GSW FlowThru User's Manual
Contents
1. year from date of installation and 3 The Unit shall not be installed where it will be exposed to adverse or Any repair or replacement of any part tank or Unit under this Warranty unusual environmental or corrosive conditions No warranty extends for will not extend the Warranty Period beyond that calculated from the date example and without limitation of the foregoing to Units exposed to of first installation of the original Unit The date of first installation will salts chemicals exhausts pollutants or contaminants Further no war be deemed to be the later of the date indicated by the Unit s serial num ranty extends to Units affected by fire freezing or flood Acts of God ber or if supplied with the Warranty claim the sales receipt or installer s or any other contingency beyond the control of GSW receipt 4 The Unit shall be equipped with a properly operating temperature and 8 A claim under this Warranty must include the model and serial number of pressure relief valve as specified by GSW and applicable standards The the Unit proof of date on which the Unit was first installed and the iden Unit shall be operated at temperatures not exceeding the maximum set tity of the defective part s for which a claim is being made and be sub ting of the thermostat and or high limit control provided by GSW and at mitted within 15 days following discovery of the defect s by personal water pressures not exceeding the pressure reading stated2. the ground con nection at the service panel to the ground screw at the junction box GROUND c CIRCULATOR PUMP FIELD PROVIDED JUNCTION BOX AT CASING TOP WHITE BLACK Figure 4 Wiring Diagram 4 The thermostat is rated for a maximum inductive current of 7 FLA at 120 VAC Do not exceed this rating for the circuit 5 Do not install or connect electrical heating elements to this tank Filling NOTE When filling avoid water leakage Do not allow the insulation of the tank to get wet as water can cause electri cal malfunction or reduce the effectiveness of the insulation 1 To insure complete filling of the tank allow air to exit by opening a hot water faucet that is served by the tank and is some distance away from the heater Ensure the storage tank drain valve is closed Open the cold water supply valve and fill the tank and piping system with water When an uninterrupted stream of water without apparent air bubbles flows from the open hot water faucet the system is full 4 Close the open hot water faucet Check the system for leaks repair as necessary and retest 5 Connect a hose to the drain valve and route to a suit able drain Open the drain valve and let water run to flush out any foreign matter that may have entered the system Once flushed close the drain valve and dis connect hose on IV OPE
3. E HOT BOOSTER TANK 1 Net NON TEMPERA COMBINATION TURE CON 5 INLET DRAIN VALVE TROLLED TANK LESS COIL BOILER Figure 3 Single Storage Tank Plumbing for a Non Temperature Controlled Tankless Coil Boiler 5 Pay attention to the desired flow direction when installing the circulator pump If the pump does not have a check valve embedded install one to ensure the desired flow direction is maintained during system oper ation 6 Install a mixing valve with the hot port going to the top tank fitting Connect the domestic hot water supply line to the mixing port of the mixing valve Connect the cold port of the mixing valve to the cold water supply line and place a shut off in this line Most mixing valves do not operate properly if the pressure differential between hot and cold port is too high If this happens lower mixed water temperature will be provided The shut off valve should be used to adjust this pressure differential Set the mixing valve outlet temperature to 49 C 120 F to avoid scalding 7 A check valve may be installed in the cold water line before the connecting tee NOTE The check valve can often be noisy and cause reduced supply pressures For multiple storage tank sys tems check valves must be installed to prevent the circula tor pump from pumping hot water into another tank and overheating it 8 The use of a pressure regulator is optional but recom mended when the cold supply pres
4. GSW WATER HEATING G SW 599 Hill Street West Fergus ON Canada N1M 2X1 STORAGE TANKS FOR INSTANTANEOUS WATER HEATERS INSTALLATION AND OPERATING INSTRUCTIONS For FlowThru Brands Read and understand these instructions thoroughly before starting TABLE OF CONTENTS Ll introduction saari Sune epee ele 3 J j I Safety ie nei er ENEEIER TAR RRN 3 j IY Installation stesen i er naa 3 IV Operation fs is escechi5 eee aye 5 V Maintenance 000 00 e eee 6 Warranty si wars E EL EEE we ARS acters 8 PLEASE RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE fed Flow TRU A WARNING Improper installation adjustment alter 5 ation service or maintenance can cause injury or property damage Refer to this manual For assistance or additional infor mation consult a qualified installer serv ice agency or the electric utility FOR YOUR SAFETY e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e Installation and service must be per formed by a qualified installer service agency or the electric utility A WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage per sonal injury or death GSW Water Heating is a division of GSW Water Products Inc PART NO 71800 REV B 06 07 INSTALLATION RECORD Record key data here f
