John Wood Commercial AJWS User Manual

GSW WATER HEATING

599 Hill Street West Fergus, ON, Canada N1M 2X1

To obtain technical, warranty or service assistance during or after the installation of this water heater, call toll free:

1-888-479-8324

When calling for assistance, please have the following information ready:

1. Model number

2. 5 digit product number

3. Serial number

4. Date of installation

5. Place of purchase

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Commercial Gas

Water Heater

Installation

Instructions and

Use & Care Guide

for Signature Series models with prefix JWS and AJWS

70305 REV.C (06-01)

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 vapours and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

GSW Water Heating is a division of GSW Water Products Inc.

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.

Important Instructions

• Do not use this appliance if any part has been under water. Immediately call a qualified service technician. Water heaters subjected to flood conditions or anytime the gas controls, main burner or electrical components have been submerged in water require replacement of the entire water heater.

• 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. When hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. There should be no smoking or open flame near the faucet at the time it is open.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause Cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon monoxide, and soot.

Table of Contents

Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Combustion Air Supply and Ventilation . . . . . . . . . . . . . . . . . . . . . . 5-8

Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Gas Supply and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operating Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19

Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . 20-21

Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

INSTALLATION INSTRUCTIONS Consumer Information

This water heater is design-certified by CSAInternational 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.

This water heater must be installed according to all local and state codes, or in the absence of local and state codes, with the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1. This is available from the following:

American Gas Association 1515 Wilson Boulevard Arlington, VA 22209

National Fire Protection Agency 1 Batterymarch Park Quincy, MA 02269

Canadian Standards Association 5060 Spectrum Way Mississauga, ON L4W 5N6

Check the phone listings for the local authorities having jurisdiction over this installation.

Installer and Owner Responsibilities

This manual has been prepared to acquaint you with the installation, operation and maintenance of this gas water heater and provide important safety information in these areas.

Read all of the instructions thoroughly before attempting the installation or operation of this water heater . Keep this manual for future reference.

Do not discard this manual. You or future users of this water heater will need it for future reference. The manufacturer and seller of this water heater will not be liable for any damages, injuries or deaths caused by failure to comply with the inst

allation and operating instructions

outlined in this manual.

The manufacturer of this water heater recommends that it be professionally installed by qualified service technicians. Examples of qualified service technicians include: those trained in the plumbing and heating industry, local gas utility personnel or an authorized service person.

Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Sections 2.00 and 5.00.

A data plate identifying this water heater can be found on

the front of the water heater. When referring to this water heater always have the information listed on the data plate readily available.

Retain your original receipt as proof of purchase.

Unpacking the Water Heater

Removing Packaging Materials

Important: Do not remove any permanent instructions, labels, or the data label from outside of the water heater or on the inside of panels.

• Remove exterior packaging and place installation components aside.

• Inspect all parts for damage prior to installation and startup.

• Completely read all instructions before attempting to assemble and install this product.

• After installation, dispose of packaging material in the proper manner.

Installation Requirements

The water heater must be installed according to all local and state codes, or in the absence of local and state codes, the "National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1.

Note: In the State of California, the water heater must be braced, anchored, or strapped to avoid moving during an earthquake. Contact local utilities for code requirements in your area or call 1-888-479-8324 and request instructions.

Site Location

• Select a location near the center of the water piping system. The water heater must be installed indoors and in a vertical position on a level surface. DO NOT install in bathrooms, bedrooms, or any occupied room normally kept closed.

• Locate the water heater as close to the gas vent as practical. Consider the vent system piping and combustion air supply requirements when selecting the water heater location. The venting system must be able to run from the water heater to termination with minimal length and elbows.

• Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows.

• The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e. attics, basements, etc.) may

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.

WARNING

require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper clearances as specified on the data plate.

• The operation of air-moving devices such as exhaust fans, ventilation systems, clothes-dryers, fire-places, etc., can affect the proper operation of the water heater. Note: Special attention must be given to the location of these devices and the conditions they may create. Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling.

Important: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation (but not limited to the following) will require outdoor air for combustion due to chemical exposure, and may reduce but not eliminate the presence of corrosive chemicals in the air:

• Beauty shops

• Photo processing labs

• Buildings with indoor pools

• Water heaters installed in laundry, hobby or craft rooms

• Water heaters installed near chemical storage areas

Clearances and Accessibility

Notice: Minimum clearances from combustible materials are stated on the data plate located on the front of the water heater.

• If the water heater is installed in a restaurant or food service location where the floor is cleaned frequently, NSF International requires the water heater to maintain 152mm (6 in) of clearance above the floor. To comply with the NSF International requirement, install leg extension kit. For availability contact 1-888-479-8324

• The water heater is certified for installation on a combustible floor.

