gas pressure Check with gas utility company Flue clogged Clean flue and burner locate source amp cor rect 4 Cold drafts Locate source and correct 1 BURNER FLAME TOO HIGH Orifice too large 1 Replace with correct orifice 1 Defective gas control thermostat Replace gas control thermostat FLAME BURNS AT ORIFICE 2 Low gas pressure Check with gas utility company 3 Orifice not properly installed Reinstall the orifice BURNER FLAME FLOATS AND LIFTS OFF PORTS IX REPAIR PARTS ILLUSTRATION NIPPLE HOT OUTLET NIPPLE COLD INLET DRAFTHOOD TEMPERATURE amp PRESSURE RELIEF VALVE REDUCER RING ANODE DIP TUBE FLUE BAFFLE DRAIN VALVE BURNER MANIFOLD ASSEMBLY GAS CONTROL THERMOSTAT OUTER
46. nterclockwise f to PILOT see Figure A Depress the gas control knob all the way in and IMME DIATELY depress the igniter button until you hear a loud click Observe the pilot through the view port Do not release the gas control knob Repeat immediately if pilot does not light on the first try If the pilot does not light by the fourth attempt with the igniter repeat steps 5 9 Continue to hold the button for about one 1 minute after the pilot is lit Release the gas control knob and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 5 9 IMPORTANT If the pilot will not stay lit after several tries turn gas control knob to OFF and call your service technician or gas supplier IMPORTANT If the gas control knob does not pop up to its orig inal position when released stop and immediately shut off the gas at the line valve or tank Call your service technician or gas suppli er 10 Turn gas control knob mh counter clockwise fato ON see Figure A 11 Once the pilot flame is estab lished replace the outer burn er door 12 Set thermostat to desired set ting 13 If the pilot will not stay lit after several tries turn the gas control knob clockwise f to OFF see Figure If the appliance will not operate fol low the instructions To Turn Off Gas To Appliance and call a qualified service techni cian or gas supplier Figure A OFF Position ferm
47. ore connecting to the gas service check that a properly sized gas meter and regulator are available to service the water heater If other appliances are using the same meter and regulator ensure that the capacity of the meter and reg ulator matches that of the combined input of all appliances connected to it DO NOT tamper with the gas control thermostat igniter thermocouple or temperature and pressure relief valve Tampering voids all warranties Only a qualified service technician should service these components MANUAL GAS SHUT OFF Gas Pressure WARNING Exposure to a higher gas supply pressure may cause damage to the control resulting in explosion or fire Consult your local gas supplier and gas authorities DO NOT PUT INTO SERVICE IF OVER PRESSURIZATION HAS OCCURRED GSW Water Heating Company recommends that the gas supply pressure as measured on the inlet side of the water heater control be set at 7 0 in w c 1 7 kPa for natural gas and 11 0 in w c 2 7 kPa for propane gas The above pres sures must be measured during water heater operation The gas control supplied with this water heater is designed for a maximum inlet pressure of 0 5 psi 14 in w c Do not exceed 0 5 psi 14 in w c The Flame Guard safety sys tem is designed to operate at a manifold pressure of 5 0 in w c 1 2 kPa for natural gas and 10 0 in w c 2 4 kPa for propane gas Gas line purging Gas line purging is required
48. ot use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call fire depart ment Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified serv ice technician Force or attempted repair may result ina fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the con trol system and any gas control which has been under water LIGHTING AND OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to lowest setting This appliance has a pilot that is lit by a spark gas igni tion system Do not try to light the pilot by hand Remove the outer burner door Push the gas control knob down slightly and turn clock ise f to OFF see Figure NOTE Knob CANNOT be turned from PILOT to OFF unless it is pushed down slightly Do not force 6 Wait ten 10 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Make sure the water heater is filled with water Turn gas control knob cou
49. ow all the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed under Operating Instructions If the water heater is going to be shut down for an extended period the drain valve should be left open Important Condensation may occur when refilling tank and should not be confused with a tank leak The installation and maintenance of the water heater must comply with all of the instructions described in sections to IX of this manual Water heater failure that is a result of the heating system is not covered by warranty The following maintenance procedures are for the Flame Guard safety system components and should be per formed by a qualified service technician Replacement parts see Figures 20 amp 21 may be ordered through your 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 Periodic Inspection Periodically a visual inspection should be made of the vent ing and air supply system piping systems main burner pilot burner and flame arrester Check the water heater for the following 1 Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed 2 Build up of soot and carbon on the main bur
