GSW 72090 User Manual
PART NO. 72090 REV. D (07-11)
WARNING:
If the information in these instructions is
not followed exactly, a fire or explosion
may result causing property damage, personal injury or death.
WARNING:
Improper installation, adjustment, alteration, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional information, consult a qualified installer, service agency, or the gas utility.
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
• Installation and service must be performed by a qualified installer, service
agency or the gas utility.
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier from
a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
WHAT TO DO IF YOU SMELL GAS
GSW Water Heating is a division of
A. O. Smith Enterprises Ltd.
FLAMMABLE VAPOR RESISTANT WATER HEATER
INSTALLATION AND OPERATING INSTRUCTIONS
Read these instructions thoroughly before starting
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This page intentionally left blank. May be used for notes or to record other installation information.
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TABLE OF CONTENTS
I) INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
User Responsibilities 4
II) SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
For Installations in Canada 4
For Installations in the United States 4
Safety Warning (Flammable Vapours) 5
Safety Warning (Scalding) 5
Safety Warning (Carbon Monoxide) 5
Relief Valves (T&P) 5
Backflow Prevention 5
III) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking the Water Heater 6
Location Requirements 6
In Earthquake Zones
Clearances and Accessibility 6
Gas Supply 7
Gas Pressure
Gas line purging
Gas Leak Testing
Air Requirements 9
Confined Space Air Requirements for Canadian
Installations 9
Confined Space Air Requirements for U.S.
Installations 10
Exhaust Venting 11
Vent Pipe System
Drafthood Installation
Water Supply 11
Piping Installation
Closed System/Thermal Expansion
Temperature and Pressure (T&P) Relief Valve 12
The Temperature And Pressure Relief Valve:
The Discharge Line:
Installations Check 13
IV) OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 14
Water Temperature Regulation 14
Temperature Adjustment
Lighting Instructions (Robertshaw 110R) 15
Lighting Instructions (Robertshaw 220R) 16
Lighting Instructions (White-Rodgers 37C) 17
V) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Burner Flames 18
Emergency Shut Down 18
Checking the Draft 18
Operating Conditions 18
Condensation
Water Heater Sounds
Safety Shut-off
Anode/Water Odour
VI) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Draining and Flushing 19
Periodic Inspection 19
External Cleaning of the Flame-arrester 20
Resetting and Replacing the Safety (TCO) Switch20
Temperature and Pressure Relief Valve 20
VII) COMBO HEATING . . . . . . . . . . . . . . . . . . . . . . . . 21
System Requirements 21
VIII) TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 22
IX) REPAIR PARTS ILLUSTRATION . . . . . . . . . . . . . 24
LIMITED WARRANTY. . . . . . . . . . . . . . . . . . . . . . 25
RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE
I) INTRODUCTION
We thank you for choosing a Flammable Vapor
Resistant Water Heater. Your satisfaction with this product
is very important to us. This gas-fired water heater has been
developed to produce domestic hot water and may also be
used in combination with space heating applications. The
Flame Guard
TM
safety system is designed to reduce the risk
of flammable vapor related fires by trapping the burning
vapors within the water heater combustion chamber using
the special flame arrester. The burning vapors literally “burn
themselves out” without escaping back into the room.
User Responsibilities
These instructions have been written for the proper installation, safe operation and maintenance of this water heater. It
is your responsibility to ensure that your water heater is
properly installed and cared for.
FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS
MANUAL MAY RESULT IN SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE. THOROUGHLY READ
ALL INSTRUCTIONS BEFORE YOU ATTEMPT TO
INSTALL, OPERATE OR MAINTAIN THIS HEATER.
Installation and service requires trade knowledge in the
area of plumbing, electricity, venting, air supply and gas
supply. If you lack these skills or do not understand these
instructions, enlist the help of a qualified professional.
The manufacturer of this water heater cannot be held liable
for those damages caused by improper installation, sizing or
failure to comply with these instructions.
Protect your warranty: Regularly maintain your water
heater and venting system as detailed in the “Maintenance”
section of this manual.
II) SAFETY
This water heater is design-certified by CSA International as
a Category I, non-direct vented water heater which takes its
combustion air either from the installation area or from air
ducted to the unit from the outside.
In addition to the installation instructions found in this manual, the heater shall be installed according to all local and
provincial or state codes or, in the absence of such codes,
with the latest edition of the following specifications.
For Installations in Canada
"Natural Gas and Propane Installation Code" CAN/CSAB149.1 and "Canadian Electrical Code (CAN/CSA
C22.1), Part I" available from:
Canadian Standards Association,
5060 Spectrum Way,
Mississauga, Ontario, Canada
L4W 5N6
For Installations in the United States
"National Fuel Gas Code" ANSI Z223.1 (NFPA 54) and
"National Electrical Code" (NFPA 70)" available from:
American National Standards Institute,
25 West 43rd Street,
New York, NY 10036
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing and
Fuel Gas Code 248 CMR Section 2.00 and 5.00.