Vapours from flammable liquids will explode and catch fire causing death or

severe burns.

Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater.

Keep flammable products:

1. far away from heater;

2. in approved containers;

3. tightly closed; and

4. out of children’s reach.

This water heater has a main burner and an automatic ignition system. The ignition system:

1. can come on at any time; and

2. will ignite flammable vapours.

Vapours:

1. cannot be seen;

2. are heavier than air;

3. go a long way on the floor; and

4. can be carried from other rooms to the water heater by air currents.

Do not install this water heater where flammable products will be stored.

WARNING

FLAMMABLE VAPOURS

Important:

The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the

water, the tank will eventually leak after an extended period of time. A suitable metal drain pan should be

installed under the water heater as shown below, to help protect the property from damage which may occur from leaks in the piping connections or tank. The pan must limit the water level to a maximum depth of 45mm (1 3/4 in) and be 50mm (2 in) wider than the water heater and piped to an adequate drain. The pan must not restrict combustion airflow. Locate the water heater near a suitable indoor drain. Outside drains are subject to freezing temperatures which can obstruct the drain line. The piping should be at least 19mm (3/4 in) ID and pitched for proper drainage. Under no circumstances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to follow these instructions.

FLAMMABLES

1 3/4” Max

Pipe to

adequate

drain

At least 2” greater than the diameter of the w ater heater

Pipe to

adequate

drain

45mm max. (1¾ in)

At least 50mm (2 in) greater than the diameter of the water heater.

Important: If installing over carpeting, the carpeting must be protected by a metal or wood panel beneath the water heater. The protective panel must extend beyond the full width and depth of the water heater by at least 76mm (3 in) in any direction, or if in an alcove the entire floor must be covered by the panel. The panel must be strong enough to carry the weight of the water heater when full of water.

Figure 1 may be used as a reference guide to locate the specific clearance locations. Aminimum of 610mm (24 in) of front clearance and 102mm (4 in) on each side should be provided for inspection and service.

COMBUSTION/VENT PIPE SYSTEM

Combustion

Combustion air must be free of acid-forming chemicals. These chemicals are found in aerosol sprays, detergents, bleaches, cleaning solvents, air freshener , paint and varnish removers, refrigerant, and many other commercial products. When burned, vapours from these products form highly corrosive acid compounds. These products should not be stored or used near the water heater or air inlet.

Venting

Vent pipe inst allation must be installed according to all state and local codes, or in the absence of local and state codes, the National Fuel Gas Code, NFPA 54, ANSI Z223.1-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1.

It is the responsibility of the installing contractor to provide a vent adequate in capacity and in good usable condition. Btu/hr capacity limitations are governed by the style and height of the vent/chimney. For installations in the United States, capacity tables are available in the National Fuel Gas Code (ANSI Z223.1- latest edition). Canadian installation information can be found in CAN/CSA-B149.1

• Venting should be as direct as possible with a minimum number of pipe fittings.

Vent

Top to ceiling

Sides

Front 24” min. for service

Sides

Back

Top View

Front View

Figure 1: Minimum Clearance Locations

Carbon Monoxide Hazard Follow all instructions to locate and install the vent pipe system. Instructions can be found in this manual, in state or local codes (or authority having jurisdiction), or in the absence of such, the National Fuel Gas Code, ANSI Z223.1, NFPA 54, latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1 Failure to properly locate and install the vent pipe system can result in death, explosion, or carbon monoxide poisoning.

WARNING

Front 610mm (24 in) min. for service

• Exhaust gas vents must be installed with U.L.listed type B vent pipe according to the vent manufacturer’s instructions and the terms of its listing.

• Single wall vent connectors must have 152mm (6 in) of clearance from unprotected combustible surfaces.

• If sidewall venting is necessary, a power vent kit is required. For availability contact 1-888-479-8324.

• Vents that run through unconditioned spaces where below freezing temperatures are expected should be properly insulated to prevent freezing.

• Existing vent systems must be inspected for obstructions, corrosion and proper installation.

• Vents must be connected to the water heater’s drafthood by a certified vent connector or by directly originating at the drafthood opening.

• Some models are shipped with a vent reducer. The vent reducer can be installed directly to the drafthood if the existing vent system is adequately sized to support the exhaust gases.

• Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer’s instructions.

• Horizontal vent connections must have an upward slope of at least 21mm per metre (1/4 in per foot).

• Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials.

• Vent connection joints should be fastened by sheet metal screws or by other approved methods.