50. piping dip tube must be in cold inlet INSUFFICIENT HOT WATER Repair faucets 5 Leaking faucets Advise customer 6 Wasted hot water Insulate piping 7 Long runs of exposed piping Insulate piping 8 Hot water piping in outside wall Check with gas utility company 9 Low gas pressure 1 Insufficient secondary air Provide ventilation to water heater Check flue way flue baffle and burner 2 Flue clogged Clean flue locate source and correct 3 Low gas pressure Check with gas utility company 4 Improper calibration Replace gas control thermostat SLOW HOT WATER RECOVERY 5 Gas control thermostat set too low Turn temperature dial to desired setting 6 Water heater too small Install adequate size heater 7 Wrong piping connections Correct piping dip tube must be in cold inlet Advise customer 8 Wasted hot water 1 Excessive water pressure Use a pressure reducing valve and relief valve 2 Heater stacking Lower the thermostat setting 3 Closed water system See Closed System Thermal Expansion 4 1 DRIP FROM RELIEF VALVE Temperature setting too high Decrease the temperature setting THERMOSTAT FAILS TO SHUT Defective gas control thermostat 1 Replace gas control thermostat OFF 2 Improper calibration 2 Replace gas control thermostat Insufficient secondary air Provide ventilation to water heater Check flue way flue baffle burner Flue clogged 2 Clean locate source and correct Heater i
51. questions please Email us at techsupport gsw wh com or Visit our websites www gsw wh com or www johnwoodwaterheaters com or Call our Technical Support line at 1 888 GSW TECH 479 8324 GSW Water Heating is a division of A O Smith Enterprises Ltd 26
52. quette n y a pas d odeur de gaz passez l tape suivante Assurez vous que le chauffe eau est compl tement rempli d eau Faites tourner le bouton de commande du gaz dans le sens anti ho A jusqu PILOT Figure A Enfoncez compl tement le bouton de commande du gaz et appuyez IMM DIATEMENT sur le bouton de l allumeur jusqu ce que vous entendiez un bon d clic Observez la veilleuse par le regard de la chambre de combustion Ne rel chez pas le bouton de commande du gaz R p tez imm diatement la man uvre si la veilleuse ne s allume pas d s la pre mi re tentative Si la veilleuse refuse toujours de s allumer la quatri me tentative avec l allumeur r p tez les tapes 5 9 inclusivement Continuez d ap puyer sur le bouton de commande du gaz pendant environ une 1 minute apr s l allumage de la veilleuse Rel chez le bouton de commande du gaz et il retournera sa position initiale La veilleuse devrait rester allum e Si la veilleuse s teint r p tez les tapes 5 9 inclusivement IMPORTANT Si la veilleuse ne reste pas allum e apr s plusieurs tentatives tournez le bouton de commande du gaz jusqu OFF et appelez un technicien qualifi ou votre fournisseur du gaz IMPORTANT Si le bouton de commande du gaz ne retourne pas sa position initiale lorsque vous le rel chez arr tez et fermez imm diatement le gaz au r gulateur principal ou au r servoir Appelez un techni cien qualif
53. r reaches a temperature of 49 C 120 F and the tank warms up usually about 1 hour the condensation will stop Note At initial start up in certain extremely cold conditions and if the water heater is not allowed enough time to reach the room temperature the pilot burner might be extin guished in the first 20 minutes from start up due to heavy condensation In this situation if the unit is relit it will follow its normal heating cycle without further incidents After installation always allow the water heater to reach the room temperature before the initial start up is initiated Supervise the flame inside the water heater at least 20 minutes at ini tial start up to ensure that heavy condensation is not turning off the water heater 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 e Normal expansion and contraction of metal parts during the periods of heat up and cool down e Condensation causing sizzling and popping within the burner area e Sediment build up in the tank bottom creating varying amounts of noise Build up may cause premature tank failure Drain and flush the tank as directed under Draining and Flushing Safety Shut off This water heater is designed to automatically shut off in the event of the following e The pilot flame is extinguished for any reason e The water temperature exceeds 93
