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18. 5 Dimension A includes wall thickness 6 Hole diameter in wall is 178mm 7 7 Venting must slope up away from the heater a minimum of 6 4mm per 305mm 0 25 per foot of length to prevent condensation from collecting and to provide sufficient draft 8 Distance above horizontal at full extension is 50mm 27 9 Use support stays to hold the venting to avoid sags or valleys Figure 28 24 www gsw wh com INSTALLATION CHECKLIST Note Use and complete this checklist before lighting the heater Correct any conditions that do not meet these instructions Water Heater Location a 0 0 a E 0 Centrally located with the water piping system Located as close to gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Installation area free of corrosive elements flammable material and flammable vapour emitting products Sufficient room to service the water heater Gas Supply and Piping 0 0 Gas supply is the same type as listed on the water heater data plate Gas line equipped vvith shut off valve union and sediment trap Adequate pipe size and of approved material Approved
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23. 27 Water Temperature Adjustment Operating Modes And Settings FOR YOUR INFORMATION 28 External Damage 28 Start Up Conditions 28 Condensate Smoke Odour Thermal Expansion 28 Strange Sounds 29 Operational Conditions 29 Smelly Water Air In Hot Water Faucets High Water Temperature Shut Off System MAINTENANCE 30 Housekeeping 30 Flood Damage 30 Venting System Inspection 30 Pilot And Main Burner 30 Burner Flames 31 Servicing The Water Heater 31 Removing And Replacing The Gas Control Valve Thermostat vive eke cr ad EDAN 31 Removing The Gas Control Valve Thermostat Replacing The Gas Control Valve Thermostat Removing The Manifold Burner Assembly 31 Removing The Burner From The Manifold Burner ASSembI Essen ten dat id ade 32 Natural Gas Low Nox amp Propane LP Gas Burner Replacing The Pilot Thermopile Assembly 32 Replacing The Manifold Burner Assembly 33 Piezoelectric Igniter System 34 Testing The Igniter System 34 Temperature Pressure Relief Valve Test 34 Draining Refilling And Flushing 34 To Drain
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27. For certain water conditions setting the gas control valve thermostat at 60 C 140 F can reduce the smell generated in the water heater Note Under these conditions install a mixing valve to limit the temperature of the water delivered to the system see Water Piping section Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or service agency for further information concerning an Anode Replacement Kit and this chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided Air In Hot Water Faucets WARNING Flammable hydrogen gases may be present e Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for seve
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30. 28 www gsw wh com STRANGE SOUNDS Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensate in this section Sediment collecting over time in the bottom of the tank can result in rumbling or percolating sounds Follow the directions given in Draining Refilling And Flushing OPERATIONAL CONDITIONS Smelly Water In each water heater there is installed at least one anode rod see Figure 1 item 22 for corrosion protection of the tank Some models will have an additional anode which is connected to the hot water outlet nipple see Figure 1 item 23 Certain water conditions will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smell is a result of four factors which must all be present for the odour to develop 1 A concentration of sulfate in the supply water 2 Little or no dissolved oxygen in the water 3 A sulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans 4 An excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode
31. NPT water connections CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will increase when heated As the volume of water increases there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief ofthermal expansion This condition is not covered under the limited warranty www gsw wh com 13 A properly sized and charged thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Note To protect against untimely corrosion of hot and cold water fittings it is recommended that di electric unions or couplings be installed on this water he
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39. Degree Most Severe Burns Time for 1st Degree Burns Less Severe Burns Water Temperature F 44 110 47 116 47 116 normal shower temp pain threshold 35 minutes 45 minutes 1 minute 5 minutes 5 seconds 25 seconds 55 131 60 140 65 149 68 154 U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 2 seconds 5 seconds 50 122 1 second 2 seconds instantaneous 1 seconds Table 1 In addition to using lowest possible temperature setting that satisfies demand of application a mixing valve should be installed at the water heater see Figure 8 or at hot water taps to further reduce system water temperature Mixing valves are available at plumbing supply stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Operating The Temperature Control System section in this manual 12 www gsw wh com INSTALLING THE NEW WATER HEATER WATER PIPING INSTALLATION Note Water piping and vent piping occupy the space above the water heater Plan the water piping to ensure it does not cause interference with the vent piping see Venting e The system should be installed only with piping that is suitable for potable drinkable vvater such as copper CPVC or polybutylene This vvater h
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42. SHEET METAL SCREVV Figure 24 OFFSET VENT ARRANGEMENT VVhere a straight vent arrangement is impossible a horizontal 90 maximum bend can be made Use the vvater heater casing outer diameter as a template to form the corrugated tube Z SMOOTH EASY CURVE SS SS LC SS S S KI S N NN NNNNNNNNNN PCC CCC CR CRC N Figure 26 Note To ensure good exhaust gas flow bend vent piping using a smooth easy curve as shown in Figure 23 thru Figure 25 Do not use reverse or compound curves as shown in Figure 26 www gsw wh com 23 Low Vent installation High Vent installation 12 MIN BELOW ANTICIPATED SOFFIT SNOW LEVEL OR 305mm 12 ABOVE GRADE 20m EOJ MAK 228mm 9 MIN RECOMMENDED 1 62 63 637 1 85m 73 00 MINIMUM 1 54 60 75 1 75 69 50 362mm 14 25 MIN NOTE Dimension C is the height above to floor to the center of the termination hole through the exterior wall Minimum Vent installation Figure 29 NOTES applies to Figure 27 thru Figure 29 1 In any installation the total of dimension A plus dimension B must not exceed 2 26m 89 SNOW LEVEL 2 This heater can be installed with Omm 0 clearance to a wall 3 Minimum vent pipe clearance to combustibles is 25mm 1 see Figure 20 4 Minimum distance from center of heater to wall is 362mm 14 25
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50. 6 ft 1 83 m toa mechanical air supply inlet Minimum 12 in 30 cm to a non mechanical air supply inlet into building or combustion air inlet to another appliance AREA WHERE TERMINAL IS NOT PERMITTED 1 Permitted only if veranda porch deck or balcony is fully opened on a minimum of two sides beneath the floor 2 Avent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Figure 14 20 www gsw wh com Figure 15 Be sure venting is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation DV TERMINATION SAFETY COVER When the heater is in operation the vent termination hood will be hot see Figure 15 A Safety cover see Figure 16 is available to prevent accidental contact with the vent terminal Contact your Customer Service Department for ordering information Figure 16 Alternatively a wire mesh or louvered fencing guard can be built around the termination as shown in Figure 17 NOT TO BE USED AS ASTORAGE AREA __ b 20 LE OE LZ Figure 17 5 After the location for the vent terminal has been selected as outlined in Figure 6 amp Figure 14 use the following illustrations for installation LOCATING CLEARANCE HOLE FOR VENT Cut a clearance hole approximately 178mm 77 in diameter th
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53. Expansion sections of this manual The T amp P valve is not intended for the constant relief of thermal expansion DANGER e Burn hazard e Hot water discharge e Keep clear of temperature pressure relief valve discharge DRAINING REFILLING AND FLUSHING Periodic draining and cleaning of sediment from the tank maybe necessary It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures or for an extended period of time See Typical Installation section Figure 1 in this manual for location of the water heater components described below To Drain The Water Heater Storage Tank 1 Turn the gas control temperature knob to the OFF position see Figure 30 and Figure 32 2 Turn OFF the gas supply at the manual gas shut off valve 3 Close the cold water inlet valve to the water heater 4 Open a nearby hot water faucet and leave open to allow for draining 5 Connect a hose to the drain valve and terminate to an adequate drain Note If the water heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 Open the water heater drain valve 7 Close the water heater drain valve when all water in the storage tank has drained 34 www gs
54. HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED 1404 327539 000 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 3 GENERAL SAFETY 4 INTRODUCTION 6 Qualified Installer Or Service Agency 6 Preparing For The Installation 6 TYPICAL INSTALLATION 7 Get To Know Your Water Heater Gas Models List Referencing Figures 1 5 7 Replacement Parts And Deliming Products 8 Combo Heating Inlet And Outlet Side Taps 8 High Limit Controls Energy Cut Off 8 Thermostat Water Temperature LOCATING THE NEW WATER HEATER 9 Facts To Consider About The Location 9 External Internal Damage 9 Air Requirements 10 Confined Space Installations 10 Clearances To Combustibles Floors With Carpeting Clearance For Servicing Chemical Vapour Corrosion 10 Storage Of Flammable Liquids 11 Insulation Blankets 11 Water Piping 12 Water Pressure Mixing Valves INSTALLING THE NEW WATER HEATER 13 Water
55. Leaking water heater see Figure 43 Many suspected Leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with gas codes your water heater and safety practices contact your gas supplier or qualified installer to check the water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater D Water at the vent assembly is water vapour which has condensed out of the combustion products This is caused by a problem in the vent Contact the gas utility E Condensation may be seen on pipes in humid weather or pipe connections may be leaking F The anode rod fitting may be leaking anode is located under the plastic plug and insulation G Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area H The temperature pressure relief valve may be leaking at the tank fitting Water from a drain valve may be due to the valve being slightly opened The drain valve may be leaking at the tank fitting K Combustion pr
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57. Piping Installation 13 Closed Water Systems 13 Thermal Expansion 13 Temperature Pressure Relief Valve 14 T amp P Valve Discharge Pipe Requirements Temperature Pressure Relief Valve And Pipe Insulation Filling The Water Heater 15 Space Heating And Potable Water Systems 16 Combo Heating 17 System Requirements Installation Gas Pipete Saad it a ido 18 Sediment Trap 19 High Altitude Installations 19 Venting cotas benne atteste 20 Vent Terminal Clearances 20 DV Termination Safety Cover 21 Vent Connections 21 Locating Clearance Hole For Vent 21 Standard Vent Arrangement 21 Vent Assembly 22 Securing Vent Termination Assembly To The Exterior Wall 22 Vent Restricter Plate 22 Uncompressing The Corrugated Tubing 22 Vent Connection To The Water Heater 23 Offset Vent Arrangement 23 Installation Checklist 25 LIGHTING INSTRUCTIONS 26 TEMPERATURE REGULATION 27 Temperature Regulation 27 Temperature Adjustment Operating The Temperature Control System
58. TOP HOLE OF MANIFOLD COMPONENT BLOCK LARGEST HOLE THERMOPILE WIRES PASS THROUGH BOTTOM HOLE IGNITER WIRE PASSES THROUGH CENTER OF MANIFOLD COMPONENT BLOCK SMALLEST HOLE OF MANIFOLD COMPONENT BLOCK Figure 37 10 Carefully bend the new pilot tube to match the bend of the manifold tube Note When bending DO NOT crimp or crease the pilot tube 11 Before you proceed to the next step install the new brass ferrule nut in the gas control valve thermostat s pilot tube opening HAND TIGHT ONLY 12 Install the manifold burner assembly Refer to the Replacing The Manifold Burner Assembly section for instructions REPLACING THE MANIFOLD BURNER ASSEMBLY 1 Check the door gasket for damage or imbedded debris prior to installation see Figure 35 2 Inspect the viewport for damage and replace as required see Figure 35 3 Insert the new manifold burner assembly into the burner compartment making sure that the tab of the manifold tube engages the slot of the bracket inside the combustion chamber see Figure 35 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber see Figure 35 5 Tighten the two screws that secure the manifold burner assembly to the combustion chamber Use a 1 4 nut driver There should be no space between the gasket part of the manifold door and combustion chamber Important Do not operate the water heater if the
59. Temperature Knob NSTRUCTIONS PAT AVERTISSEMENT Tout manquement aux pr sentes directives peut causer un incendie ou une explosion I munun des dommages mat riels des blessures ou la mo AVANT L ALLUMAGE LE R SEAU D ALIMENTATION EN EAU DOIT ETRE ENTIEREMENT REMPLI D EAU ET L AIR ENTIEREMENT PURGE A Lallumage de la veilleuse de cet appareil au gaz 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 B AVANT LALLUMAGE humez Fair tout autour de afin d y d celer une ventuelle odeur de gaz Humez aussi l air pr s du sol car certains gaz sont plus lourds que Fair et s y accumulent SI VOUS D TECTEZ UNE ODEUR DE GAZ Ne mettez aucun appareil en marche Ne touchez aucun interrupteur ne vous servez pas des t l phones se trouvant dans le b timent Appelez imm diatement votre fournisseur de service de gaz partir du t l phone d un voisin et suivez ses directives Si vous ne pouvez communiquer avec votre fournisseur de service de gaz appelez le service des incendies Le bouton de r glage du gaz ne doit tre enfonc ou tourn qu la main n utilisez jamais d outil Si le bouton reste coinc ne tentez pas une r paration appelez plut t un technicien d entretien qualifi Si vous forcez ou tentez de r parer le bouton il a risque d explosion ou d incendie N utilisez