• Vent and vent connectors should have adequate support to keep weight off the drafthood.

All pipe, fittings, and procedures must conform to American National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) standards in the United States. Important: If you lack the necessary skills required to properly install this venting system, you should not proceed, but get help from a qualified service technician.

Air Requirements

General

Where an exhaust fan or any other air consuming appliance (Eg. Clothes dryer, furnace, etc.) is installed in the same space as the water heater, sufficient air openings must be available to provide fresh air when all appliances are oper-

ating simultaneously. The area in which the heater is located is classified as either “an unconfined space” or “a confined space”. An unconfined sp

ace is defined as a sp ace having a volume not less than 50 cubic feet per 1000 BTU/hour (4.8 cubic meters per kilowatt) of combined input rating of all appliances using the space. Adjacent open rooms may be included as part of the unconfined space. There shall be no closeable doors between these rooms. An example of this is an open basement. A confined sp

ace is one smaller than described above. Air shall be supplied through permanent openings as described in Figure 2. At no time shall an air opening have a dimen- sion of less than 76mm (3 in) and at no time shall any top opening be lower than the top of the water heater.

For buildings that are not well sealed (do not have tight fitting doors and windows) natural air infiltration may provide sufficient air required for combustion and ventilation. For buildings using tight construction (newer and renovated structures), the air supply shall be introduced from the outdoors, regardless of whether the space is confined or unconfined.

Combustion Air “Supply” Ducts

Air supply ducts shall be of galvanized steel or equivalent corrosion resistant material. A single air duct may not be substituted when required for upper and lower air openings. Horizontal upper combustion air ducts shall not slope downward toward the air inlet.

Louvers and Grills

Openings for air supply ducts must provide free unobstructed air movement. Louver and grill openings must be sized to ensure that the FREE OPEN AREAis never less than the area of the air duct.

LOCATION:

The location for top and bottom openings are as follows; For U.S. installations: The top opening shall commence within 305mm (12 in) of the top of space and the bottom opening shall commence within 305mm (12 in) of the bottom of the enclosure. For Canadian installations: The top opening shall be located as close to the ceiling as practical but never lower than the relief opening of the lowest draft control device. The bottom opening shall be located neither more than 457mm (18 in), nor less than 152mm (6 in), above floor level.

An adequate air supply shall be provided for combustion and ventilation of this water heater. An insufficient supply can result in poor combustion and possible sooting of the burner, combustion chamber, or flue passageway. This may present a potential fire hazard or create a serious health hazard by producing carbon monoxide.

WARNING

Air Opening Requirements

(a) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM INSIDE THE BUILDING.

Two permanent openings (top and bottom) shall be provided connecting the confined space (e.g., closet/small room) with the unconfined space. Each opening shall have a free area of one square inch per 1,000 BTU/hour (22 cm²/kW) input of all appliances in the confined space, but not less than 100 square inches (645 cm²).

(b) BASEMENT INST ALLATION, EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS.

Outside air inlets shall be a minimum of 305mm (12 in) above the grade (snow) line. When supplying air directly from the outdoors: For American installations: Two openings (top and bottom) shall be provided with each opening having a minimum free area of one square inch per 4,000 BTU/hour input (5.5 cm²/kW) of total input rating of all appliances in the confined space. For Canadian installations: Canadian codes specify single air supply source. Canadian customers and authorities having jurisdiction may use the sizing listed in Table 1. When using a single air supply, the duct shall terminate within 305mm (12 in) above and within 610mm (24 in) horizontally from the burner level of the appliance having the largest input.

(c) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS. For American installations: When supplying air directly from the out-

doors using horizontal ducting, each opening shall have a free minimum area of one square inch per 2,000 BTU/hour (11 cm²/kW) of total input rating of all appliances in the confined space.

For Canadian installations: Refer to Table 1 of part (b). (d) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM

OUTDOORS THROUGH VENTILATED ATTIC. For American installations: When supplying air directly through vertical

ducting, each opening shall have a free minimum area of one square inch per 4,000 BTU/hour (5.5 cm²/kW) of total input rating of all appliances in the confined space.

Combustion

Air Duct

Permanent

Ventilation

Air

12” Grade

12”

Outdoor

Air Ducts

Venting

Combustion

Inlet

Air Ducts

Outlet Air

(a)

(b)

(d)

(c)

Figure 2: Equipment Location and

Combustion/Ventilation Air Requirements

*U.S. installations require a dual duct system.