5. RATION 1 Follow boiler or instantaneous water heater installation and operating instructions Fill the tank see Filling section The boiler or instantaneous water heater should be set to provide at least 11 C 20 F higher water temperature than the temperature setting of the storage tank 4 Turn power on check for proper operation of boiler or instantaneous water heater and storage tank On 5 Temperature Adjustment A DANGER POE HOT 4A N Water temperature over 52 C 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at the storage tank Feel water before bathing or showering Temperature limiting valves are available see man ual Thermostats are factory set at 140 F 60 C The thermo stat operates automatically It can be adjusted to provide a higher or lower water temperature If water temperature adjustment is required 1 Turn the electrical supply OFF 2 Remove the access door and insulation pad 3 Check with a voltage tester at terminal 1 and 3 of the limit control that power is indeed OFF 4 Adjust the thermostat to the water temperature desired 5 Ensure insulation pad is in the door cavity Replace access door s 6 Turn the electrical supply ON WARNING Risk of scalding There is a hot water scald potential if the
6. ctrical supply to the tank 2 Close the cold water supply valve 3 Open a nearby hot water faucet served by the system to depressurize the system 4 Connect a hose to the drain valve and drain 22 litres 6 gal as directed in the Draining and Flushing section A CAUTION Hydrogen gas can be produced in a hot water system served by this storage tank that has not been used for a long period of time generally two 2 weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To reduce the risk of injury under these conditions it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance con nected to the hot water system Use caution in opening faucets If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open Using an adjustable pipe wrench remove the anode and inspect it The surface may be rough full of pits and crevices but this is normal If it is less than approxi mately 6mm 1 4 in in diameter or the inner steel core is exposed the anode should be replaced Apply Teflon tape or sealing compounds approved for use with potable water to the threads of the anode and install into the tank top Open the cold water supply valve and open a nearby h
7. e water heaters of the same storage capacity Always use a mixing valve on the hot water outlet not provided Il SAFETY Relief Valve Requirements For protection against excessive temperatures and pres sure install temperature and pressure protective equipment required by local codes but no less than a combination Temperature and Pressure T amp P Relief Valve certified as meeting the requirements for Standard For Relief Valves For Hot Water Supply Systems ANSI Z21 22 CSA 4 4 The valve shall be marked with a maximum set pressure not to exceed the maximum working pressure of the storage tank The T amp P valve shall be rated for the BTU INPUT of the entire system This T amp P valve may be in addition to any T amp P valve that is required on the boiler or instantaneous water heater system Install the valve into the opening pro vided on the storage tank or other approved system loca tion Provide tubing so that any discharge from the valve will exit within 152mm 6 in above or any distance below the structural floor and cannot contact any live electrical part The end of the relief pipe opening should terminate near the floor drain or other suitable location Do not place a valve s or any other blockage or restrictions between the tank and the T amp P valve lll INSTALLATION A WARNING Excessive Weight Hazard Use two or more people to move and install storage tank Failure to do so can result in back or other inju
8. lled IWH is used as a heat source install the combination inlet drain valve in one arm of a tee connected to the lower storage tank fit ting Connect the cold water supply piping to the inlet of the combination inlet drain valve Connect the other arm of this tee to the IWH inlet line and place the cir culating pump in this line Connect the IWH outlet to the upper storage tank side fitting see Figure 2 Proceed to step 5 4 For a tankless coil boiler install the combination inlet drain valve in the lower storage tank fitting Connect the inlet of the combination inlet drain valve to the hot outlet of the tankless coil boiler In this instance the leg of a tee should connect to the cold water sup ply line one arm connects to the circulator pump and the other arm to the inlet of the tankless coil boiler The circulator pump connects to the upper side fitting of storage tank see Figure 3 COLD MIXING HOT VALVE TEMPERATURE CONTROLLED va IWH T amp P STORAGE TANK On DRAIN 53 CHECK EXPANSION TANK CIRCULATOR i VALVE OPTIONAL PUMP COLD 6 Figure 2 Single Storage Tank Plumbing for a Temperature Controlled IWH CHECK VALVE EXPANSION TANK OPTIONAL PRESSURE n oS REGULATOR CIRCULATOR y x OQ TIONAD COLD y PUMP oN Hor J MIXING Va VALVE COLD 1 T bi T amp P VALVE STORAG