60. The VVater Heater Storage Tank To Refill The VVater Heater Storage Tank To Flush The Water Heater Storage Tank Drain Valve VVasher Replacement 35 Anode Rod Maintenance 35 To Remove The Anode Rod To Install The Anode Rod LEAKAGE CHECKPOINTS 37 S TVIC 1 0070000000 773 37 REFERENCE PARTS LISTING 38 TROUBLESHOOTING GUIDELINES 40 NOTES ad 44 2 www gsw wh com SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury WARNING indicates a potentially A WWA Ive hazardous situation which if not avoided could result in death or injury CAUTION indicates
61. a potentially A 67 0 0 hazardous situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert CAUTI ON symbol indicates a potentially hazardous situation which if not avoided could result in property damage DANGER All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury IMPORTANT DEFINITIONS Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified installer must also be familiar with the design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this Installation and Operating manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding of this Installation and Operating manual and be able to perform repairs strictly in accordance wit
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63. addition to being highly flammable in many cases will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater The results can be hazardous and also cause product failure INSULATION BLANKETS Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products The purpose of an insulation blanket is to reduce standby heat loss encountered with storage tank heaters Your water heater meets or exceeds the current standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary Do not install any insulation blankets on this water heater www gsw wh com 11 WATER PIPING Water Pressure The water supply pressure should not exceed 80 psi Ifthis occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures See also Closed Water Systems and Thermal Expansion sections Mixing Valves HOT WATER CAN SCALD Water heaters are intended to heat water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Short repeated heating cycles caused by small hot water uses can cause a temperature increase of
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65. and or the circulating pump in a baseboard hydronic loop will require a dedicated 120V circuit This must be provided and identified for this purpose 6 All piping between the water heater and the air handler or hydronic baseboard loop must be adequately insulated to reduce heat loss 7 Ifthe local jurisdiction requires a back flow preventer in the cold water line an expansion tank of adequate size must be installed 8 Combo Heating Systems require higher water temperatures than other applications When the system is used to supply water for Combo Heating applications a means such as mixing valve must be installed to temper the water in order to reduce scald hazard potential see Figure 11 amp Figure 12 Installation The heating mode may be one of the following options A A fan coil air handler Figure 11 B Ahydronic baseboard finned tube loop In floor heating Figure 12 The following is a list of requirements for the installation of option A or B 1 Install shut off valves and unions so that the water heater can be isolated from the heating module should servicing of the water heater become necessary 2 Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating module without affecting the water heater 3 If the air handler does not have a venting means at the highest point of the piping arrangement install an air bleed at the highest point of the plumbi
66. and then entire manual carefully If you don t follow safety rules the water heater will not operate properly lt could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for installation operation and maintenance of the gas fired water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and instructions are essential to proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The installation must conform with these instructions and local code authority having jurisdiction In absence of local codes installation must comply with current editions of the Natural Gas and Propane Installation Code B149 1 and Canadian Electrical Code C22 1 Part I All documents are available from Canadian Standards Association 5060 Spectrum Way Mississauga Ontario Canada L4W 5N6 If after reading this manual you have any questions or do not understand any portion of the instructions call the local gas utility or the manufacturer whose name appears on the rating plate Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires see Figure 6 Examine the loca
67. door gasket does not create a seal between the manifold door and the combustion chamber 6 Reconnect the manifold tube 3 4 wrench and pilot tube 7 16 wrench to the gas control valve thermostat see Figure 32 Do not cross thread or apply any thread sealant to the fittings Important If you were supplied with a new ferrule nut in a parts kit follow these steps to connect the pilot tube 1 Install the ferrule nut into the gas valve at the pilot tube location hand tight only 2 Insert the pilot tube into the ferrule nut until the tube bottoms out then tighten the nut with a 7 16 wrench until the crimp connection seals to the pilot tube 3 Continue to tighten until the nut is tight in the gas valve Note Propane LP Gas systems use reverse left hand threads on the manifold tube 7 Connect thermopile connector to the gas control valve thermostat see Figure 32 Reconnect the igniter wire see Figure 32 Turn ON the gas supply to the water heater at the manual gas shut off valve see Figure 1 10 Follow the lighting instructions on the label or see Lighting Instructions to restart the water heater With the main burner lit check for leaks at the manifold and pilot connections by brushing on an approved noncorrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble sol
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69. if the thermostat is set too high Note Temperatures shown on the gas control valve thermostat are approximates The actual temperature of the heated water may vary Important Adjusting the thermostat past the 49 C 120 F mark on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Water Temperature C F 44 110 47 116 47 116 Time for 1st Degree Burns Less Severe Burns normal shower temp pain threshold 35 minutes 45 minutes 1 minute 5 minutes 55 131 60 140 65 149 68 154 U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 5 seconds 25 seconds 2 seconds 5 seconds 50 122 1 second 2 seconds instantaneous 1 seconds Table 2 Should overheating occur or the gas supply fail to shut off turn OFF the manual gas shut off valve to the appliance see Figure 1 item 18 OPERATING THE TEMPERATURE CONTROL SYSTEM Water Temperature Adjustment The water temperature setting can be adjusted from 33 C 91 F to 68 C 155 F Turn the Gas Control Valve Temperature Knob to the desired setting temperature Note The temperatures indicated are approximates The actual temperature of the heated water may vary Operating Modes And Settings Standard Mode The controller adjusts the water
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71. into the T amp P valve discharge opening per the instructions in this manual 1 Locate the hot water outlet and cold water inlet pipes to the water heater 2 Locate the slit running the length of a section of pipe insulation 3 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equivalent Repeat steps 2 and 3 for the hot water outlet pipe 5 Add additional sections of pipe insulation as needed gt FILLING THE WATER HEATER CAUTION e Avoid water heater damage Fill tank with water before operating e Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water 1 Close the water heater drain valve by turning handle to the right clockwise The drain valve is on the lower front of water heater see Figure 9 2 Important If the heater is equipped with plumbing side taps and they are not connected to piping ensure the side taps have been closed with pipe plugs 3 Open all hot water faucets served by the water heater t
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74. near the heater or the vent termination hood Air which is brought in contact with the heater or the vent termination hood should not contain any of the chemicals The Limited Warranty is voided when failure of water heater is due to a corrosive atmosphere See Limited Warranty for complete terms and conditions WARNING Fire or Explosion Hazard e Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this water heater the vent termination hood or any other appliance e Avoid all ignition sources if you smell gas e Do not expose water heater control to excessive gas pressure e Use only gas shown on rating plate e Maintain required clearances to combustibles e Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater 10 www gsw wh com WARNING FLAMMABLES p gt A Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death A WARNING For continued protection against risk of fire e Do not install water heater on carpeted floor e Do not operate water heater if flood damaged A WA
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78. over the water heater s center for bending see Figure 22 2 Pull the outer corrugated tube toward the water heater and leave it 50mm 2 shorter than the inner corrugated tube 3 Make sure there are two springs evenly spaced at the bend in the tube 4 Use metal hangers to keep venting level or with a slope upward from the heater to terminal 22 www gsw wh com Figure 22 VENT CONNECTION TO THE WATER HEATER Bend both the corrugated pipes toward the flue connection on the water heater Pull and connect the inner corrugated pipe to the water heater s flue tube reducer with hi temp red silicone included and gear clamp Make sure this connection is tight and leak proof see Figure 23 The sealant between the inner corrugated pipe and water heater s flue tube reducer must be hi temp red silicone or other material suitable for 315 C 600 F continuous service Note If you are using the vent restricter plate the inner vent pipe is to go over the side legs and down the stops RESTRICTER PLATE STOP CUTAWAY TO SHOW DETAILS Figure 23 Apply hi temp red silicone included around the collar on air manifold box Pull the outer corrugated pipe all the way on to collar and secure with the gear clamp Pull the free end of the corrugated pipe past the gear clamp and secure with one sheet metal screw see Figure 24 SMOOTH EASY APPLY SILICONE TO AIRBOX BEFORE ATTACHING PIPING SECURE VVITHA
79. pas cet appareil m me s il n a t que partiellement submerg par de l eau Communiquez imm diatement avec un installateur qualifi ou un centre de service afin de faire remplacer tout chauffe eau ayant t submerg lors d une inondation Ne tentez jamais de r parer l appareil Il doit tre remplac Bouton r glage du gaz amp temp FIGURE B FIGURE C Pilot Flame FIGURE D Status y Roper Repere Flamme de la veilleuse Main Burner Br leur lumineux Igniter Button Bouton plot OF allumeur OFF POSITION 9 STOP It is imperative that you read all safety warnings before lighting the pilot Turn the gas control temperature knob counterclockwisef Mo the OFF position Wait ten 10 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Turn the gas control temperature knob clockwise Yto PILOT See Figure B Press the gas control temperature knob all the way in and hold itin The knob should travel in about 6mm 1 4 inch if it is set to PILOT correctly While holding the gas control temperature knob in click the igniter button continuously about once a second for up to 90 seconds or until Status Light begins to 120 120 Mark d Mark 1 p r l r OF por OF POSITION ON POSITION PILO 77 gt POSITION OFF POSITION PILOT POSI
80. pilot and verify 4 flashes If 4 flashes are observed turn Gas Control Valve Thermostat knob to OFF Turn Main Gas Supply OFF Replace the Gas Control Valve Thermostat See Removing and Replacing the Gas Control Valve Thermostat Turn Gas Control Valve Thermostat knob to OFF Replace the temperature sensor thermistor Turn Gas Control Valve Thermostat knob to OFF Turn Main Gas Supply OFF Replace the Gas Control Valve Thermostat See Removing and Replacing the Gas Control Valve Thermostat Make sure that the gas control valve thermostat knob is set to OFF Wait one minute Remove the outer door Look through the sight glass for a pilot flame If a pilot flame is observed with the gas control valve thermostat knob set to the OFF position the pilot valve is stuck open Turn the main gas supply OFF Replace the gas control valve thermostat For instructions see Removing and Replacing the Gas Control Valve Thermostat If the pilot flame is not observed when the gas control valve thermostat knob is set to the OFF position wait 10 minutes for the thermopile to cool then attempt to relight the pilot by following the lighting instructions on the water heater s label If this condition returns replace the gas control valve thermostat See Removing And Replacing The Gas Control Valve Thermostat for instructions 43 NOTES 44 www gsw wh com NOT