BTU/h (kW) mm2 (in2) mm (in) mm (in)

75,000 (23) 7,000 (11) 100 (4) 125 (5) 100,000 (30) 9,000 (14) 100 (4) 125 (5) 125,000 (37) 12,000 (18) 125 (5) 150 (6) 150,000 (45) 14,000 (22) 125 (5) 150 (6) 175,000 (53) 16,000 (25) 150 (6) 175 (7) 200,000 (60) 19,000 (29) 150 (6) 175 (7) 225,000 (68) 21,000 (32) 150 (6) 175 (7) 250,000 (75) 23,000 (36) 175 (7) 200 (8) 275,000 (83) 26,000 (40) 175 (7) 200 (8) 300,000 (90) 28,000 (43) 175 (7) 200 (8) 325,000 (98) 30,000 (47) 200 (8) 225 (9)

350,000 (105) 32,000 (50) 200 (8) 225 (9) 375,000 (113) 35,000 (54) 200 (8) 225 (9) 400,000 (120) 37,000 (58) 225 (9) 250 (10)

Combined input of

all appliances in

conf ined space

Required free

area of duct

Acceptable equivalent

duct diameter

Table 1

Notes:

1. Maximum length of ducts in column Ais 6.1 equivalent metres (20 ft).

2. Maximum length of ducts in column B is 15.2 equivalent metres (50 ft).

305mm (12 in)

Drafthood/Damper Installation

Install the supplied drafthood and damper on the flue outlet collar. Use only the supplied drafthood and damper, DO NOT use any substitute or alter the components in any way. Place the damper on the water heater (see figure 3A). Align the four pilot holes on top of the water heater with the 4 corresponding holes on the damper bracket and secure with the supplied screws. Next, align the drafthood legs with the 4 corresponding pilot holes on top of the water heater and attach securely with the supplied screws. Locate the wiring from the ECO, and attach it to the wiring harness on the damper (see Figure 3A). Once damper is installed, ensure that the damper position indicator is visible (See figure 3A).

Flue Outlet Reducer

Some units are shipped with a flue outlet reducer (See Figure 3B). Use only the flue outlet reducer supplied with this unit. The flue outlet reducer should be connected to the top of the flue damper and sealed by high temperature silicon. The vent pipe must be installed according to all local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA54)-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1.

WATER SYSTEM PIPING Piping Installation

Piping, fittings, and valves should be installed according to the installation drawing (Figure 4). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the working pressure of the water heater. The working pressure is stated on the water heater’s data plate. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line to the entire system. This should be placed on the supply to the entire structure in order to maintain equal hot and cold water pressures. Note: Water supplied to the unit that exceeds 12 grains (205 mg/l) total hardness may reduce the life and performance of the water heater. Depending on the degree of hardness, it is recommended that either a water pre-treatment system or a water softener be installed and properly maintained. Important: Heat cannot be applied to the water fittings on the water 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.

1. The water heater may have three water piping connection points. The top and front are 1 - 1/2” NPT and the connections on the back of some heaters are 2” NPT. When using front or back connections a combination nipple inlet tube is required (top entry uses a dip tube). Any one of the options listed in Table 5 may be used.

For availability contact 1-888-479-8324.

Do not operate heater with damper in closed position, it must be in the open position during water heater operation. Do not negate the action of any existing safety or operational controls.

WARNING

Bracket screws

Draft hood screws

Draft hood

Damper motor

Damper wiring harness

ECO wiring harness

Damper in OPEN position

Damper wiring harness

Damper motor

Damper position indicator

Figure 3A: Flue Damper Assembly

Damper in OPEN position

Damper wiring harness

Damper motor

Flue outlet reducer

High temperature silicon sealant

Figure 3B: Flue Outlet Reducer

Note: Inlet and outlet piping connections cannot be mixed.

For example, a top inlet connection must use a top outlet connection.

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. Since most commercial installations utilize higher temperatures, the use of a tempering valve is strongly

recommended in all domestic hot water lines (i.e. public restroom sinks, etc).

4. If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under “Closed System/Thermal Expansion” (Page

12).

5. 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.

6. The water heater is shipped with a factory-installed Temperature and Pressure Relief Valve. Install a discharge line in the opening in the T & P valve (see instructions on Page 13).

7. 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 and check all connections for leaks.

Space Heating

If this unit is to be used to supply both space heating and domestic potable (drinking) water then the following instructions must be followed:

1. All piping and components used must be suitable for use with domestic (potable) drinking water.

2. Do not use piping or components that have been connected to a nonpotable system or treated with chromates or other toxic chemicals. Do not add any chemicals to the water heater piping.