Check your phone listings for the local authorities having
jurisdiction over your installation.
Important: All supply equipment, installation, approvals,
permits, inspections, etc. are the responsibility of the owner
of this water heater. Consult your local authorities for regulations specific to your area.
Your safety and the safety of others is very important.
We have provided many important safety messages in this manual and on your appliance.
Always read and obey all safety messages.
All safety messages will tell you what the potential hazard is, tell you how to reduce the
chance of injury, and tell you what can happen if the instructions are not followed.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER” or “WARNING”.
DANGER
WARNING
You can be killed or seriously injured if you don’t immediately follow
instructions.
You can be killed or seriously injured if you don’t follow instructions.
WARNING
Service to the Flame GuardTMsafety system
should only be performed by a qualified
service technician.
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Safety Warning (Flammable Vapours)
There is a risk in using fuel-burning appliances such as
water heaters. Areas that may not be suitable for water
heater installation include those where flammable liquids,
gasoline, solvents, adhesives, etc., or engine-driven equipment or vehicles are stored, operated or repaired. Due to
the nature of air movement, flammable vapors can be carried some distance from the point of storage. The gas-fired
water heater igniter or main burner flame can ignite these
vapors causing a flashback, fire or explosion which may
result in serious personal injury or death, as well as severe
property damage.
Safety Warning (Scalding)
Hot water produced by this appliance can cause severe
burns due to scalding. The hazard is increased for young
children, the aged or the disabled where water temperatures exceed 52°C (125°F). Use tempering valves (see
Figure 11), in the hot water system to reduce the risk of
scalding at point-of-use such as lavatories, sinks and
bathing facilities. Such precautions must be followed when
this heater is operated in combination with dishwashing or
space heating applications.
Safety Warning (Carbon Monoxide)
As with all fuel burning equipment, this heater requires an
adequate supply of air for combustion and ventilation. An
insufficient air supply can result in poor combustion or the
re-circulation of the exhaust flue gases. Such a condition
can cause soot build-up or present a fire hazard, and may
result in serious bodily harm or death from asphyxiation.
MAKE SURE THE FLOW OF COMBUSTION AND VENTILATION AIR IS NOT RESTRICTED.
Relief Valves (T&P)
All water heaters must be installed with a proper temperature and pressure relief valve. These valves must be certified as meeting the requirements of the “Standard for
Temperature, Pressure, Temperature and Pressure
Relief and Vacuum Relief” CSA 4.4 in Canada. In the
United States “Relief Valves and Automatic Gas Shut-Off
Devices for Hot Water Supply Systems”, ANSI Z21.22 is
applicable.
If this water heater has been exposed to flooding, freezing,
fire or any unusual condition, do not put it into operation until
it has been inspected and approved by a qualified professional. THESE CONDITIONS CAN RESULT IN UNSEEN
INTERNAL DAMAGE which is not subject to warranty coverage.
Backflow Prevention
Certain jurisdictions may require the installation of a backflow device (e.g., check valve) in the water supply line. Such
a device will require the use of a system expansion tank of
adequate size to control the thermal expansion generated
during the heating cycle. Consult your water supplier or
local plumbing authority.
Important: The supply water meter may have a built-in
check valve device. Contact your local water authority.
WARNING
Flammable Vapours
FLAMMABLES
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other flammable vapours and liquids
in the vicinity of this or any other appliance. Storage of or use of gasoline
or other flammable vapours or liquids in the vicinity of this or any other
appliance can result in serious injury or death.
DANGER
DANGER
Carbon Monoxide Warning
• Follow all vent system requirements by
the local authorities having jurisdiction
over your installation.
• Failure to do so can result in death, explosion or carbon monoxide poisoning.
CAUTION
Hydrogen gas can be produced in a hot water system
served by this heater that has not been used for a long
period of time (generally two (2) weeks or more).
Hydrogen gas is extremely flammable and can ignite
when exposed to a spark or flame. To reduce the risk of
injury under these conditions, it is recommended that the
hot water faucet be opened for several minutes at the
kitchen sink before using any electrical appliance connected 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.
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III) INSTALLATION
Unpacking the Water Heater
Important: Do not remove any permanent instructions,
labels or the rating plate from the outside of the water heater
or on the inside of panels.
1. Move the water heater to the location of installation
before removing the exterior packaging.
2. Remove exterior packaging and place installation components aside.
3. Inspect all parts for damage prior to installation and
start-up.