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83. termination hood or other appliance e Can cause serious injury or death INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Locating The New Water Heater section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater which can cause a fire FLOOD DAMAGE Flood damage to a water heater may not be readily visible orimmediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced VENTING SYSTEM INSPECTION At least once a year a visual inspection should be made of the venting system You should look for 1 Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed 2 Damage or deterioration which could cause improper venting or leakage of combustion products Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiation Chemical vapour corrosion of the flue and vent system
84. thermostat ECO switch open Defective igniter or electrode Low gas pressure 10 Incorrect gas Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall OOMNDDGBON Pilot line or orifice clogged Low gas pressure Defective pilot Incorrect gas www gsw wh com N 00 4 Light pilot Turn temp dial to desired temperature Check with gas utility company Notify utility install trap in gas line Clean locate source and correct Clean locate source and correct Replace thermopile Replace gas control thermostat Replace the anode with a special anode Raising the water heater temperature setting to 60 C 140 F may help to eliminate the odour will require the use of a mixing valve Check with gas utility company Clean locate source and correct Clean locate source and correct Clean or replace orifice Check that the vent termination hood and venting pipe is not blocked Bleed the air from the gas line Check with gas utility company Notify utility install sediment trap dirt leg in gas line Clean locate source and correct Replace thermopile Check that the vent termination hood and venting pipe is not blocked Replace gas control thermostat Replace igniter or p
85. to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways e Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected e Sensors mounted in the metal drain pan that turn off the water supply to the entire building when water is detected in the metal drain pan e Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply EXTERNAL INTERNAL DAMAGE Do not operate the water heater until it has been fully checked out by a qualified technician if the water heater e Has been exposed to fire or damage e Displays evidence of sooting e Produces steam or unusually hot water If the water heater has been flooded it must be replaced www gsw wh com 9 AIR REQUIREMENTS For safe operation an adequate supply of fresh uncontaminated air must be provided for combustion This gas fired water heater is a direct vent model It connects directly to the outside of the building through the vent termination hood The
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87. utility company FORMATION SOOTING 4 Defective gas control thermostat 3 Clean locate source and correct 5 Burner flame yellow lazy 4 Replace gas control thermostat 5 See Burner Flame Yellow Lazy 1 Temperature setting too low 1 Increase the temperature setting CONDENSATION 2 Water heater too small 2 Install adequate size heater 1 Orifice too large 1 Replace with correct orifice BURNER FLAME 9 57 gt 2 High gas pressure 2 Check with gas utility company FLOATS AND LIFTS OFF 3 Flue clogged 3 Clean flue and burner locate source PORTS and correct BURNER FLAME TOO 1 Orifice too large 1 Replace with correct orifice HIGH 2 High gas pressure 2 Check with gas utility company FLAME BURNS AT 1 Defective gas control thermostat 1 Replace gas control thermostat ORIFICE 2 Low gas pressure 2 Check with gas utility company 3 Orifice not properly installed 3 Reinstall the orifice www gsw wh com 41 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES LED NOT LIT Pilot light is not lit or Turn Gas Control Valve Thermostat knob to thermopile has not yet reached OFF Wait 10 minutes then attempt to relight normal operating temperature Pilot by following the lighting instructions on the water heater s label Until the thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit It may take up to 90 se
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89. 1 should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement see Figure 42 PITTED ANODE ROD 7 Figure 42 Note Artificially softened water requires the anode rod to be inspected annually The following are typical but not all signs of a depleted anode rod e The majority of the rods diameter is less than 10mm 3 8 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of either or both it should be replaced Note Whether re installing or replacing the anode rod check for any leaks and immediately correct if found To Remove The Anode Rod 1 Tum the gas control temperature knob to the OFF position see Figure 30 and Figure 32 2 Tum OFF the gas at the manual gas shut off valve see Figure 1 3 Shut off the incoming water supply to the water heater and open a nearby hot vvater faucet to depressurize the vvater tank 4 Connect a hose to the drain valve and terminate it to adequate drain or to the exterior of the building Open the drain valve and drain approximately 191 5 gallons of water from tank Refer to Draining Refilling And Flushing for proper procedures Close drain valve and remove hose 5 Remove and retain the anode cap on top of the heater and remove and retain just enough insulation so you can access to the anode head see Figu
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97. EMPERATURE PRESSURE RELIEF VALVE TEST It is recommended that the temperature pressure relief valve be checked to ensure it is in operating condition at least once a year When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the T amp P valve discharge line and 2 that water discharge will not cause any property damage as water may be extremely hot Use care when operating valve as the valve may be hot To check the relief valve lift lever at the end of valve several times see Figure 39 The valve should seat properly and operate freely If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater and drain the water heater see Draining Refilling And Flushing section Replace the T amp P valve with a properly rated sized new one see Temperature Pressure Relief Valve for instructions on replacement TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE Figure 39 If the Temperature Pressure Relief Valve on the water heater weeps or discharges periodically it may be due to thermal expansion Note Excessive water pressure is the most common cause of temperature pressure relief valve leakage Excessive water system pressure is most often caused by thermal expansion in a closed system See Closed Water Systems and Thermal
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99. G This section serves as a guide for the installation and use of Combo heating systems utilizing a domestic water heater that has been specifically approved for such use Itis 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 All components used for the distribution of water in the heating loop must be suitable for potable water These include all piping fittings solder and fluxes pumps for circulation of water valves etc 2 The water heater must not be connected to a hydronic heating system that has been used previously 3 No boiler treatment chemicals of any kind shall be introduced into the system 4 The Combo System components must be selected and sized to meet and maintain the total calculated demands for both domestic service hot water and space heating requirement The sizing and installation must be performed in accordance with good engineering practice such as ASHRAE Handbooks HRAI s Unified Combo Guidelines Hydronics Institute Manuals ANSI Z223 1 CSA F280 National Provincial Building Codes ANSI and or codes having jurisdiction 5 The air handler fan coil
100. Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS A E CERTIFIED WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DOIF YOU SMELL GAS e Donottrytolight any appliance e Do not touch any electrical switch do not use any phone in your building e 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 Installation and service must be performed by a qualified installer service agency or the gas supplier DIRECT VENTED GAS MODELS NOT FOR USE IN MANUFACTURED MOBILE HOMES if FE o 1 m ol LL LL LI LL LL hal ila 1 TIT e AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater For Your Safety AN ODOURANT IS ADDED TO THE GAS USED BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER
101. Instructions and proceed with lighting the heater www gsw wh com 25 26 LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion J may result causing property damage personal injury or loss of life BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance has a pilot which is lit by a piezoelectric spark gas ignition system Do not open the inner door of the appliance and try to light the pilot by hand B BEFORE LIGHTING 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 Do not try to light any appliance Do not touch any electric 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 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 service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit lt must be replaced Gas Control amp
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105. RNING Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the instruction manual and B149 1 To avoid injury combustion air must be taken from outdoors A Do not place chemical vapor emitting products near water heater or near the vent termination hood Do not obstruct the vent termination hood Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual STORAGE OF FLAMMABLE LIQUIDS Flammable liquids such as gasoline solvents propane LP or butane etc and other substances such as adhesives paints etc emit flammable vapours which can be ignited by a gas water heater s pilot or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area Even though this water heater is a flammable vapours ignition resistant FVIR water heater and is designed to reduce the chances of flammable vapours being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater the vent termination hood or other open flame or spark producing appliance Examples of such locations are garages storage and utility areas The water heater must be located and or protected so it is not subject to physical damage by a moving vehicle Propellants of aerosol sprays and volatile compounds cleaners chlorine based chemicals refrigerants etc in
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110. TION ON Thermopile GAS CONTROL COMMANDE DU GAZ CONTROL KNOB BOUTON DE R GLAGE DU GAZ d avertissement avant d allumer la veilleuse 2 Tournez le bouton de r glage du gaz temp rature dans le sens antihoraire Niusqu la position OFF 3 Afin de laisser se dissiper tout gaz ayant pu s accumuler attendez dix 10 minutes Si vous d tectez une odeur de gaz ARR TEZ Suivez la directive de s curit B au haut de cette Diin Si vous ne d tectez pas d odeur de gaz proc dez la prochaine tape Tournez le bouton de r glage du gaz temp rature dans le sens horaire Y jusqu la position PILOT Figure B Appuyez compl tement sur le bouton de r glage du gaz temp rature et maintenez le enfonc Le bouton peut s enfoncer d environ 6 mm 1 4 po lorsqu il est bien positionn PILOT Tout en maintenant le bouton de r glage du gaz temp rature enfonc appuyez de fa on r p titive une fois 1 ARR TEZ Il est essentiel de lire attentivement tous les messages blink The pilot flame should envelop the thermopile See Figure D When the status light starts blinking release the gas control temperature knob Set the gas control temperature knob to the desired setting See Figure C If the status light does not start blinking within 90 seconds repeat steps 2 through 5 up to THREE 3 times waiting 10 minutes between lighting attempts The circuitry in this advanced gas valve require
111. Tower 28 Airbox 29 Thermal Expansion Tank required for all closed systems 30 Sheet Metal Burner see Figure 3 amp Figure 4 31 Gas Orifice see Figure 3 amp Figure 4 www gsw wh com 32 Gas Manifold see Figure 3 amp Figure 4 33 Manifold Door Gasket see Figure 3 amp Figure 4 34 Manifold Door see Figure 3 amp Figure 4 35 Two Piece Grommet With Clip see Figure 3 amp Figure 4 36 Viewport see Figure 3 amp Figure 4 37 Flexible Manifold Tube see Figure 3 amp Figure 4 38 Pilot see Figure 3 amp Figure 4 39 Thermopile see Figure 3 amp Figure 4 40 Pilot Shield see Figure 3 amp Figure 4 see notes on following page Rear View Figure 2 Natural gas and Propane LP main burner with igniter assembly for 38k to 42k Btu hr models Natural gas and Propane LP main burner with igniter assembly for 47k Btu hr models Figure 3 Figure 4 Vacuum relief valve install per local codes not supplied with heater Figure 5 Notes Items not supplied with the water heater The side recirculation loop connections may not be used as the primary water inlet and outlet connections See Combo Heating Inlet And Outlet Side Taps below During operation the vent pipe and airbox can get hot kk REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When
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118. ater when connected to copper pipe CAUTION e Avoid water heater damage e Install thermal expansion tank if necessary e Do not apply heat to cold water inlet or hot water outlet e Contact qualified installer or service agency TEMPERATURE PRESSURE RELIEF VALVE WARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Do not plug block or cap the discharge line e Failure to follow this warning can result in excessive tank pressure serious injury or death This water heater is provided with a properly rated sized and certified combination Temperature Pressure Relief Valve T amp P valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 and the code requirements of ASME If replaced the new T amp P valve must meet the requirements of local codes but notless than a combination temperature pressure relief valve rated sized and certified as indicated in the above paragraph The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi and a discharge capacity not less than the water heate