3. If system requires temperatures in excess of 49°C (120°F) install a tempering valve, per the manufacturers instructions, in the domestic (potable) hot water line to limit the risk of scalding (See Figure 5).

4. Be sure to follow the manual(s) shipped with the heating system. Also follow any state or local codes.

Tempering Valve Installation

A Tempering Valve should be installed per the manufacturer’s instructions in the hot water line. See Figure 5 for sample tempering valve installation.

Please note the following: DO NOT install this water heater with iron piping. The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene.DO NOT use PVC water piping. DO NOT use any pumps, valves, or fittings that are not compatible with potable water. DO NOT use valves that may cause excessive restriction to water flow. Use full flow ball or gate valves only. DO NOT use 50/50 tin-lead solder (or any lead based solder) in potable water lines. Use 95/5 tin-antimony or other equivalent material. DO NOT tamper with the gas valve/thermostat, igniter, or temperature and pressure relief valve. Tampering voids all warranties. Only qualified service technicians should service these components. DO NOT use with piping that has been treated with chromates, boiler seal, or other chemicals. DO NOT add any chemicals to the system piping which will contaminate the potable water supply.

Follow the tempe r in g valve manufacturer’s instructions.

Cold

Water

Inlet

Hot Water Outlet

Tempered water to fixtures

Tempering valve (Set to 120°F)

Figure 5: Tempering Valve

Water Heater

Model B ase #

Dip Tube

Inlet Tube

(Optional F ront )

Inlet Tube

(Optional Bac k )

75-125 60238 60239 60239 80-199 60053 60057 60057

80-250 60053 60057 60057 100-199 71325 75085 75086 100-270 71325 75085 60023

75-300 60053 60057 60057

75-360 N/A 60194 60195

75-399 N/A 60194 60195

75-300NO

x N/A 60194 60195

75-350NO

x N/A 60194 60195

Table 5: Dip Tube Useage

Hot Water Outlet

Unions

Cold Water Inlet Valve

Discharge line 6” max. above drain

Cold Water Supply to Fixtures

In a closed system use a Thermal Expa nsion Tank

Temperature and Pressure Relief Valve

Drain line 3/4” ID min.

Drain

Metal drain pan 1 3/4” depth max.

Pressure Reducing Valve with Bypass

Main Water Supply

Figure 4: Water Piping Installation

Massachusetts: Install a vacuum relief in cold water line per section 19MGL 142

Drain line 19mm (3/4 in) ID min.

Discharge line 152mm (6 in) max. above

drain Metal drain pan 45mm (1-3/4 in.) depth max.

Thermometer

Temperature and Pressure Relief Valve

Hot Water to Fixtures

Temperature and Pressure Relief Valve

Typical Booster Heater

Pre-Heater

Pre-Heated Water to the Booster

Outlet Boosted Temperature

1 1/2” Cold water supply

Thermal Expansion Tank

Pressure Reducing Valve

Thermometer

Shut-off valve

Check Valve

Shut-off valve

Figure 6: Commercial Unit with Auxiliary Booster Heater - Two Temperature (With or Without Building Recirculation)

Note:Install a vacuum

relief valve if required by local codes.

Thermometer

Temperature and Pressure Relief Valve

Storage Tank

Heater

1 1/2” Cold water supply

Hot Water Outlet

Thermal Expansion Tank

Pressure Reducing Valve

Check Valve

Circulating Pump

Plug Cock

Shut-off valve

Figure 7: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation

- Front Inlet/Outlet Connections

Note:Install a vacuum relief valve if required by local codes.

45mm (1 1/2 in) Cold water supply

Closed System/Ther mal Expansion

Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system. The water utility supply meter may contain a check valve, backflow preventer or water pressure reducing valve. This will create a closed water system. During the heating cycle of the water heater, the water expands causing pressure inside the water heater to increase. This may cause the temperature and pressure relief valve to discharge small quantities of hot water. To prevent this, it is recommended that a diaphragm-type expansion tank (suitable for potable water) be installed on the cold water supply line. The expansion tank must be properly sized for the application. Contact the local water supplier or plumbing inspector for information on other methods to control this situation.

Important: Do not plug or remove the temperature and pressure relief valve.

1 1/2” Cold water supply

Pressure Reducing Valve

Thermometer

Temperature and Pressure Relief Valve

Hot Water to Fixtures

Pre-Heater

Pre-Heated Water to the Booster

Outlet Boosted Temperature

Temperature and Pressure Relief V alve

Typical Booster Heater

Shut-off valve

Thermometer

Thermal Expansion Tank

Shut-off valve

Check valve

Figure 8: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without Building Recirculation

- Top Inlet/Outlet Connections

Note:Install a vacuum relief valve if required by local codes.