4. Completely read and understand all instructions before
attempting to assemble and install this product.
If you observe damage to the water heater or any of its components, DO NOT ASSEMBLE OR INSTALL IT OR MAKE
ANY ATTEMPT TO FIX THE DAMAGED PART(S). Contact
the place of purchase for further instructions.
5. After installation, dispose of packaging material in the
proper manner.
Location Requirements
Note: Before installing this water heater, consideration and
planning must be given to the following details:
•
Location and Clearances.
•
Access for gas supply; See “Gas Supply”.
•
How and where to obtain combustion and ventilation air
supply; See “Air Requirements”.
•
Routing and support of the vent piping.
•
Position of water supply and placement of water piping
for hot and cold water; See “Water Supply”.
•
Floor drain and service.
In Earthquake Zones
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area.
Note: REVIEW SAFETY WARNINGS FOUND IN THE
FRONT OF THIS MANUAL BEFORE PROCEEDING
Clearances and Accessibility
Specific clearance locations are shown in Figure 3. A minimum of 600mm (24 in.) of front clearance shall be provided
for inspection and service. We recommend that 0.9m (36
in.) above be maintained for serviceability.
Locate the water heater such that all controls are easily
accessible.
Clearance to combustibles varies by model. Refer to rating
plate to confirm clearances.
Heaters with a volume of 19 gallons through 50 gallons and
60 gallon (standard input) must have the following minimum
clearances to combustibles:
Front 102mm (4 in.)
Sides and Rear 25mm (1 in.)
Top 203mm (8 in.)
Flue 152mm (6 in.)
JW6058 and G6058 (high input) series heaters must have
the following minimum clearances to combustibles:
Front 127mm (5 in.)
Sides and Rear 25mm (1 in.)
Top 203mm (8 in.)
Flue 152mm (6 in.)
WARNING
Excessive Weight Hazard
Use two or more people to move and install
water heater. Failure to do so can result in
back or other injury.
IMPORTANT:
This water heater must be installed strictly in accordance
with the instructions enclosed, and local electrical, fuel
and building codes. It is possible that connections to the
water heater, or the water heater itself, may develop
leaks. IT IS THEREFORE IMPERATIVE that the water
heater be installed so that any leakage of the tank or related water piping is directed to an adequate drain in such a
manner that it cannot damage the building, furniture, floor
covering, adjacent areas, lower floors of the structure or
other property subject to water damage. This is particularly important if the water heater is installed in a multi-story
building, on finished flooring or carpeted surfaces. GSW
WILL NOT ASSUME ANY LIABILITY for damage caused
by water leaking from the water heater, pressure relief
valve, or related fittings. Select a location as centralized
within the piping system as possible. In any location
selected, it is recommended that a suitable drain pan be
installed under the water heater. This pan must limit the
water level to a MAXIMUM depth of 45mm (1 3/4 in.) and
have a diameter that is a minimum of 50mm (2 in.) greater
than the diameter of the water heater. Suitable piping shall
connect the drain pan to a properly operating floor drain.
When used with a fuel-fired heater, this drain pan must not
restrict combustion air flow.
45mm
(1 3/4 in.)
MAX
AT LEAST 50mm (2 in.)
GREATER THAN THE
DIAMETER OF THE
WATER HEATER.
PIPE TO
ADEQUATE
DRAIN
Figure 1 Typical Drain Pan Installation
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The 60 gallon heater is equipped with a Heat Reflector
Shield (see Figure 2). This Shield reflects heat from the
High-input heaters to prevent damage to combustible floors.
The Shield is held in place by three (3) tabs that rest on the
inside of the legs of the water heater. Ensure the Shield is
positioned horizontally (parallel to the bottom of the heater)
and in the designated position of 38mm (1.5 in.) below the
flame-arrester.
The water heater shall be located in an area not subject to
freezing temperatures. Water heaters located in unconditioned spaces (e.g., attics, basements, etc.) may require
insulation of the water and drain piping to protect against
freezing. Proper ventilation needs to be provided for water
heaters installed in unconditioned spaces (e.g., attics, basements, etc.) in order to avoid an event where air temperature exceeds 42°C (108°F). The drain and controls must be
easily accessible for operation and service. Maintain proper
clearances as specified on the data plate.
Ensure that the water heater is level. This heater may be
installed in a closet or alcove and is certified for operation
on a combustible floor.
Do not locate the water heater near an air-moving device.
The operation of air-moving devices such as exhaust fans,
ventilation systems, clothes dryers, fireplaces, etc., can
affect the proper operation of the water heater. Special
attention must be given to conditions these devices may
create. Flow reversal of flue gases may cause an increase
of carbon monoxide inside of the dwelling, as shown in
Figure 7.