119. aving heat traps to minimize the migration of heat to the pipes Do not remove the inserts within the heat traps 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 Ifinstalling the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed Water Systems and Thermal Expansion 4 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 5 After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet reinstall the aerator and check all connections for leaks Repair as needed SHUT OFF HOT WATER pe OUTLET COLD WATER 3 4 SWEAT INLET FITTING EXPANSION TANK UNION gt EP 3 4 SWEAT FITTING TEMPERATURE PRESSURE RELIEF VALVE COMPONENTS NOT SHOWN FOR CLARITY DISCHARGE PIPE DO NOT CAP OR PLUG Figure 9 Figure 9 shows typical attachment of water piping to the water heater The water heater is equipped with 3 4
120. be from the outside wall Ensure the vent termination position maintains the clearances as outlined in Figure 27 thru Figure 29 2 Selected location must provide adequate clearances for servicing and proper operation of the water heater 3 Avoid locations that could cause the water heater to freeze from outside air 4 Avoid locations that expose the water heater to direct sunlight 5 Keep combustibles such as boxes magazines clothes etc away from the water heater area CAUTION All water heaters eventually leak e Do not install without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow of water will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor In all cases a metal drain pan should be installed under the water heater Metal drain pans are available at your local hardware store Such a metal drain pan must have a clearance of at least 25mm 1 greater than any point on the water heater s outer jacket and must be piped to an adequate drain The pan must have a maximum depth of 45mm 1 75 Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped
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122. ces stated on the heater see Figure 6 Floors With Carpeting This water heater must not be installed directly on carpeting Carpeting must be protected by a metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 76mm 3 in every direction or ifthe appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard Clearance For Servicing Adequate clearance of 610mm 24 for servicing this appliance should be considered before installation such as changing the anodes etc A minimum clearance of 140mm 5 5 must be allowed for access to replaceable parts such as thermostats drain valve and relief valve When installing the heater consideration must be given to proper location Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible CHEMICAL VAPOUR CORROSION CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPOURS SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes and process chemicals are typical compounds which are potentially corrosive Do not store products of this sort
123. charge Pipe Requirements e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe e Must terminate a maximum of 305mm 12 above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building e Shall not have any valve or other obstruction between the relief valve and the drain DANGER e Burn hazard e Hot water discharge e Keep clear of temperature pressure relief valve discharge 14 www gsw wh com The T amp P valve must be manually operated at least once a year Caution should be taken to ensure 1 no one is in front of or around the outlet of the discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions in this manual and replace the temperature pressure relief valve with a properly rated sized new one Note The p
124. comply with local codes and ordinances or with the Natural Gas and Propane Installation Code B149 1 Copper or brass tubing and fittings except that which is certified for gas usage should not be used lf the gas control valve thermostat is subjected to pressures exceeding 1 2 psi 14 inch w c the damage to the gas control valve thermostat could result in a fire or explosion from leaking gas If the main gas line shut off serving all gas appliances is used also turn OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of the Natural Gas and Propane Installation Code B149 1 and your gas supplier concerning pipe size There must be e A readily accessible manual shut off valve in the gas supply line serving the water heater and e Asediment trap ahead of gas control valve thermostat to help prevent dirt and foreign materials from entering the gas control valve thermostat Aflexible gas connector or a ground joint union between the manual gas shut off valve and gas control valve thermostat to permit servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Repair and retest as required When finished rinse off soapy solution and wipe dry WARNING
125. conds of continuous Pilot operation before the thermopile reaches normal operating temperature and the Status Light starts to blink If the Status Light does not blink after three lighting attempts check to make sure unit is getting gas Remove the outer door Press reset button Replace outer door Turn Gas Control Valve Thermostat knob to OFF Wait 10 minutes then attempt to light Pilot by following the lighting instructions on the water heater s label Look through the view port for the Pilot flame If Pilot is not visible the spark igniter or gas supply to the Pilot should be checked If the Pilot is visible and the Status Light does not blink after 90 seconds of continuous Pilot operation the Pilot flame may not be heating the thermopile sufficiently weak Pilot the thermopile may be defective or wiring connectors may be loose RED LIGHT ON SOLID Pilot light was recently Turn Gas Control Valve Thermostat knob to extinguished and the OFF Wait 10 minutes for the thermopile to thermopile is cooling down cool then attempt to relight Pilot by following the lighting instructions on the water heater s label NOTE This gas control valve thermostat has built in circuitry that requires waiting 10 minutes between lighting attempts Until the thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit lt may take up to 90 seconds of continuous Pilot operation before the t
126. d the two corrugated pipes in position When the pipes are stretched to the required length the springs will remain properly spaced To connect the vent piping to the vent termination hood first slide the inner 3 corrugated pipe over the inner vent termination pipe Continue this action until the locking clip on the corrugated pipe snaps into position in the corresponding groove see Figure 18 Secure corrugated pipe with screw supplied inserted through hole opposite the locking clip Repeat this process with the outer 6 corrugated pipe and lock it into position on the outer pipe on the vent termination see Figure 18 Secure corrugated pipe with screw supplied inserted through hole opposite the locking clip Note To reduce the friction between the corrugated pipe and the O rings it is recommended to dampen the O rings with water The completed connection is shown in Figure 19 TER LOCKING INNER VENT CLIP TERMINATION PIPE OUTER VENT TERMINATION PIPE mm mm il Y d Figure 19 SECURING VENT TERMINATION ASSEMBLY TO THE EXTERIOR WALL Some models are supplied with trim plates which may be used to cover the holes in the wall see Figure 1 and Figure 20 Slide one trim plate if supplied over the outer corrugated tube then insert the outer corrugated tube through the clearance hole from exterior wall Secure the trim plate to the exterior wall then secure the
127. e Use joint compound or tape compatible with propane e Leak test before operating heater e Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape marked as being resistant to the action of gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual manual gas shut off valve should be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi It should be isolated from the gas supply piping system by closing its individual manual gas shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi Connecting gas piping to the gas control valve thermostat of water heater can be accomplished by the method shown in Figure 13 18 www gsw wh com Figure 13 SEDIMENT TRAP A WARNING e Contaminants in gas lines can cause fire or explosion e Clean all gas piping before installation e Install sediment trap in accor dance with B149 1 A sediment trap should be installed as close to the inlet of the water heater as practical at the time of water heater installation The sediment trap should be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap If a tee fitting is used it should be ins
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130. eater must not be installed using iron piping or PVC vvater piping e Use only pumps valves or fittings that are compatible vvith potable vvater e t is recommend that only full flow ball or gate valves are used in vvater piping installations The use of valves that may cause excessive restriction to vvater flovv is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used e Piping that has been treated vvith chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Piping fittings and valves should be installed according to the installation drawing see Figure 9 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation 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 Important Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 9 Connect the cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water supply 3 4 NPT to the hot water outlet fitting Important These models may contain energy s
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133. ench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve thermostat may result Replacing The Gas Control Valve Thermostat To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a 100mm 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat clockwise DO NOT OVER TIGHTEN damage may result e Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into the tank e Be sure to remove the pilot ferrule nut from the new gas control valve thermostat Reconnectthe manifold tube pilot tube igniter wire and the thermopile connections e Tum the main gas supply ON and check the gas supply connections for leaks Correct any leak found e Light the pilot and main burner then check the manifold tube and pilot tube connections for leaks Use an approved noncorrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Correct any leak found e Be sure tank is completely filled with water before lighting and activating the water heater Follow the light
134. er flame characteristics are not evident see Figure 31 make sure that the flow of combustion and ventilation air is not blocked in the venting system You should also check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage If proper flame characteristics are not evident call your service agency to remove and clean the burner and correct any operational problem 30 www gsw wh com BURNER FLAMES Inspect the burner flames through the viewport and compare them to the drawings in Figure 31 A properly operating 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 colour Contaminated air may cause an orange coloured flame Contact a qualified service technician if the flame is not satisfactor TIPS MAY HAVE AYELLOW TINT YELLOW INNER CONES ARE INCORRECT FLAME LAZY YELLOW SATISFACTORY CORRECT FLAME SOFT BLUE Figure 31 SERVICING THE WATER HEATER Servicing this water heater shall be done by qualified service personnel only 1 Before performing any maintenance it is important t
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136. etectors are available Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual ADANGER A Flammable Vapours Vapours from flammable Water heater has a main iquids may explode and burner and pilot While catch fire causing death or operating the pilot flame severe burns 1 is in continuous operation and Do not use or store will ignite flammable flammable products such as vapours gasoline solvents or adhe sives in the same room or Vapours area near the water heateror 1 cannot be seen the vent termination hood 2 are heavier than air Keep flammable products 3 go a long way on the floor 1 far away from heater and 2 in approved containers 4 can be carried from other 3 tightly closed and rooms by air currents 4 out of children s reach Installation Do not install the water heater or the vent termina tion hood where flammable products will be stored or used www gsw wh com 5 INTRODUCTION PREPARING FOR THE INSTALLATION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service This water heater is suitable for potable water heating and space heating applications but not for space heating only applications Abbreviations found in this Installation and Operating manual e CSA Canadian Standards Association e ANSI American National Standards Institute e ASME American Socie
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138. ffle and burner 2 Clean flue locate source and correct 3 Check with gas utility company 4 Replace gas control thermostat 1 Insufficient combustion air 2 Venting flue clogged 3 Low gas pressure 4 Improper calibration 5 Gas control thermostat set too low 6 Water heater too small 5 Turn temperature dial to desired 7 Wrong piping connections setting 8 Wasted hot water 6 Install adequate size heater 9 Sediment or lime in tank 7 Correct piping dip tube must be in cold inlet 8 Advise customer 9 Drain flush provide water treatment if needed SLOW HOT WATER RECOVERY 1 Excessive water pressure 1 Use a pressure reducing valve and 2 Heater stacking relief valve 3 Closed water system thermal 2 Lower the thermostat setting expansion 3 See Closed System Thermal Expansion THERMOSTAT FAILS TO 1 Defective gas control thermostat 1 Replace gas control thermostat SHUT OFF 2 Improper calibration 2 Replace gas control thermostat 1 Insufficient ventilation air 1 Provide ventilation to the water heater 2 Flue clogged or vent system blocked Check flueway flue baffle burner 3 Heater installed in a confined area 2 Clean locate source and correct 3 Provide fresh air ventilation DRIP FROM RELIEF VALVE COMBUSTION ODOURS 1 Insufficient combustion air 1 Check vent termination hood and 2 Low gas pressure venting flueway flue baffle and burner SMOKING AND CARBON 3 Venting flue clogged 2 Check with gas