45mm (1 1/2 in) Cold water supply

Temper ature and Pressur e Relief Valve

For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF VALVE” (See Figure 9). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22. (CSA4.4, Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves in Canada). The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve's relief pressure must not exceed the working pressure of the water heater as stated on the data plate. Important: Only a new temperature and pressure relief valve should be used with this water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any valve or piping between the relief valve and the tank.

The Temperature & Pressure Relief Valve:

• Must not be in contact with any electrical part.

• Must be connected to an adequate discharge line.

• Must not be rated higher than the working pressure shown on the data plate of the water heater.

• The BTUH rating of the T & P valve must be greater than, or equal to, the input rating of the water heater.

The Discharge Line:

• Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line.

• Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line.

• Must terminate a maximum of 152mm (6 in) above a floor drain or external to the building.

• Must be capable of withstanding 121°C (250°F) without distortion.

• Must be installed to allow complete drainage of both the valve and discharge line.

GAS SUPPLY AND PIPING

Gas Requirements

Read the data plate to be sure the water heater is made for the type of gas being used. This information will be found on the data plate located on the front of the water heater. If the information does not agree with the type of gas available, do not install or operate the water heater. Call your dealer. Note: An odourant may be added by the gas supplier to the gas used by this water heater. This odourant may fade over an extended period of time. Do not depend upon this odourant as an indication of leaking gas.

Gas Piping

The gas piping must be installed according to all local and state codes, or in absence of local and state codes, with the “National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1. Note: If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater. Tables 2, 3A, and 3B on page 15 provide a sizing reference for commonly used gas pipe materials. Consult the

Figure 9: T&P Relief Valve

Explosion Hazard Use a new AGA or CSA approved gas supply line. Install a shut-off valve. Do not connect a natural gas water heater to a L.P. gas supply. Do not connect a L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.

WARNING

Explosion Hazard

If the temperature and pressure relief valve is dripping or leaking, have a qualified service technician replace it. Do not plug valve. Do not remove valve. Failure to follow these instructions can result in death, or explosion.

WARNING

Discharge line 152mm (6 in) above drain.

Drain line 19mm (3/4 in) min.

“National Fuel Gas Code” or “Natural Gas and Propane Installation Code” for the recommended gas pipe size of other materials. Follow the instructions below and reference Figure 10 for gas piping installation.

1. Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local utility. Know the location of this valve and how to turn off the gas to this unit.

2. Install a drip leg as shown. The drip leg must be no less than 76mm (3 in) long for the accumulation of dirt,foreign material and water droplets.

3. Install a ground joint union between the water heater and the manual shut-off valve. This is to allow easy servicing.

4. Turn the gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method.

Gas Pressure

Important: The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater’s data plate. Minimum supply pressure should also be maintained per the data plate.

Gas Pressure Testing

Important: This water heater and its gas connection must be leak tested before placing the appliance in operation.

• If the code requires the gas lines to be tested at a pres-

sure of 14 inches water column or greater, the water heater and its manual shut-off valve must be discon- nected from the gas supply piping system and the line capped.

• If the gas lines are to be tested at a pressure less than 14 inches water column, the water heater must be iso- lated from the gas supply piping system by closing its manual shut-off valve.

U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be installed using the manufacturer’s instructions and local codes, rules, or regulations. Note: Air may be present in the gas lines and could prevent the burner from lighting on initial start-up. The gas lines should be purged of air by a qualified service technician after installation of the gas piping system.

Explosion Hazard Have a qualified service technician make sure L.P. gas pressure does not exceed 13 inches water column. Failure to do so can result in death, explosion, or fire.

WARNING

Drip leg

Check with local utility for min. height

Ground

Joint

Union

Manual Gas Shut-off Valve

Figure 10: Gas Piping

L.P. Ga s Capa city

Si ze, (i n ) 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 n/a n/a n/a n/a n/a n/a n/a n/a n/a 3/4 576 393 315 267 237 217 196 185 173 162 146 132

1 1071 732 590 504 448 409 378 346 322 307 275 252

1-1/4 2205 1496 1212 1039 913 834 771 724 677 630 567 511 Max i m um capac i ty of gas pipe i n thous ands of BTU per hour of undi l uted li qui fied pet rol eum gass es (at 11 i nches water c ol um n press ure). B ased on a P res sure Drop of 0.5 Inch Wat er Col um n.

Nomina l Iron P i pe

Length of pipe , Fe et

Exampl e: Input B TU requirement s of the wat er heat er, 199,000 BTUH Total pipe l engt h, 80 feet - 1" IPS required.