54. s shown on the rating plate Natural Gas Propane Is the clearance between the water heater and combustible construction as per specifica tions Is the water piping correctly connected Are you certain that there are no leaks Is the water heater filled with water Is the cold water supply valve open Is the vent pipe installed properly and are the vertical and horizontal runs properly support ed Is the vent hood air intake opening unobstruct ed Is the T amp P valve installed Are the drain pipe and T amp P valve unobstructed Is a drain pan installed with a proper overflow pipe directed to a drain Have you taken steps to prevent water damage in case of leaks Does the area around the water heater have adequate ventilation Air moving device does not create negative pressure Flammable vapors are not placed in the prox imity of the water heater Manifold gasket properly sealed Viewport not damaged or cracked Flame arrester free of debris and undamaged Two piece grommet properly installed No leaks at pilot and manifold connection Manifold door screws securely tightened Extra care for proper ventilation for attic or unconditioned space installation max air tem perature 42 C 108 F Check Here d 0 O OOO HAE Ta O0 O0 O0 0 0 0 0 000 O IV OPERATING INSTRUCTIONS Water Temperature Regulation HOT WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a
55. space heating applications The Flame Guard safety system is designed to reduce the risk of flammable vapor related fires by trapping the burning vapors within the water heater combustion chamber using the special flame arrester The burning vapors literally burn themselves out without escaping back into the room User Responsibilities These instructions have been written for the proper installa tion safe operation and maintenance of this water heater It is your responsibility to ensure that your water heater is properly installed and cared for FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL MAY RESULT IN SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE THOROUGHLY READ ALL INSTRUCTIONS BEFORE YOU ATTEMPT TO INSTALL OPERATE OR MAINTAIN THIS HEATER Installation and service requires trade knowledge in the area of plumbing electricity venting air supply and gas supply If you lack these skills or do not understand these instructions enlist the help of a qualified professional The manufacturer of this water heater cannot be held liable for those damages caused by improper installation sizing or failure to comply with these instructions Protect your warranty Regularly maintain your water heater and venting system as detailed in the Maintenance section of this manual WARNING Service to the Flame Guard safety system should only be performed by a qualified service technician Il SAFETY This water he
56. tal or wood panel extending a minimum of 75mm 3 in from all sides In alcoves or closets cover the carpet completely Ensure this panel is capable of supporting the weight of this heater when filled with water FAILURE TO PROPERLY INSTALL THIS HEATER MAY RESULT IN A FIRE HAZARD The water heater shall be located in an area not subject to freezing temperatures Water heaters located in uncondi tioned spaces e g attics basements etc may require insulation of the water and drain piping to protect against freezing Proper ventilation needs to be provided for water heaters installed in unconditioned spaces e g attics base ments etc in order to avoid an event where air tempera ture exceeds 42 C 108 F The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the data plate Ensure that the water heater is level This heater may be installed in a closet or alcove and is certified for operation on a combustible floor Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans BACK 25mm 1 in TOP TO CEILING 200mm 8 in sipeEs SIDES ele 25mm BACK 25mm Tain in AIR INTAKE FRONT 600mm 24 in MIN FOR SERVICE Figure 3 Minimum Clearance Locations ventilation systems clothes dryers fireplaces e
57. tc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling as shown in Figure 7 If the water heater is located in an area that is subject to an excessive amount of lint dirt or oil it may be necessary to clean the flame arrester periodically see Maintenance section Important It is always recommended that a suitable drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation a leaking tank or piping connections Refer to Figure 1 Under no circumstances is the manufacturer to be held responsi ble for any water damage in connection with this water heater Gas Supply Install the gas piping as shown in Figure 4 Use only new pipe and fittings with clean cut threads Sealing compounds used on the pipe threads shall be approved for use with nat ural and propane gas Use gas piping of adequate sizing to ensure gas input Gas piping material must be approved for use with natural gas and propane fuels All piping must comply with all local codes or in the absence of such codes with the latest edi tion of Natural Gas and Propane Installation Code CAN CSA B149 1 in Canada National Fuel Gas Code ANSI 2223 1 NFPA 54 in the U S A The final connection to the water heater is made using 1 2 NPT Bef