139. fold burner assembly from the combustion chamber BE SURE NOT TO DAMAGE ANY INTERNAL PARTS AS CONTROL PIEZO IGNITER BUTTON PILOT TUBE VIEWPORT MANIFOLD TUBE MANIFOLD SCREW 2 MANIFOLD DOOR OUTER DOOR NOT SHOWN MANIFOLD COMPONENT Figure 33 REMOVING THE BURNER FROM THE MANIFOLD BURNER ASSEMBLY Natural Gas Low Nox amp Propane LP Gas Burner 1 Take off the burner by removing the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water see Figure 34 Important DO NOT remove the orifice lt lt KEEP DRAIN EX HOLE IN THIS POSITION BURNER BOTTOM VIEW Figure 34 3 When replacing the burner ensure the drain hole is in the position shown in Figure 34 REPLACING THE PILOT THERMOPILE ASSEMBLY 1 Remove the manifold door assembly as described in Removing The Manifold Burner Assembly section 2 Remove the burner to access the pilot thermopile assembly Remove and keep the screws securing the burner to the manifold see Figure 34 Important DO NOT remove the orifice 3 Remove the screw securing the pilot thermopile assembly to the pilot bracket and keep for reuse later see Figure 35 8 Figure 38 4 Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold do
140. h a non potable water heating appliance e All piping components connected to this unit for space heating applications should be suitable for use with potable water e Pumps valves piping and fittings must be compatible with potable water e Toxic chemicals such as those used for boiler treatment shall not be introduced into the potable water used for space heating e When the system requires water for space heating at temperatures higher than required for domestic water purposes a mixing valve must be installed Please refer to Figure 8 for suggested piping arrangement e Be sure to follow the manual s shipped with the air handler or other type heating system e This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e A properly installed flow control valve is required to prevent thermosiphoning Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle Weeping blow off of the temperature pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning e The hot water line from the water heater should be vertical past any mixing valve or supply line to the heating system to remove air bubbles from the system 16 www gsw wh com COMBO HEATIN
141. h the service guidelines provided by the manufacturer Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building www gsw wh com 3 GENERAL SAFETY AWARNING AWARNING Read and understand instruction manual and safety messages For continued protection against before installing operating or risk of fire servicing this water heater Do not install water heater on Failure to follow instructions and carpeted floor safety messages could result in y Do not operate water heater if death or serious injury flood damaged Instruction manual must remain with water heater Water temperature over 52 C A DANG ER 125 F can cause severe burns A WA RN N G ae resulting in severe injury or Explosion Hazard Children the elderly and the physically or mentally disabled are at highest risk for scald injury Overheated water can cause water tank explosion Feel water before bathing or SN showering i Properly sized temperature Temperature limiting valves are and pressure relief valve available must be installed in opening Read instruction manual for safe p
142. heater to maintain the temperature set by the user Setting for vacation The LOW position sets the controller at approximately 33 C 91 F This setting is recommended for times when the water heater will not be in use for an extended period of time It effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy www gsw wh com 27 FOR YOUR INFORMATION EXTERNAL DAMAGE Do not operate the water heater until it has been fully checked out by a qualified technician if the water heater e Has been exposed to fire or damage e Displays evidence of sooting e Produces steam or unusually hot water If the water heater has been flooded it must be replaced START UP CONDITIONS NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER DO NOT ATTEMPT TO OPERATE HEATER WITH COLD WATER INLET VALVE CLOSED Condensate Whenever the water heater is filled with cold water some condensate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensate This usually happens when a A new water heater is filled with cold water for the first time b Burning gas produces water vapour in water heaters particularly high efficiency models where flue temperatures are lo
143. heater uses a sealed venting system to supply fresh combustion air to the heater and to exhaust the products of combustion flue gases to the outdoors The venting is a pipe in a pipe system The inner 3 piping carries out the exhaust flue gases while the outer 6 piping carries in fresh combustion air The corrugated end of the vent piping connects to the top of the water heater and the opposite end connects to the vent termination hood which will be mounted on the exterior wall see Figure 15 Figure 15 shows the hot exhaust gas exit and the location of the combustion air intake Figure 18 thru Figure 25 show how to assemble and connect the venting system Figure 27 thru Figure 29 show various installation options DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPOURS AND LIQUIDS IN THE VICINITY OF THE VENT TERMINATION HOOD NEVER OPERATE THE WATER HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION FIRE EXPLOSION OR ASPHYXIATION DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATINGAIR ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION Mininum 12 in 30 cm to a window or door INSIDE CORNER DE D that may be opened Minimum 12 in 30 cm from soffit Minimum Minimum 7 ft 2 3 m above public sidewalk or paved driveway see footnote 2 AIR SUPPLY INLET VENT TERMINAL A WARNING e Install ven
144. hermopile reaches normal operating temperature and the Status Light starts to blink 1 FLASH EVERY 3 Normal operation No corrective action necessary SECONDS 2 FLASHES Pilot is lit but the thermopile Turn Gas Control Valve Thermostat knob to is not producing the required OFF The thermopile is probably defective but output voltage loose wiring connections or a weak Pilot flame can also cause this symptom 42 www gsw wh com LED STATUS PROBLEM CORRECTIVE ACTION 4 FLASHES 5 FLASHES 7 FLASHES 8 FLASHES The Gas Control Valve s temperature sensor has detected that the water temperature was too high Once this condition occurs the Main Burner and the Pilot Light will be shut off Since the Pilot light will be off should this condition occur this Flash Code will only be displayed immediately after the Pilot has been relit Turn Gas Control Valve Thermostat knob to OFF The temperature sensor thermistor is defective Gas Control Valve failure This condition only appears if the gas control temperature knob has been turned off and the thermopile continued to produce electric power This condition can occur if the thermopile does not cool down as quickly as expected when the unit is shut off This condition can also occur if the gas control temperature knob has been turned off and the pilot continues to operate because the pilot valve is stuck in the open position www gsw wh com Relight
145. hood operates as both the combustion air intake and the heater exhaust port see Figure 15 All combustion air is obtained from outside the building through this hood Ensure the area around the termination hood is always kept clear and that the air supply is not exposed to contamination or flammable vapours CONFINED SPACE INSTALLATIONS This water heater connects to the vent termination hood using the sealed air intake and exhaust piping see Figure 1 and Figure 2 During operation this piping can become hot especially in areas experiencing high ambient temperatures When installed in a confined space such as a closet it is recommended that the confined space be ventilated to minimize the buildup of heat around the heater Figure 6 and Figure 7 show an examples of ventilating a confined space TOP VIEW OF CLOSET WITHOUT DOOR TOP VIEW OF CLOSET WITH DOOR Omm 0 MIN J 140mm 0mm 5 5 MIN 0 MIN 21 AE Figure 6 ROOM AIR Ku VENTILATION AIR OPENING E FRONT VIEW OF DOOR ROOM AIR FLOW Figure 7 Clearances To Combustibles Minimum clearances between water heater and combustibles are Omm 0 at the sides and rear 140mm 5 5 from the front and 305mm 12 from top Minimum clearances from vent piping to combustibles is 25mm 1 except as noted in Figure 20 If clearances stated on the heater differ from these clearances install water heater according to clearan
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147. ilot assembly Check with gas utility company 0 Check rating plate for correct gas type Check with gas utility company Set temperature dial to lower setting 2 Drain Flush Provide water treatment if E 48 Oo O O1 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 Clean locate source and correct Check with gas utility company Replace pilot Check rating plate for correct gas type Check with gas utility company PROBLEM POSSIBLE CAUSE S CORRECTION INSUFFICIENT HOT WATER Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure 10 Leaks or cracks in dip tube 11 Incorrect plumbing plumbing crossover 0 NN O O1 Turn temperature dial to desired setting 2 Drain flush provide water treatment if needed Install adequate size heater Correct piping dip tube must be in cold inlet Repair faucets Advise customer Insulate piping Insulate piping Check with gas utility company 10 Check dip tube Replace if faulty 11 Correct cold water crossover 1 Check vent termination hood and venting flueway flue ba
148. ing instructions on the label or see Lighting Instructions to restart the water heater If additional information is required reference the number on the cover of this manual for service information TEFLON is a registered trademark of E l Du Pont De Nemours and Company REMOVING THE MANIFOLD BURNER ASSEMBLY 1 Turn the gas control temperature knob to the OFF position see Figure 30 and Figure 32 2 Turn OFF the gas at the manual gas shut off valve see Figure 1 GAS CONTROL TEMPERATURE KNOB um m THERMOPILE CONNECTOR IGNITER WA EB BUTTON mi IGNITER nE WHITE LEAD WIRE WIRE FW PILOT IGNITER TUBE RED WIRE WIRE MANIFOLD TUBE Figure 32 3 Remove the outer door 4 Disconnect the following from the gas control valve thermostat pilot tube 7 16 wrench igniter wire from the igniter lead wire and manifold tube 3 4 wrench see Figure 32 Note Propane LP Gas systems use reverse left hand threads on the manifold tube 5 Use needle nose pliers to disconnect the thermopile connector from the gas control valve thermostat see Figure 32 www gsw wh com 31 6 Grasp the manifold tube and push down slightly to free the manifold tube and pilot tube 7 Remove the screws 1 4 nut driver securing the manifold burner assembly to the combustion chamber Figure 33 8 Carefully remove the mani
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155. l Valve Thermostat Honeywell 9 Discharge Pipe 10 Drain Valve 11 Outer Gas Door 12 Manifold Door Assembly behind outer door see Figure 3 8 Figure 4 see also Figure 46 amp Figure 47 13 Floor Drain 14 Metal Drain Pan QE a q Front View Figure 44 38 15 Flexible Manifold Tube see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 22 Anode under cap 23 Hot Water Outlet Nipple or Optional Nipple Anode 26 Air Inlet Snorkel 27 Air Tower 28 Airbox 29 Thermal Expansion Tank required for all closed systems 30 Sheet Metal Burner see Figure 3 amp Figure 4 see see also Figure 46 amp Figure 47 31 Gas Orifice see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 32 Gas Manifold see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 33 Manifold Door Gasket see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 34 Manifold Door see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 www gsw wh com 35 Two Piece Grommet With Clip see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 36 Viewport see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 37 Flexible Manifold Tube see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 38 Pilot see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 39 Thermopile see Figure 3 amp Figure 4 see also Fig
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160. may occur if air for combustion contains certain chemical vapours Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If after inspection of the vent system you found sooting or deterioration something is wrong Call the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater A WARNING Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of the water heater or the vent termination hood Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual PILOT AND MAIN BURNER At least once a year a visual inspection should be made of the main burner and the pilot assembly for proper flame characteristics This can be done by removing the Outer Door and viewing the main burner operation through the Viewport on the Inner Door see Figure 37 The main burner should provide complete combustion of gas ignite rapidly give reasonably quiet operation and cause no excessive flame lifting from the burner ports If the prop