L.P. Ga s Capa city

Si ze, (i n ) 10 20 30 40 50 60 80 100 125

5/8 206 141 n/a n/a n/a n/a n/a n/a n/a 3/4 348 239 192 164 146 132 n/a n/a n/a 7/8 536 368 296 253 224 203 174 154 137

Max i m um capac i ty of gas pipe i n thous ands of BTU per hour of undi l uted li qui fied pet rol eum gass es (at 11 i nches water c ol um n press ure). B ased on a P res sure Drop of 0.5 Inch Wat er Col um n.

Copper Tubing OD

Exampl e: Input B TU requirement s of the wat er heat er, 199,000 BTUH Total pipe l engt h, 50 feet = 7/8" IPS required.

Length of pipe , Fe et

Na tu r al Gas Pi p e Cap acity (Cu . ft. /hr )

Si ze, i n . 10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2 132 n/a n/a n/ a n/a n/ a n/a n/ a n/a n/ a n/a n/ a n/a n/ a 3/4 278 190 152 130 115 105 96 n/ a n/a n/a n/a n/ a n/a n/ a

1 520 350 285 245 215 195 180 170 160 150 130 120 110 100 1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210 1-1/2 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

Cu. Ft. P er Hr. Required =

Gas Input of W ater Heater (B TU/HR)

Heating Value of Gas (B TU/FT 3)

The gas input of the water heater i s mark ed on the wat er heat er dat a pl ate. The heati ng value of the gas (B TU/ft3) may be determ ined by c onsulting the local nat ural gas ut ilit y.

Capaci t y of gas pi pe of different diam eters and l engt hs in cu. ft. per hr. wi t h press ure drop of 0.3 i n. and s pecific gravity of 0. 60 (nat ural gas ).

Nomina l Iron P i pe

Length of Pipe , Fee t

After the lengt h of pipe has been det erm i ned, select t he pi pe size which will provide the maximum cubic feet per hour required for the gas i nput rating of the water heater. By formul a:

Table 2

Table 3 - A

Table 3 - B

ELECTRICAL CONNECTIONS

If you lack the necessary skills required to properly install

the electrical wiring to this water heater, do not proceed but

have a qualified service technician perform the installation.

When making the electrical connections, always make sure:

• The voltage and frequency correspond to that specified on the water heater data plate on the front of the water heater.

• The electrical supply has the proper overload fuse or breaker protection. The water heater draws less than 7 amps.

• Wire sizes and connections comply with all applicable codes.

• Wiring is enclosed in approved conduit (if required by local codes).

• The water heater and electrical supply are properly grounded.

• This water heater must be “hard-wired” do not use an extension cord to supply electrical power to this water heater.

Note: The wiring diagram can be found on page 17. Always reference the wiring diagram(s) for the correct electrical connections. Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Electrical Installation

1. Shut off the power at the electrical service box.

2. Loosen the screws securing the access panel to the

electrical compartment. (The electrical wiring diagram can be found on the inside of the access panel.) Set the access panel aside.

3. Connect the electrical supply to the water heater in

accordance with local utility requirements and codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1, Electrical Code. Use only a dedicated electrical circuit containing a properly sized fuse or circuit breaker. Maximum overload protection should not exceed 15 Amperes.

4. Connect this circuit (directly from the electrical service

box) to an electrical disconnect switch.

5. Ground the water heater by connecting the electrical

service ground wire to the green ground wire (provided).

Note: The power supply to this water heater must be properly polarized, [120 volts from the hot lead (black) to ground and 0 volts from the neutral lead (white) to ground] otherwise, the unit will not operate.

6. After making all electrical connections, completely fill the tank with water and check all connections for leaks. Open the nearest hot water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank. The electrical power may then be turned on.

Electrical Shock Hazard

WARNING

Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.

WIRING DIAGRAM

INSTALLATION CHECKLIST Water Heater Location Requirements

• Centrally located with the water piping system. Located as close to the 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. Sufficient room to service the water heater.

• Provisions made to protect the area from water damage. Properly sized drain pan installed and piped to an adequate drain.

• Installation area free of corrosive elements and flammable materials.

Vent Pipe System

• Drafthood and damper properly installed.

• Vent connectors securely fastened with screws and supported properly to maintain 152mm (6 in) clearance.

• Vent pipe and fittings of approved material.

• Acceptable size, length, and number of elbows on exhaust outlet pipe.

• Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Fuel Gas Code, NFPA 54, ANSI Z223.1-Latest Edition. Canadian Installations must be performed in accordance with CAN/CSA-B149.1.