9. ny other foreign mat ter that may have entered the system Close the cold water supply valve when clean water flows Perform any other servicing as required 8 Close the drain valve disconnect hose and refill the tank see Filling section If the water heater is going to be shut down for an extended period the drain valve should be left open 9 Turn ON the electrical supply to the tank PONS nN Water Odor Sacrificial Anode Your storage tank has been equipped with one magnesium anode that will slowly deplete while protecting the glass lined tank thus prolonging its life Certain water conditions may cause a reaction between the anode and the water The most common complaint associated with the anode is a rotten egg smell produced by the presence of sulfur Do not remove this anode permanently as it will void any warranties stated or implied An aluminum anode may reduce if not eliminate water odor problems The water sup ply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odor problems Artificially softened water is exceed ingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water sof tener may decrease the life of the water heater tank The anode should be inspected periodically If the anode is more than 50 depleted the anode should be replaced Anode Maintenance 1 Turn OFF the ele
10. on the Unit delivery to a GSW authorized dealer point of purchase or GSW itself at 5 The Unit must be carefully inspected maintained and operated in accor GSW Water Heating dance with the manufacturer s instructions No warranty extends for GSW Water Heating is a division of GSW Water Products Inc example and without limitation of the foregoing to any Unit operated 599 Hill Street West without the tank being completely filled with water without an operating Fergus ON Canada N1M 2X1 anode with levels of sediment or lime precipitate which cause failure in Should you have questions please call our Technical Support Line at 1 connection to any attachment s energy saving device s or other means 888 479 8324 of heating except as approved by GSW for the Unit other than with 9 Ifrequested by GSW information relating to the purchase transportation potable water without any additives such as salts chlorine or chemicals operation and installation of the Unit must be supplied The defective except those added for the sole purpose of rendering the water fit for part s or Unit with all components properly and securely packed shall domestic use be returned transportation pre paid to the address designated by GSW in 6 All repairs must be made by a competent and qualified person who is cer the written request All claims are subject to validation by GSW tified by GSW or one of its authorized dealers to work on the Unit using factory ap
11. or future reference and prompt service Installed By Purchased From Installation Date Model Number Circulator Pump Type Location of Electrical Switch or Circuit Protector Serial Number Boiler Water Heater BTU Input Volts PSL U S Gal 1 INTRODUCTION Thank you for purchasing this FlowThru storage tank Properly installed and maintained it will provide years of trouble free service The warranty on this storage tank is in effect only when the tank is installed and operated in accordance with these instructions The manufacturer of this tank will not be liable for any injury or property damage resulting from failure to comply with these instructions IMPORTANT Read and understand these instructions before installing and operating your storage tank Description The FlowThru series of storage tanks have been designed to supply hot water for domestic use when combined with a tankless coil boiler or instantaneous water heater IWH Each tank is equipped with an adjustable thermostat pre wired and ready for connection to a circulator pump not supplied These tanks are not constructed to ASME requirements and should not be used for such applications The FlowThru series of storage tanks has been optimized to maximize hot water flow rate capabilities of an instanta neous water heater or tankless coil boiler They provide a faster recovery than regular electric or gas fired tank typ
12. ot be introduced into the tank For a temperature controlled instantaneous water heater it is recommended to install the plumbing as shown in Figure 2 It is also recommended to set up and control the IWH out let temperature to be at least 11 C 20 F above tank ther mostat temperature The recommended plumbing installa tion for a tankless coil boiler is shown in Figure 3 In this case because the tankless coil boiler is able to control only the differential between inlet and outlet temperature the cold water entering the tankless coil boiler must be tem pered with hot water from the storage tank As there is a large variety of heat sources and control systems please contact your local distributor for the plumbing system to identify the solution that best suits your application Important Do not apply heat directly to tank fittings when making sweat connections They contain non metallic material NOTE ORIENTATION OF J TUBE T amp P VALVE a PIPE INSULATION FROM IWH THERMOSTAT WITH HIGH LIMIT SWITCH TO IWH amp CIRCULATOR PUMP DRAIN PAN FLOOR DRAIN Z DRAIN VALVE Figure 1 Main Parts and Features for Connection to a Temperature Controlled IWH COLD IN 1 Ensure the storage tank is level before starting installa tion 2 Install a circulation loop as shown using 19mm 3 4 in copper piping 3 If the heating source is a tankless coil boiler go to step 4 If a temperature contro