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166. ng arrangement HOT WATER EXPANSION TANK OPTIONAL TO HOUSE FIXTURE COLD SUPPLY CHECK VALVE IF USED REQUIRES EXPANSION TANK MIXING VALVE COLD INLET CHECK FLOW VALVE 12 in MAX CONTROL EXTERNAL CIRCULATOR RETURN DRAIN WATER PURGE HEATER INTERNAL CIRCULATOR Figure 11 HOT WATER EXPANSION TANK OPTIONAL TO HOUSE FIXTURE COLD SUPPLY CHECK VALVE IF USED 1 REQUIRES EXPANSION TANK COLD INLET CHECK FLOW VALVE CONTROL EXTERNAL CIRCULATOR RETURN WATER HEATER HYDRONIC BASEBOARDS SERIES CONNECTED SHOWN Figure 12 www gsw wh com 17 GAS PIPING A WARNING e Do not use water heater with any gas other than the gas shown on the rating plate e Excessive pressure to gas control valve can cause serious injury or death e Turn off gas lines during installation e Contact qualified installer or service agency AWARNING Explosion Hazard Have a qualified technician make sure that the L P gas operating pressure does not exceed 13 water column Failure to do so can result in death explosion or fire Make sure the gas supplied is the same type listed on the model rating plate The inlet gas pressure must not exceed 13 inch w c for natural gas and propane LP gas The minimum inlet gas pressure shown on the rating plate is that which will permit firing at rated input All gas piping must
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169. o allow air to escape from the tank and the water piping Ensure any shut off valves between the heater and the faucets are in the open position 4 Open the cold water supply valve to the water heater Notes e The cold water supply valve must be left open when the water heater is in use e Avoid water leakage when filling the tank Do not allow the insulation of the water heater to get wet as water can reduce the effectiveness of the insulation 5 Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping 6 Check all water piping and connections for leaks Repair as needed www gsw wh com 15 SPACE HEATING AND POTABLE WATER SYSTEMS This appliance has been design certified as complying with American National Standard CSA Standard for water heaters and are considered suitable for Water Potable Heating and Space Heating Note This water heater may be used in combination potable water space heating system Do not use in a space heating only application A WARNING Toxic Chemical Hazard e Do not connect to non potable water system Note Ensure the water heater has been properly sized to accommodate the needs of the hot water demand and space heating load Undersizing the water heater can result in insufficient hot water excessive condensation and inefficient operation e This water heater should not be connected to any heating systems or components previously used wit
170. o turn OFF the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it OFF see Figure 1 2 With the water heater shut off allow sufficient time for the it to cool off before performing any service REMOVING AND REPLACING THE GAS CONTROL VALVE THERMOSTAT Removing The Gas Control Valve Thermostat 1 Turn the gas control temperature knob to the OFF position see Figure 30 and Figure 32 2 Turn OFF the gas at the manual gas shut off valve see Figure 1 3 Drain the water heater Refer to the Draining Refilling And Flushing section and follow the procedure 4 Disconnect the igniter wire from the igniter lead wire Use needle nose pliers to disconnect the thermopile connector Disconnect the pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas control valve thermostat see Figure 32 Note Propane LP Gas systems use reverse left hand threads on the manifold tube 5 Refer to Gas Piping and disconnect the ground joint union in the gas piping see Figure 13 Disconnect the remaining pipe from the gas control valve thermostat 6 To remove the gas control valve thermostat thread a 100mm 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use a pipe wr
171. oducts contain water vapour which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold L Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken M The combo heating system connections may be leaking a Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow the draining instructions in this manual and then remove fitting Put pipe dope or Teflon tape on the threads and replace To refill the water heater follow the instructions in Draining Refilling And Flushing NS Figure 43 www gsw wh com 37 REFERENCE PARTS LISTING Replacement parts may be ordered through your plumber or the local distributor When ordering replacement parts always have the following information ready 1 Model Serial and Product number 2 Type of gas 3 Item number 4 Parts description 1 Vent Termination Hood 2 Wall Plate 3 Vent Pipe 4 Cold Water Inlet Nipple Diptube 6 T amp P Valve 7 Gas Contro
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174. or see Figure 35 Important Be careful not to bend or alter the position of the pilot tube It will be used as a bending template for the new pilot assembly Note the placement order of the wires in the manifold component block THERMOPILE PILOT RETAINER CONNECTOR TUBE CLIP IGNITER WIRE PILOT THERMOPILE a ASSEMBLY SCREW PILOT THERMOPILE ASSEMBLY BURNER AND OTHER FITTINGS NOT SHOW FOR CLARITY sasrer MANIFOLD DOOR Figure 35 5 Lift the pilot thermopile assembly including the igniter wire from the manifold assembly see Figure 36 6 Read this step carefully before proceeding Using the old pilot pilot tube assembly as a guide bend the new pilot tube to match the old one Make only the bends closest to the pilot before going to the next step THERMOPILE PILOT THERMOPILE CONNECTOR igniter NET re CONNECTOR PAS PILOT VE THERMOPILE ASSEMBLY PILOT TUBE NOT SHOWN FOR CLARITY Figure 36 7 Route the new pilot tube igniter wire and thermopile wires through the opening in the manifold door see Figure 35 32 www gsw wh com 8 Using the pilot screw removed earlier attach the new pilot thermopile assembly Reattach the burner to the manifold using the screws removed earlier 9 Reinstall the manifold component block in the manifold door Ensure that the pilot tube and wires are positioned as shown in Figure 37 MANIFOLD COMPONENT BLOCK VIEWPORT PILOT TUBE PASSES THROUGH
175. ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired Standard hardware items may be purchased locally COMBO HEATING INLET AND OUTLET SIDE TAPS Models equipped with Combo Heating capabilities are shipped with the two side plumbing taps OPEN items 5 and 8 in Figure 1 and see also Figure 8 If the heater is to be operated without using the side taps these openings must be closed with the two pipe plugs supplied with the heaters HIGH LIMIT CONTROLS ENERGY CUT OFF Thermostat Water Temperature This feature is a part of the gas control valve thermostat see Figure 1 item 7 and limits the maximum water temperature In the event of the water overheating this safety feature shuts off the fuel supply to the burner www gsw wh com LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed 1 Select a location indoors as close as practical to the vent termination position Figure 27 shows the venting distances that the heater can
176. osip saueyuswa ddns suonoas s p zamoly G nes apyneyo np pneu ne p vonesieues e uns 2 sedeje s zajaeday y juajeambas no nbi l 4inpuo e ueqna ap apre e sesejd ua 2 ejsnfe u lq JUBIOSI S10 SUN nea ayneyo l dane j9ejuos ua U9IQ ajua jue os p SINSUSJU nb snor zamssy UOHESIIEUEO e 1 nb uye juejosI Ins juaweaJeBa ze nddy apio nes p uojesijeued e ins juejos Ze19SUI Sealed xn p s l zauesyq SUORESIIEUB e juejos INS ajeuipnj Buo ajuda ej z s d Z nes ayneyo np nes p apneyo nes p alos suolesijeues s l zeledal aynsuy 9NUBUI SUBP JUISP SLUWOD YY l s dednos E SUEP 919SUI UBW9 991J09 15 JUALUA NOIA Pp nen nb snoa zainssy 01 a1n6B14 sBseyosp 19148 ne S2992 no dednos ej ebleyosp sinweAno a nbolq sed yop eu ueqni l no yugjos jue31oduu juajyeamba no nbi l 4inpuo e aple e a9ejd ua 2 a snfe u lq 051 SIO auf d 9 1 a 81ns adednos e dare j9ejuos us 1910 aJjue nb uye juejos1 ins 14 z Anddy 01 1 491 9 91nS adednos ej ins juejos p nesoJow l 2006 4 je seed xn p sad juawaj eolop z ied s z 491 9181ns ap adednos juejos INS ajeuipny Buo ajua
177. ouuosiod sa sjuejua s r abejue moqs 1ed yow e no sainjnig aa desea 5 u ul uec ue sul mad nea 9 asun e E y clio n 4 29 2 SZ TETE ENT YY YAONVG V nes 9meyo np uonepuoul sun p ayuixo d e Jemeuep yop januew 89 s10 bewwopua aye e I S pow ej no sejnssejq nea alyneyo s sin sed N sene Jeujesjue ed esleyinoes sesside aoejins aun ins SSANOSIP sep janueU np seanoaip sep 08dse1 uou nes ayneyo 8 sed N 0 lDU SUL DP nu nu p s silmnn p s nbst s p 1969 01d ap uyy JUeAe 8118 1n99S uonesiln p S sano Je jenuew jueseld l JUSLUSAQUSE el ZANA TETE EN A YY INSINASSILYSAV 4 3114 239 34 S31vV43n39 53 11 0310 UJOD YM MSB MMM ze6 ne jueuuorouol sil ledde p voneJeda ap je uonoadsu p Sadi Mas sap Juawajeba JUSIYO 286 ap sinassiujno sin lsnidi juauwneg np uedod ap 110 no yu uuneq np a siuidwos uewuneq np 266 us suonesieues s p uoneqoldde ja uonoadsu1 jqesuods jeJausB ue 159 266 unassiusnoj 97 enueu juesa1d a SUP syusap ajgnsnquios e sil sedde se sed silin auedodd l no jeinjeu 266 a juessiunoy lelol ululo asiudaJ ua no s liqnd sao1nas ap es1denus 266 Inassiuno y upoluqe np ua1 a1Jue p SEANIOIUP
178. oy z yuno qouy ainyesadwiay joujuoo se ayy olid ayy loy q sBulusem yes 2 peas no yey AMed dul 5111 idO LS 5 Zv9 Nd 3ONVNNO uomnog yuoyng JayuB xn uluuni ujowe 3467 smes dul 9 266 np abejbau uoynog IONLNOSD SVD 140 NOLLISOd S NOILISOd 4304 5 024 d y M 38N9l4 i Eldul l 9132 Op Il nesedde saseda ap srewef zajua N uorjepuoul sio bl ulqns juefe nea ajyneyo zno Jaoejdwiad 9118 ap ule BdIAJaS 217089 un no 3ijijenb in yeyle sul un l eip ulul z nbiunululo nea Jed aBsawiqns juewueperied anb aja eu 1 5 resedde 399 sed z silln N lpu ul p no uorso dxa p nbsil e ji Uo nog Jeseda zajua no Z9910 SNOA IS 9 enb v r lu un jojn d 2 uoresedai aun sed za ua au ulo 3 59 uo noq f IS NO p Siewef z siln u urew e nb ausno no ee yop au zef np ap uoznog 97 S lpu ul sap ao aJas l Zajadde zeB ap INISSIUANO DIAL JINDIUNUIWOI zeAnod au SNOA IS S Al H p S S ZAAINS Ja UISIOA n p auoyda9 uued e 206 ap andes 1n9SSIUINO 3140A l yelp ulull Zajaddy juawijeq l suep yueAnoly s s uoud l s p sed 2 5 snoA au UNIN
179. p eun zanbijeld in Li x INW l Y NOSIVNIWYAL V1 30 NOILVTIVLSNI 1 YNOd 19141140 SSJUBAINS UO e e SUI P SUONEI SNI I xne 9 2 pL 9 eunBi4 ep suoneolpul xne 1 4 UOSIBUIWIS ej juawese duea ISIOU9 SIO auf 30 LINANO9 Nd NOILVTIVLSNI 2 eanbi4 YISOAIYLNA _ Nal SN LL 8614 nsnill SWWOD UOSIEUIUL none s wej e no oeuf 21918An09 do d uos 18nbligqez ap ejqissod issne se 91 JOPUCLULUOD l nod 890 JUBTIIE 9P 3440A SipUIOf Z8 IN8A UOSIEUILUIS e ejuapio9e J98 U09 n0 JIU8A91d uye 91 21nBI4 10A uonoajold un 181n901d s ejqissod 159 GL JIOA uuonouo nes nes ayneyo a anbsio apneyo 5911 S UOSIBUILIS ET Aq NOSIVNIIMNM ZL V1 30 ALIMNDAS 30 AIDYSANOD O9 UM MSB MMM oz ex ydse sed pow e Jaueua pelunod inb uoneyqey suep juaddeyoa s au uonsnquuo 266 nb jiuangid ulje UOREIRBU A ynpuos np uoq SNOA ZaJmssy gy o1nBl4 ap s An lip s l ZIAINS 2051 ow no sobeuwuiop s p a sne ad euoqgies ap xouou ap 1400 El no saunssa q ap Jasneo yn d sanbiwiyo synpold s p sed awajsA
180. p sed yop su adednos ns sanbipul jew xew uolssald ej sq juapa98 d ne uoisseid ya 99UIQUIO9 edednos adi ne sn tl lul ilenb aun p sed jueza u Ud no xneo sapos s p sasuabixa xne auojuos yop adednos ll Anou e Gel ejes adednos e Jaoejduwa sess u 5 S HOW no sanssajq S ABIB J3SNEI JUBANOA 110 l suep voissaldins aun Jaureua nad juaulassiuene juesaid np joadsa u0u 97 e juaua no99 p ne n a s uonoq no s nbolq l uuouonde sed N e ul eyes e annaud Iny ano SUEP lle sul n HOP 491 9J21nS ap adednos aun e AWSV 19 T TVSO C 122 ISNV E E S Op 4891 21210S adednos ET TERE RE VAI ANS Sawou xne nb isure sua3s s Aiddns aje M JOH 10 S991A9Q H lnuS seg JIJEWOJNY pue SIAJEA PPY Tv VSO CC 122 ISNV SUHOU e ap UONIPS sn d ey e seubisep sjieJedde p eyunojuos e uoe HH A mb uoneBojouiou p 8110 210qe un Jed lill is dednos n JPUUOISUJWIP 1U9191991109 481 uoIssald je 1 9 81ns adednos aun p duisn ua lunu sa nes ayneyo 99 dol 4144M0S AG AdVdNOS un no ayijenb inajejjejsu u
181. pipe joint compound or tape used Chloride free soap and vvater solution or other approved means used to check all connections and fittings for possible gas leaks Vent Pipe System 0 0 0 0 0 0 Evenly stretched out between water heater and vent termination hood Smooth bend with adequate support to prevent sagging 6 4mm per 305mm 0 25 per foot Inside pipe 3 and outside pipe 6 securely fastened to vent termination hood Vent restricter plate installed on heater flue outlet as applicable Inside pipe 3 and outside pipe 6 securely fastened to water heater with silicone and gear clamps Not obstructed in any way Vent Termination Hood a a a a a a Wa a ODODO Securely fastened to exterior wall Above anticipated snow level or 305mm 12 above grade Proper clearances from windows doors corners other vent openings etc Area around vent termination hood clear and unobstructed No flammable vapour emitting products stored nearby Safety covers in place when applicable ter System Piping Temperature Pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up precautions installed Mixing valve installed when applicable After all actions on checklist are checked completed read the Lighting
182. q s p s ulenu med A sed s u 11 s nb jenusjod s Buep INENERSIEENLVA 4 uonen s aun ajeubls LNANASSILHAAY 3001 T you no s inss lq s p eJoulejue auna sed 3sau 1 5 mb u ululul EDAM a Buep uonenjis aun ajeubis JOU 97 ow Sainssajq s p 19 A9 p uye aJoquAs 99 juanims mb ajiejundas uones lnn p s An lip SA SAINOJ 2JAINS sinolno z llin A s inss lq senbsis s p SNOA e asia 19Buep np juaweassi1ane p ajoquiAs 3sa 1999 ne uneu su nu p s silnn p 19 83SUI p JUBAe san1 98 11p UONEJIJIUBIS ZaIUaIdWOD su91914y99 Sa Ja Sin Esimnn sa sin eyle sul sa aeuau snoa nb juejloduu se 3s T nupul ja sobessau sa Sno s nofno zeAIns zasi7 Sainssajq ap s nbs u s p 3170A Ja BWIQW SNOA ISULIOQUI SNOA E jU9SIA mb ap sabessaw sinaisnjd jusqueseid nes ayneyo 2104 ins s sodde s upilo oyne s p anb sure januew s ld 97 ne Hneq u n nu 9p 3 uonesilnn l UO JE 23SUI SO un p JUOS abeinojua 3170A ll HYINIHS 170A N3ILAYLNA 13 NOILVSITILN NOLLVT VASN 3 14 9 30 93 1 O9 UM MSB MMM FA