58. temperature that will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be perma nently injured by hot water than others These include the elderly children the infirm or physically mentally handi capped If anyone using hot water in your home fits into one of these groups or if there is a provincial state law or local code requiring a specific hot water temperature at the tap then you must take special precautions Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unat tended in a bathtub or shower DANGER PON HOT WA t Water temperature over 52 C 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 Temperature limiting valves are available It is recommended that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that the water temperature be set for the lowest tem perature that satisfies your hot water needs This will also provide the most energy efficient operation of the water heater WARNING Risk of scalding There is a hot water scald potential if the thermostat is set too high Adjusting the thermostat past the 49 C 120 F bar on the temper
59. tions or 25 33777 2D S The water heater or any of its component parts are damaged or fails from operation with an empty or partially empty tank such as but not limited to elements burned out in a dry tank or The water heater or any part has been under water or The water heater is exposed to highly corrosive atmospheric conditions No warranty extends for example and without limitation of the foregoing to Units exposed to salts chemicals exhausts pollutants or contaminants or The water heater is not continuously supplied with potable water or The water heater replacement is requested for reasons of noise taste odor discoloration and or rust or The water heater is operated at temperatures exceeding the maximum setting of the thermostat and or high limit control provided by the Manufacturer or at water pressures exceeding the pressure reading stated on the Unit or The water heater is operated without an operating anode or The water heater is supplied or operated with deionized water or The water heater is removed from its original installation location or The water heater is installed outdoors this water heater is intended only for indoor installation or The water heater is converted or is attempted to be converted from one voltage or wattage to another if an elec tric water heater or from one type gas to another if a gas water heater or The water heater has not been fired at the factory r
60. to the water heater for the space heating applications shall be suit able for use with potable water The system should be installed with new non ferrous piping Do not use pumps valves fittings solder gluing and pipe sealant that are not completely compatible with potable water piping 2 A water heater which will be used to supply potable water must not be connected to any heating system or components previously used with a non potable water heating appliance Do not use piping that has been treated with chromates broiler seal or other chemicals and do not add chemicals to the water heating piping Do not introduce toxic chemicals such as those used for boiler treatment into the potable water used for space heating 3 Do not use this heater as a replacement for an existing boiler installation CHECK VALVE CIRC PUMP o N J QO COLD TO WATER HEATER HOT WATER TO HOUSE DA TT WATER HEATER HANDLER MASSACHUSETTS CODE DOES NOT ALLOW THIS TYPE OF INSTALLATION RADIATOR OR RADIANT FLOOR PIPING ARE VIABLE ALTERNATIVES TO AIR HANDLER Figure 19 Example Of Combo Heating Piping Schematic 4 If the space heating water system requires water with temperatures in excess of 60 C 140 F a mixing valve or other means to temper the water and reduce scald hazard potential must be installed in the potable hot water supply 5 If the heater
61. turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS GAS CONTROL KNOB IN PILOT POSITION TEMPERATURE DIAL ROBERTSHAW GAS CONTROL 4 Turn gas control knob clockwise f to the OFF position 5 To clear any gas that may have accu mulated wait ten 10 minutes If you then smell gas STOP Follow instruction B described above 6 Turn the gas control knob counter clockwise 1 to PILOT r 7 Depress the pilot button all the way in and IMMEDIATELY depress the igniter button until you hear loud click Observe the pilot through the view port Do not release the pilot button Repeat immediately if pilot does not light on the first try If the pilot does not light by the fourth attempt with the igniter repeat steps 3 6 Continue to hold the button for about 1 minute after the pilot is lit Release the pilot button and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 3 7 IMPORTANT If the pilot will not stay lit after several tries tum gas control knob to OFF and call your service tech nician or

GSW 72090 User's Manual

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