13. ot water faucet to purge air from the tank as directed in the Filling section Check for leaks repair as required and re test Turn ON the electrical supply to the tank Certificate of Warranty See Rating Label Serial Number prefix for Warranty Code P RS T UV W Y Warranty Code Reduced warranty period Standard Warranty Year 3 5 6 7 8 9 10 12 applies to Newfoundland Reduced Warranty Years 2 3 3 5 5 5 5 7 For its GSW and John Wood water heaters and storage boosters Unit GSW Water Heating GSW warrants that upon receipt of a properly verified Warranty claim within the Warranty Period it will at its election repair or replace units which leak or parts which are defective in material or workmanship subject to the terms and conditions set forth in this certificate GSW will not assume any expense or liability for unauthorized returns nor repairs made by a person who has not been authorized by GSW or one of its authorized dealers GSW Units parts must be replaced with GSW or John Wood products to be eligible for Warranty This Warranty is available to the original owner of a Unit installed within the boundaries of continental United States of Canada or their territories Consumers must retain point of sale proof of purchase to validate warranty entitlement This Warranty does not cover components not manufactured by GSW such as oil burners which carry the warranty given by the manufacturer thereof copy of which
14. proved replacement parts and the Unit shall not be otherwise modified altered or improperly repaired 8
15. re and pressure relief valve see Figure 5 to allow the valve to operate freely and return to its closed position If the valve fails to completely reset and continues to release water immediately turn OFF the electrical supply to the tank close the cold water supply valve and call a qualified service technician TEMPERATURE AND PRESSURE RELIEF VALVE go MANUAL RELIEF VALVE DISCHARGE LINE TO DRAIN Figure 5 T amp P Relief Valve Test Draining and Flushing It is recommended that the storage tank be drained and flushed every 6 months to remove sediment that may build up during operation The storage tank should also be drained if being shut down for extended periods of time To drain the tank perform the following steps A CAUTION The water being drained can be extremely hot The drain hose should be rated for at least 93 C 200 F If the drain hose does not have this rating open the cold water supply valve and a nearby hot water faucet served by the system until the water flow is no longer hot Close the cold water supply valve and resume Turn OFF the electrical supply to the tank Close the cold water supply valve Open a nearby hot water faucet served by the system Connect a hose to the drain valve and route it to an adequate drain 5 Open the drain valve and allow all the water to drain from the tank 6 Open the cold water supply valve and flush the tank as needed to remove sediment and a
16. ry Local Codes The installation of this storage tank must be In accordance with these Instructions and all applicable local codes Location Locate the storage tank in a clean dry area close to the water heating source and preferably central to the piping system Adequate clearance for accessibility to permit main tenance and service must be provided Water lines and the storage tank should be protected from freezing tempera tures Do not install the storage tank in outdoor unprotected areas It is necessary to have a floor drain nearby to permit easy draining see Figure 1 IMPORTANT This storage tank must be installed strictly in accordance with the instructions enclosed and local electrical fuel and building codes It is possible that connections to the tank or the tank itself may develop leaks IT IS THERE FORE IMPERATIVE that the storage tank be installed so that any leakage of the tank or related water piping is directed to an adequate drain in such a manner that it can not damage the building furniture floor covering adja cent areas lower floors of the structure or other property subject to water damage This is particularly important if the tank is installed in a multi story building on finished flooring or carpeted surfaces GSW WILL NOT ASSUME ANY LIABILITY for damage caused by water leaking from the storage tank pressure relief valve or related fittings Select a location as centralized within the piping sys
17. sure is over 80 psi Reducing the inlet pressure to 45 60 psi will reduce probability of relief valve discharge due to thermal expansion 9 The water utility supply meter may contain a check valve back flow preventer or water pressure reducing valve This will create a closed water system During a heating cycle water expands creating a pressure buildup in the water system A Temperature and Pressure T amp P Relief Valve must be installed 150 psi maximum pressure See preceding section If the T amp P valve discharges periodically it may be due to thermal expansion in a closed system To prevent this condition and to reduce the possible buildup of lime on the T amp P Relief Valve seat install a thermal expansion tank in the circulating loop as shown in Figure 2 and 3 10 Some jurisdictions require a Vacuum Relief Valve to be installed Such a valve allows air to enter the piping sys tem thus preventing vacuum conditions that could siphon water from the system Check local code requirements Electrical Wiring Electrical wiring must be in accordance with local codes or in the absence of such codes with the Canadian Electrical Code Part I C22 1 or the National Electrical Code NFPA 70 as applicable 1 Supply 110 120 volts 60Hz power to the junction box located at the top of the tank 2 Connect the circulator pump in series with the thermo stat as shown in Figure 4 3 A ground wire must be supplied from