183. r Btu hr input rate as shown on the water heater s model rating plate For safe operation of the water heater the temperature pressure relief valve must not be removed from its designated opening nor plugged The T amp P valve must be installed directly into the fitting of the water heater designed for the relief valve Install discharge piping so that any discharge will exit the pipe within 305mm 12 above an adequate floor drain or external to the building In cold climates it is recommended that it be terminated at an adequate drain inside the building Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 9 14m 1307 or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the T amp P valve and the tank Do not connect discharge piping directly to the drain unless a maximum of 305mm 12 air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in adequate quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage CAUTION Temperature pressure relief valve discharge pipe must terminate at an adequate drain T amp P Valve Dis
184. ral minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open High Water Temperature Shut Off System This water heater is equipped with an automatic gas shut off system This system works when high water temperatures are present Turn OFF the entire gas supply to the water heater The high temperature shut off is built into the gas control valve It is non resettable If the high temperature shut off activates the gas control valve must be replaced Contact your gas supplier or service agency www gsw wh com 29 MAINTENANCE FOR YOUR SAFETY AND SATISFACTORY OPERATION IT IS RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR BY A COMPETENT SERVICE PERSON USERS OF THIS WATER HEATER SHOULD BE AWARE THAT GAS COMPONENTS WEAR OUT OVER A PERIOD OF TIME THE GAS CARRYING COMPONENTS OF THIS WATER HEATER SHOULD BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY QUALIFIED SERVICE TECHNICIAN HOUSEKEEPING DANGER Do not obstruct combustion air openings at the vent termination hood Do not use or store flammable vapour products such as gasoline solvents or adhesives in the same room or area near water heater the vent
185. re 41 Keep in a safe place for reinstallation later 6 Remove the anode rod by using a ratchet and a 1 1 16 socket turning counter clockwise see Figure 41 To Install The Anode Rod 1 Use Teflon tape or an approved pipe sealant on threads of the new anode rod 2 Place the anode rod in the spud top of the tank see Figure 41 and turn clockwise until the threads are hand tight Using a ratchet and 1 1 16 socket tighten down water tight 3 Open a nearby hot water faucet to purge air from the water line Fill water heater tank completely Refer to Draining Refilling And Flushing for proper procedures Note To assure the water heater tank is full keep the hot water faucet open for 3 minutes after a constant flow of water is obtained 4 After turning closing the hot water faucet check for water leaks around anode rod and immediately correct any if found 5 Reinstall the insulation and anode cap which were removed in step 5 of removal process 6 Turn ON the manual gas shut off valve see Figure 1 7 Turn the gas control temperature knob to the ON position see Figure 30 and Figure 32 8 Follow the lighting instructions on the label or see Lighting Instructions to restart the water heater 36 www gsw wh com LEAKAGE CHECKPOINTS SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a service agency Use this guide to check a
186. rough the exterior wall for the vent assembly The recommended height is 1 62m 64 for 1511 40 gal models 1 85m 73 for 1891 50 gal models and 1 88m 74 for 1891 50 gal Hi Input models as measured from the hole center to bottom of water heater Where the wall is combustible and the wall thickness is over 356mm 14 25mm 1 clearance to combustible surfaces around the vent terminal is needed The first 356mm 14 is zero clearance see Figure 20 STANDARD VENT ARRANGEMENT Ifthe horizontal length of the venting is less than 762mm 30 the restricter plate must be installed see Figure 21 Figure 27 thru Figure 29 e Do not use the restricter plate in an offset installation see Figure 25 e Do not use the restricter plate the horizontal length of the venting is greater than 762mm 30 Note The length of unstretched corrugated tube could cause the length of the vent run to exceed the minimum In this case cut off a piece of the corrugated tube to achieve the 432mm 17 minimum vent length www gsw wh com 21 VENT ASSEMBLY The vent piping and the vent termination hood are to be connected as shown in Figure 19 Maintain vent clearances to combustibles as shown in Figure 20 Depending on your access to where the vent termination passes through the wall you may wish to connect the piping and vent termination hood together first Inside the vent piping there are springs that hol
187. rovided temperature setting WARNING Fire or Explosion Hazard e Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this water heater the vent termination hood or any other appliance e Avoid all ignition sources if you smell gas Do not expose water heater control to excessive gas pressure e Use only gas shown on rating plate e Maintain required clearances to combustibles e Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing vvater heater 4 www gsw wh com GENERAL SAFETY CAUTION Improper Installation use and service may result in property damage Do not operate water heater if flood damaged Inspect anode rods regularly replace when significantly depleted Install in location with drainage Fill tank with water before operation Properly sized thermal expansion tanks are required on all closed water systems Refer to this manual for installation and service WARNING Breathing Hazard Carbon Monoxide Gas e Install vent system in accordance with codes Do not operate water heater if flood damaged For operation above 2347m 7 700 a high altitude orifice must be installed Do not operate if soot buildup is present Do not place chemical vapor emitting products near water heater or vent termination hood Gas and carbon monoxide d
188. s anne unone tu ess J9 10Q 2121pneup e JUe Jeos ap ajeuoJyo sesoduwoo juo mb suonesieues ap sed Z silin N 21e1pneu9 eun 199e duu81 nod n uo sed 3s u nes apneyo e eBeyneus ap ul s s np no janueu np sa sajno SJAINS 2 SIIe 9p sn d nod g e snoa zaeyoday enbneysouwueu euueA aun p asod ej e 18p 901d me xneool s p ebeyneyo voneoijdde sun suep x enbnsewop esn un nod asinba 2189 e aunaledns armjejedula aun e ssjineyo s8 nessa un p ne enbsio7 nauaju aBeyneyo a nod siln lqeyod nes ap e JUOWOIJIPJ l SUBP 5951 1 xn WWOID sanbixo senbiwiyo synpold ap siewel zajmolen nes dare aBesn un nod snduos Sp10991 s p no e ap s dulod s p juawsanbiun z siln nes p juausunuaysge nod newajyew un p Seonbliqe 2119 JUBSAIOP 1n919jUI eBeyneuyo ap uoneoidde sun suep ne yneyo e S99p 10998 SA Ja SUORES IEUE S lqeyod uou nes p abeyneuo op aus s s suep 1 5 efap e sajuesoduloo sap aun sulow ne juop aBeuneyo ap auejs s jno e 9pi09921 H siewel pop au ned ajjneyo a e S991 9UI jualwesuuo j9uoy un UOIJesuUSpuos A SS X UONJe WO ej epneuo nes p
189. s np UOIEN928A9 P ynpuos UOISOJ109 E7 e uos ISUIE UOHeNdeAV P ynpuos suep 18 NLN99 S ss nd au uonesu puo ap nb s nsse p ue ua aWa sAs l zajoadsu sjuedn990 s p aixAydse no uolsoldx aun un ap juausuuon9uo SIBANEUI l 199 p uye ajenbape aonos aun p asodsip juetuneq np E 9p109921 105 1 nb SUIOW e l z uuonouo SIEU E N uoq eo ap xouou s lqiysnqulo 266 ap sinaj0aJ9p Sep 19 8 SUI P 3S UOIJENDEAY P UOSIEUILUIS e ap no nes ayneyo np syiwixod e 1es110deA es jueAnod sanbiwiyo synpold ap sed zasoda ua N e nea ayneyo np asd ej sed Z N SqO N a nun998 s ains ap Is nes ayneyo sed z siiliniN ap s Ah lip Se 2 AB 9yuojuos UD nea eyneyo a za e3su aun p S10 abewwopue 9 e s nea ayneyo sed z siln N sapos S AB ayunojuos anbipul ua 9439 WOp awuajs s T L6bLg euedoid jounyeu 266 np uoleyje sul p auoques ap p xououl uoneleuul p anbsiy 2p03 np ua no sapos s p SUOI ISOdSIP xne JALLOJUOD S yop lel dS uonen
190. s that you wait 10 minutes between lighting attempts If the status light turns a solid color release the gas control temperature knob and repeat steps 2 through 5 waiting 10 minutes before attempting to relight the pilot If the status light does not start blinking after three lighting attempts turn the gas control temperature knob to the OFF position and call a qualified service technician or your gas supplier DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing the temperature setting Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information Turn the gas control temperature knob counterclockwisef 3 to the OFF position The status light will stop blinking and stay on for a short time after the water heater is turned off See Figure A par seconde sur le bouton de Fallumeur jusqu 90 secondes ou jusqu ce que le t moin lumineux s allume La flamme de la veilleuse devrait envelopper la thermopile Voir figure D Lorsque le t moin lumineux se met clignoter rel chez le bouton de r glage du gaz temp rature R glez le bouton la position d sir e Figure C Si le t moin lumineux ne se met pas clignoter en moins de 90 secondes reprenez les tapes 2 5 jusqu TROIS 3 reprises en prenant une pause de 10 minutes entre chaque essai d allumage Le processeur sophistiqu de ce
191. sena p 1 ul s4S uosiEulul juewsuuolisod 27 NOSIVNINAL V1 30 91 Y INVHNENOO 1 3391N3 xn p s l sajno Jassap s f inb sajeijiwejiun suoneyqey xn p anys Inod saved nu aun p no 110401 un p snssap ne Jaula S sed yeJnap au UOI EN9EAS P UOS EU UL aun z 3SINYW3Id SVd 1S3 N NOSIVNINYAL Y1 NO SIDVIINS S Q2 xn p SUIOW ne ins juauaJaua 159 UOXlEQ SIVHA HIV Q 33N3 NW O 39NLHANO Q no esse118 np ej sayouejd l snos aoedsa IS sed juawanbiun 50707 NOLLVTOVAZ G NOSIVNIWYAL A resedde ene un e uoljsngwoo 11e p 1 39 u3 juauwneq l suep nb ueo w uou J1e p uonejusuye p seua aun e WD QE od z WNUWUIUIW un p 0091 euuoqe p Jnajejnbaj un p voyensena p UOSIEUILUIS Wd 9p SUIOU ny e ap juawabeBbap id wo 6 sulow ny juewenbiueseuu ouidse Sie z N JIOA seed id 9 ul g sulou ny no ap snss p ne id 2 wnwiuiw w ez el ap od ZL WI WNUWIUIN un p un p ou jion uooleq snss p ne Id GL w 9 unayney un no auelef sun aun e nbsn jejuozuoy eBieu ayuu
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193. st one anode rod which will slowly deplete due to electrolysis prolonging the life of the water heater by protecting the glass lined tank from corrosion Adverse water quality hotter water temperatures high hot water usage hydronic heating devices and water softening methods can increase the rate of anode rod depletion Once the anode rod is depleted the tank will start to corrode eventually developing a leak Certain water conditions will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfide gas dissolved in the water See Operational Conditions Important Do not remove this rod permanently as it will void any warranties A special anode rod may be available if water odour or discolouration occurs THE ANODE ROD IS COVERED BY URETHANE FOAM LOCATED UNDER THE CAP CHIP AWAY THE FOAM TO EXPOSE THE TOP OF THE ANODE ROD Figure 41 www gsw wh com 35 Note This rod may reduce but not eliminate water odour problems The water supply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odour problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod see Figure 4
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195. t system In accordance with codes Do not operate water heater if flood damaged e Install water heater in accordance with the instruction manual Do not operate if soot buildup is present Do not obstruct water heater air intake Do not place chemical vapor emitting products near water heater or vent terminal hood e Gas and carbon monoxide detectors are available e Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation fire explosion or asphyxia tion Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent e Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual VENT TERMINAL CLEARANCES The vent system mustterminate so that proper clearances are maintained as cited in local codes or the current edition of the Natural Gas and Propane Installation Code B149 1 as follows Minimum 12 in 30 cm Minimum 3 ft 91 cm within a height of 15 ft 4 6 m above 12 in 50 cm meter regulator assembly above grade or expected snow fall Minimum 3 ft 91 cm clearance to service regulator vent outlet Minimum 12 in 30 cm under veranda porch deck or balcony see footnote 1 Minimum
196. talled in conformance with the method of installation shown in Figure 13 Contaminants in the gas lines may cause improper operation of the gas control valve thermostat that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a sediment trap sometimes called a dirt leg must be incorporated in the piping The sediment trap must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the Natural Gas and Propane Installation Code B149 1 HIGH ALTITUDE INSTALLATIONS Installations above 2 347m 7 700 require replacement of the burner orifice in accordance with the current edition of the Natural Gas and Propane Installation Code B149 1 Failure to replace the orifice could result in improper and inefficient operation of the appliance producing carbon monoxide gas in excess of safe limits which could result in serious personal injury or death Contact your gas supplier for any specific changes which may be required in your area WARNING e High altitude orifice must be installed for operation above 2 347 metres 7 700 ft e Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual www gsw wh com 19 VENTING This direct vent water
197. the hot water by 11C 20F higher than the heater s temperature settings TEMPERED mp POTABLE WATER SUGGESTED PIPING ARRANGEMENT FOR SHUT OFF CA TOP CONNECTIONS VALVE COLD WATER INLET MIXING VALVE CERTAIN MODELS ARE EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE TEMPERATURE PRESSURE RELIEF VALVE HEATING THE HOT AND COLD FITTING ASSEMBLIES PART 9001262 CAN BE ORDERED THROUGH THE DISCHARGE MANUFACTURER PIPE DO NOT CAP OR PLUG METAL DRAIN Figure 8 s2 c 12577 can cause severe burns instantly resulting in severe injury or death Children the elderly and the disabled and are at highest risk of scald injury Feel water before bathing or showering Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm and the physically mentally disabled Table 1 published by U S Government Memorandum 1978 shows the approximate time to burn relationship for normal adult skin If anyone using hot water provided by the water heater being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precautions must be taken see Figure 8 Time for Permanent Burns 2nd amp 3rd