If the water heater is located in an area that is subject to an
excessive amount of lint, dirt or oil, it may be necessary to
clean the flame arrester periodically (see “Maintenance”
section).
Important: It is always recommended that a suitable drain
pan be installed under the water heater to protect the area
from water damage resulting from normal condensation, a
leaking tank or piping connections. Refer to Figure 1. Under
no circumstances is the manufacturer to be held responsible for any water damage in connection with this water
heater.
Gas Supply
Install the gas piping as shown in Figure 4. Use only new
pipe and fittings with clean-cut threads. Sealing compounds
used on the pipe threads shall be approved for use with natural and propane gas.
Use gas piping of adequate sizing to ensure gas input. Gas
piping material must be approved for use with natural gas
and propane fuels. All piping must comply with all local
codes or, in the absence of such codes, with the latest edition of “Natural Gas and Propane Installation Code”
CAN/CSA-B149.1 in Canada, “National Fuel Gas Code”
ANSI Z223.1 (NFPA 54) in the U.S.A. The final connection
to the water heater is made using 1/2” NPT.
Before connecting to the gas service, check that a properly
sized gas meter and regulator are available to service the
water heater. If other appliances are using the same meter
and regulator, ensure that the capacity of the meter and regulator matches that of the combined input of all appliances
connected to it.
DO NOT tamper with the gas control/thermostat, igniter,
thermocouple, or temperature and pressure relief valve.
Tampering voids all warranties. Only a qualified service
technician should service these components.
WARNING
Do not install directly on carpet. Instead, place the
water heater on a metal or wood panel extending a
minimum of 75mm (3 in.) from all sides. In alcoves or
closets, cover the carpet completely. Ensure this
panel is capable of supporting the weight of this
heater when filled with water.
FAILURE TO PROPERLY INSTALL THIS HEATER MAY
RESULT IN A FIRE HAZARD.
Figure 3 Minimum Clearance Locations
AIR INTAKE
VENT
FRONT 600mm
(24 in.) MIN.
FOR SERVICE
BACK 25mm (1 in.)
SIDES
25mm
(1 in.)
SIDES AND
BACK 25mm
(1 in.)
TOP TO CEILING
200mm (8 in.)
Figure 2 Heat Shield Installation (60 gallon only)
HEAT SHIELD
FLAME
ARRESTER
DRAIN
VALV E
LEG
BOTTOM
PAN
Figure 4 Recommended Gas Piping
GROUND-
JOINT UNION
MANUAL
GAS
SHUT-OFF
GAS CONTROL/THERMOSTAT
75mm (3 in.)
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Gas Pressure
GSW Water Heating Company recommends that the gas
supply pressure, as measured on the inlet side of the water
heater control, be set at 7.0 in. w.c.(1.7 kPa) for natural gas
and 11.0 in. w.c. (2.7 kPa) for propane gas. The above pressures must be measured during water heater operation. The
gas control supplied with this water heater is designed for a
maximum inlet pressure of 0.5 psi (14 in. w.c.). Do not
exceed 0.5 psi (14 in. w.c.). The Flame Guard
TM
safety system is designed to operate at a manifold pressure of 5.0 in.
w.c. (1.2 kPa) for natural gas and 10.0 in. w.c. (2.4 kPa) for
propane gas.
Gas line purging
Gas line purging is required to eliminate air from the piping
system. Purging should be performed by persons experienced in this type of gas service in compliance with the
code having jurisdiction. Do not purge in confined areas or
space where ignition may occur. To avoid risk of fire or
explosion ensure the area is well ventilated and all sources
of ignition are de-activated. Contact your local gas authority
for local requirements.
Gas Leak Testing
Important: This water heater and its gas connection must
be tested for leaks before placing the appliance in operation. Perform a leak test at normal gas pressure. If the applicable code(s) require the gas lines to be tested at a pressure of 14 in. w.c. (3.5 kPa) or greater, the water heater and
its manual shut-off valve must be disconnected from the gas
supply piping system and the line capped. Test all connections of the gas system with a chloride-free soap and water
solution or equivalent leak test liquid. Bubbles will indicate
leaks. Never use a match or open flame to test for gas
leaks. A fire or explosion could result. If leaks exist repair as
required and retest.
DO NOT light the burner before the tank is filled with water
and you have confirmed that there are no leaks in the piping and connections.
– 8 –
WARNING
Exposure to a higher gas supply pressure
may cause damage to the control, resulting
in explosion or fire. Consult your local gas
supplier and gas authorities. DO NOT PUT
INTO SERVICE IF OVER-PRESSURIZATION
HAS OCCURRED.
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