18. t the remaining provisions Any and all repair and or replacement of part s or Unit are the sole and exclusive remedy available against GSW LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING 1 The Unit shall be installed in accordance with all manufacturers instruc 7 A properly documented claim shall be received by GSW or one of its tions all applicable equipment and building codes ordinances and regu authorized dealers or point of purchase within the following Warranty lations hereinafter referred to as the standards Period except as provided otherwise below 2 The Unit must not be installed where water damage can result from a a for any defective part within one 1 year or leak while provision s shall be made for directing any water escaping b for any Unit that develops leaks in the inner tank due to rust corrosion from the Unit to a properly operating drainpipe As all units of this type or other chemical reactions caused by the potable domestic water sup may eventually leak you must protect against any potential water dam plied to your home within the period of time shown in table at the top of age GSW accepts no responsibility for such damage nor any incidental this page or consequential loss nor damage s related thereto suffered by the Residential units installed and used in a commercial application carry a owner of the Unit nor by any third party warranty period of one 1
19. tem as possible In any location selected it is recommended that a suitable drain pan be installed under the storage tank This pan must limit the water level to a MAXIMUM depth of 45mm 1 3 4 in and have a diameter that is a minimum of 50mm 2 in greater than the diameter of the storage tank Suitable piping shall connect the drain pan to a properly operating floor drain Circulator Pump A circulator pump is not supplied Use only a bronze body model rated for 110 120 volts 60Hz Install in accordance with the pump manufacturer s instructions using standard plumbing practices Size the circulator pump taking into account the pressure loss through the tankless coil boiler or instantaneous water heater as well as pressure losses through the connecting pipes that are part of the circulating loop 13 4 Sizing The Hot Water System Temperature of the system is controlled by the temperature set point of the instantaneous water heater or boiler coil Given the limited storage capacity of the storage tank and the maximum output of the tankless coil boiler or instanta neous water heater large hot water draws significantly exceeding the circulating loop flow rate may lead to a reduc tion in temperature of hot water delivered Plumbing Connections A WARNING The water heating source piping and components con nected to the tank must be suitable for potable water use TOXIC chemicals such as used for boiler treatment must n
20. thermostat is set too high Adjusting the thermostat past the 49 C 120 F bar on the temperature dial will increase the risk of scald injury Hot water can cause severe burns in 1 1 2 seconds at 66 C 150 F Sisecondsiat ewes eeer nae eae 60 C 140 F 20 secondsS at 24 2 5 5 54 C 130 F Initial Temperature Adjustment 1 For the temperature controlled IWH ensure the tem perature set point is 11 C 20 F higher than the storage tank set point 2 If at the end of the recovery cycle the IWH is OFF but the circulator pump does not turn OFF automatically reduce the storage tank thermostat set point until the pump shuts off Check that pump is off Temperature Limit Control For safety a non adjustable high limit temperature switch will shut off the power when excessive water temperatures are reached This switch must be re set manually V MAINTENANCE Temperature and Pressure Relief Valve Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connect ed to a discharge line that terminates at an adequate drain A CAUTION The out flowing water is hot Avoid splashing the water on yourself or on the surroundings where it may cause dam age Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temper atu
21. warranty GSW will make available to the extent supplied by the manufacturer without recourse to GSW THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF THIS EXPRESS WARRANTY IS WHERE PERMITTED BY LAW IN LIEU OF AND EXCLUDES AND REPLACES ALL OTHER CONDITIONS WARRANTIES GUARANTEES REPRESENTATIONS OBLIGATIONS OR LIABILITIES OF GSW OF ANY NATURE OR KIND EXPRESS OR IMPLIED HOWEVER ARISING WHETHER BY CONTRACT CONDUCT STATEMENT STATUTE NEGLI GENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW OR OTHERWISE WITH RESPECT TO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY INSTALLATION OPERATION REPAIR OR REPLACEMENT GSW EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES IN NO EVENT WILL GSW S LIA BILITIES EXCEED THE COST OF THE DEFECTIVE PART S OR UNIT GSW WILL NOT PAY FOR ANY TRANSPORTATION LABOUR INSTALLATION OR OTHER INCIDENTAL COSTS ASSOCIATED WITH THE REPAIR OR REPLACEMENT OF A DEFECTIVE PART OR UNIT This warranty and GSW s obligations shall be construed and determined in accordance with the laws of both the Province of Ontario and of Canada in force therein This Warranty does not affect specific legal rights of a consumer under applicable law except to the extent that such rights may be waived or replaced and the provisions hereof are deemed to be amended to the extent necessary The unenforceability of any provision in whole or in part of this Certificate shall not affec
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