198. the water heater 12 Allow the water heater to complete several heating cycles to ensure it is operating properly Caution Do not turn on the gas to the water heater unless the tank is full Open a hot water faucet and allow the water to run until the air is purged and the water flows uninterrupted from the faucet Important When operating a cold tank condensation can occur and drip on the burner This should not be confused with a tank leak DRAIN VALVE WASHER REPLACEMENT 1 Turn OFF the gas at the manual gas shut off valve see Figure 1 2 Follow Draining instructions in the Draining Refilling And Flushing section 3 Turning counterclockwise remove the hex cap below the screw handle Remove the washer and put the new one in place 5 Screw the handle and cap assembly back into the drain valve and retighten using a wrench DO NOT OVER TIGHTEN 6 Follow Refilling instructions in the Draining Refilling And Flushing section gt 7 Check for leaks Repair as needed 8 Follow the lighting instructions on the label or see Lighting Instructions to restart the water heater ALTERNATIVE HANDLE AND STEM HANDLE CAP ASSEMBLY RE a Og 11 WASHER Figure 40 ANODE ROD MAINTENANCE CAUTION Property Damage Hazard s Avoid water heater damage Inspection and replacement of anode rod required Each water heater contains at lea
199. tion manual for safe temperature setting Temperature Adjustment Valves for reducing the point of use temperature by mixing cold and hot water are available see Figure 8 Also available 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 setting will reduce energy losses and may satisfy your normal hot water needs If hot water use 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 AS CONTROL VALVE THERMOSTAT 55 C 60C 650 130 F 140 F 150 F 155 ETTINGS gt GAS CONTROL MARK MARK MARK MARK TEMPERATURE KNOB STATUS LIGHT U 49 C 120 F MARK y O IGNITER Figure 30 The thermostat is adjusted to the OFF position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 49 C 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 30 There is a hot water scald potential
200. tion to ensure the water heater complies with the Locating The New Water Heater section in this manual For installation in areas subject to earthquakes this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake Contact local utilities for code requirements in your area This product is certified to comply with a maximum weighted average of 0 25 lead content as required in some areas 6 www gsw wh com TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS LIST REFERENCING FIGURES 1 5 Vent Termination Hood Wall Plate Vent Pipe Cold Water Inlet Nipple Diptube Combo Heating System Supply Outlet Optional T amp P Valve Gas Control Valve Thermostat Honeywell 8 Combo Heating System Return Inlet Optional 9 Discharge Pipe 10 Drain Valve 11 Outer Gas Door 12 Manifold Door Assembly behind outer door see Figure 3 8 Figure 4 13 Floor Drain 14 Metal Drain Pan 15 Flexible Manifold Tube see Figure 3 8 Figure 4 Ka O1 ND O CET zr TET TS CAR s 8 S Front Vievv Figure 1 16 Sediment Trap 17 Ground Joint Union gas connection 18 Main Manual Gas Shut off Valve 19 Gas Supply 20 Baffle Assembly 21 Rating Plate 22 Anode under cap 23 Hot Water Outlet Nipple or Optional Nipple Anode 24 Inlet Water Shut off Valve 25 Union water connection 26 Air Inlet Snorkel 27 Air
201. tte commande du gaz force une p riode d attente de 10 minutes entre chaque essai d allumage Si le t moin lumineux passe au une couleur unie continue relachez le bouton de r glage du gaz temp rature et reprenez les tapes 2 5 en prenant une pause de 10 minutes entre chaque essai d allumage Si le t moin lumineux ne se met pas clignoter en trois essais d allumage ramenez le bouton de r glage du gaz temp rature la position OFF et faites appel un technicien d entretien qualifi ou votre fournisseur du gaz DANGER Plus l eau est chaude plus le risque d bouillantage est lev Consultez les directives du manuel ce sujet avant de r gler la temp rature Reportez vous aux Directives d allumage du manuel d installation pour des instructions de d pannage plus d taill es 1 Tournez le bouton de r glage du gaz temp rature dans le sens antihorairef Y jusqu la position OFF Le t moin lumineux cesse de clignoter et reste allum un court moment apr s l arr t du chauffe eau Figure A 329353 000 www gsw wh com TEMPERATURE REGULATION TEMPERATURE REGULATION A DANGER Water temperature over 52 C 125 F can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruc
202. ty of Mechanical Engineers This gas fired water heater is design certified by CSA International under Water Heater Standard ANSI Z21 10 1 CSA 4 1 current edition QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this water heater requires ability equivalent to that of a Qualified Agency as defined by ANSI below in the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI Z223 1 2006 Sec 3 3 83 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual 1 Read the General Safety section of this manual first
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209. uos zeb s n p s p 4 lle sul p 3S ne uneu np ulxold e Jasiiodea S jueanod sanbiwiys synpoid sed zasoda ua N H lunos ej ap asiid ej sed Zon1 S4O N JULJOSI sejajeu un dane odde p sed z nbolq N 3 nuIN998 S ains E ap 15 ne uneu l sed z silnniN id 002 2 w 9 2 ap snid e lle sul 3s resedde anbs1o sajney Se anod n uo 391 110 Un z le sui uoljepuouI aun p S10 939 e 1 s ne uneu a sed z silniN UOHE E3suL p SAPOI SA IIAL SYUIOJUOD ua 9 8 SUI 9179 Op UOIENIBAS p aWa SAS aje MENESSINENNVA 4 U91 9J UB P UOHEI EJSUI p SII2J9p sa sno a euuos nod a 19 NSU09 Z liln AN JP aua s s un suep 911ESSO9OU S9 anbiuay uolsuedx p 4OAH S L UN p aduasaJld e7 e 9191 9919 US nes ayneyo l s u uulle p JUBAE l zessijduay e enb pe un juepodulos nal un suep uonelle surl z ni lizq u nsuo2 JUSWUIESINS 189 5 ae nbso e z vejdw 1 apoue zajoadsu e uonEpuoul aun p sio gew e IS nes eyneyo a s siln sed N sabewwop s p s ule nu ad yenbapeul u n nu un no uonesiln sun uoneylesul un 4 4 Na 49 3114 239 AG 531
210. ure 46 amp Figure 47 40 Pilot Shield see Figure 3 amp Figure 4 see also Figure 46 amp Figure 47 Items not supplied with the water heater During operation the vent pipe and airbox can get hot Rear View Figure 45 Natural gas and Propane LP main burner with igniter assembly for 47k Btu hr models Natural gas and Propane LP main burner with igniter assembly for 38k to 42k Btu hr models Figure 46 Figure 47 Notes t The orifice on Natural gas models has Right hand thread the orifice on Propane LP models has Left hand thread tt For Natural gas models the Flare Nut has Right hand thread For Propane LP models the Flare Nut has Left hand thread www gsw wh com 39 TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE S CORRECTION PILOT WILL NOT LIGHT 40 BURNER WILL NOT IGNITE SMELLY WATER BURNER FLAME YELLOW LAZY OR REMAIN LIT HIGH OPERATION COSTS PILOT FLAME TOO SMALL Pilot not lit Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged Defective thermopile Defective gas control thermostat Sulfur in the water DIN EC A Low gas pressure Flue clogged Main burner line clogged Obstruction in main burner orifice Insufficient combustion air Air in gas line No gas Dirt in gas lines Pilot line or orifice clogged Defective thermopile Insufficient combustion air Gas control
211. urpose of a temperature pressure relief valve is to prevent excessive temperatures and pressures in the storage tank The T amp P valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion see Closed Water Systems and Thermal Expansion sections Temperature Pressure Relief Valve And Pipe Insulation The T amp P valve installed on this water heater is covered by insulation to minimize heat loss The insulation has a hole on the bottom side to accommodate the valve outlet and allow for the piping connection Do not restrict the outlet opening of the T amp P valve T amp P Relief Valve Insulation Outlet opening on underside T amp P Relief Valve Drain Line Figure 10 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve see Figure 10 1 Locate the slit running the length of the T amp P relief valve insulation 2 Spread the slit open and fit the insulation over the T amp P relief valve see Figure 10 Apply gentle pressure to the insulation to ensure that it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape electrical tape or equivalent Important The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 10 Ensure a discharge pipe is installed
212. ution Bubbles forming indicate a leak Correct any leak found 11 Verify proper operation then replace the outer door 8 9 A WARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace manifold component block if miss ing or removed Replace door gasket if damaged Failure to do so can result in death explosion or fire www gsw wh com 33 PIEZOELECTRIC IGNITER SYSTEM The piezoelectric igniter system consists of the igniter button electrode and wire The pilot is ignited by an electric spark generated when the igniter button is pressed see Figure 38 WIRE TO ELECTRODE IGNITER BUTTON Figure 38 TESTING THE IGNITER SYSTEM Turn OFF the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper T
213. vent terminal to the exterior wall with 4 screw anchors included appropriate for the type of wall construction Caulk the junction of the vent terminal base plate and the exterior wall with exterior type sealant not included Slide the trim plate inside over the outer corrugated tube and fasten the trim plate to the interior wall Caulk the junction of the outer corrugated tube and the trim plate inside with suitable sealant The vent termination hood attaches to the vent piping as shown in Figure 19 356m lt eof ae 14 ZERO CLEARANCE Ae SPRING TRIM PLATE TRIM PLATE OUTSIDE CUTAWAY TO SHOW SPRING PLACEMENT SEALANT Figure 20 VENT RESTRICTER PLATE The vent restricter plate see Figure 21 is required for short horizontal runs on low vent installations see Figure 28 and high vent installations see Figure 29 For short horizontal vent runs see Figure 28 place the restricter plate over the flue tube reducer before connecting the inner corrugated tube to the flue tube reducer DO NOT use the restricter plate if the horizontal run is greater than 762mm 30 For high vertical runs use the restricter plate only when the vertical run of the venting above the heater is greater than 1 21m 48 see Figure 29 FLUE TUBE UPPER AIR INLET BOX RESTRICTER PLATE Figure 21 UNCOMPRESSING THE CORRUGATED TUBING 1 Pull the inner corrugated tube towards the water heater and leave some length
214. vice if necessary Contact qualified installer or service agency Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among others have installed devices such as pressure reducing valves check valves back flow preventers etc to control these types of problems When these devices are not equipped with an internal by pass and no other measures are taken the devices cause the water system to be closed As water is heated it expands thermal expansion and closed systems do not allow for the expansion of heated water As water is heated it expands thermal expansion As the volume of water increases there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank
215. w wh com To Refill The Water Heater Storage Tank 1 Close the water heater drain valve 2 Remove the drain hose 3 Open a nearby hot water faucet and leave open to allow air to escape 4 Open the cold water inlet valve to the water heater 5 To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained 6 Turn ON the gas supply at the manual gas shut off valve 7 Follow the lighting instructions on the label or see Lighting Instructions to restart the water heater To Flush The Water Heater Storage Tank 1 Turn OFF the gas at the manual gas shut off valve see Figure 1 2 Ensure the cold water inlet valve is open 3 Connect a hose to the drain valve and terminate it to an adequate drain 4 Ensure the drain hose is secured before and during the entire flushing procedure Flushing is performed with system water pressure applied to the water heater 5 Open the water heater drain valve to flush the storage tank Caution Water will be hot 6 Flush the water heater storage tank to remove sediment and allow the water to flow until it runs clean 7 Close the water heater drain valve when flushing is completed 8 Remove the drain hose 9 Ensure the heater is full of water 10 Turn ON the gas supply at the manual gas shut off valve 11 Follow the lighting instructions on the label or see Lighting Instructions to restart
216. wer c Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise Because of the suddenness and amount of water condensate water may be diagnosed as a tank leak After the water in the tank warms up about 1 2 hours the condition should disappear Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up An undersized water heater will cause more condensation The water heater must be sized properly to meet the family s demands for hot water including dishwashers washing machines and shower heads Excessive condensate may be noticed during the winter and early spring months when incoming water temperatures are at their lowest Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapour Smoke Odour It is not uncommon to experience a small amount of smoke and odour during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while THERMAL EXPANSION CAUTION Improper installation and use may result in property damage Avoid water heater damage e Install thermal expansion tank or de
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