• Drafthood or vent pipe should not be obstructed in any way.

Vent Termination

Vertical

• Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer’s instructions.

Water System Piping

• Temperature and 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.

• Water heater completely filled with water.

• A properly sized expansion tank must be installed on all closed systems.

• A tempering valve should be installed per the manufacturer’s instructions.

Gas Supply and Piping

• If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater.

• Adequate pipe size and of approved material.

• Gas supply is the same type as listed on the water heater data plate.

• Gas line equipped with full opening shut-off valve, union and drip leg.

• Approved pipe joint compound used.

• Chloride-free soap and water solution or other approved means used to check all connections and fittings for possible gas leaks.

Electrical Connections

• Unit must be “hard-wired” to a dedicated 120V power supply.

• Proper polarity.

• Water heater properly grounded.

• Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Electrical Code, ANSI/NFPA 70 and/or the CSA C22.1, Electrical Code.

OPERATING YOUR WATER HEATER

Read and understand these directions thoroughly before attempting to operate the water heater (see Lighting Instructions on page 20). Check the data plate on the front of the water heater for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate. If you have any questions or doubts, consult your gas supplier or gas utility company.

L.P. (Propane) Models

Propane gas is heavier than air and in the occurrence of a leak in the system, the gas will settle on the floor level. Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting a propane gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page. When your propane tank runs out of fuel, turn off the gas at all gas appliances including pilot lights. After the tank is refilled, all appliances must be re-lit according to their manufacturer’s instructions.

Water Heater Operation

When the thermostat calls for heat, it will signal the damper to open. Once the damper fully opens, it will signal the igniter to light the pilot. The pilot will then ignite the main burners. The water heater will operate until the call for heat ends. At this time the main burners and pilot will shut-of f and the damper will close. See Figure 12 for a sequence of operation flowchart.

Figure 12: Sequence of Operation

ELECTRICAL POWER

APPLIED TO UNIT

THERMOSTAT CALLS

FOR HEAT

DAMPER OPENS

PILOT IGNITES

BURNER

WATER HEATER OPERATES TILL

CALL FOR HEATING

ENDS.

THERMOSTAT

SATISFIES

BURNER & PILOT

SHUT OFF

DAMPER CLOSES

Stacking

Stacking occurs when a series of short draws of hot water are taken from the water heater tank. This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet. A tempering valve should be installed in the hot water supply line to reduce the risk of scald injury.

Water Temperature Regulation

The thermostat is adjusted to its lowest temperature setting 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) Important: Since most commercial installations utilize higher temperatures, the use of a tempering valve is strongly recommended in all domestic hot water lines (i.e. public restroom sinks, etc). Auxiliary commercial equipment (i.e. dishwashers, laundry equipment, etc.) may require higher temperature settings. Refer to instruction manuals supplied with this type equipment for recommended temperature settings. Important: Adjusting the thermostat past the 49°C (120°F) setting on the temperature dial (see Figure 13) will increase the risk of scald injury. Hot water can produce first degree burns within: 49°C (120°F) more than 5 minutes 54°C (130°F) at 20 seconds 60°C (140°F) at 3 seconds 66°C (150°F) at 1-1/2 seconds 71°C (160°F) at less than 1 second

Each water heater consists of a mechanical temperature stop set to 60°C (140°F). To set to a different setting remove the temperature dial knob, loosen the shaft nut and re-position the mechanical temperature stop. Tighten the shaft nut and replace the temperature dial knob.

1. Turn off all electric power to the appliance if service is to be performed.

2. Set the thermostat to lowest setting.

3. Turn the gas control knob clockwise to the “OFF” position. Do not force.

1. STOP! Read the safety information above on this label.

2. Turn off all electric power to the appliance.

3. Set the thermostat to the lowest setting.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. Turn the gas control knob clockwise to the “OFF” position. Do not force.

6. Wait ten (10) minutes to clear any

gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.

7. Turn gas control knob counterclockwise to “ON”.

8. Set thermostat to desired setting.

9. Turn on all electric power to the appliance.

10. If the appliance will not operate after three automatic tries, follow these instructions once more. If the appliance still refuses to light, follow the instructions "To Turn Off Gas To Appliance" and call a qualified service technician.

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

DANGER

Water temperature over 52°C (125°F) can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. Feel water before bathing or showering. Temperature limiting valves are recommended.

Figure 13: Tempera-

ture Dial

Emergency Shut Down

Important: If overheating occurs or the gas supply fails to shut off, close the manual gas supply valve and turn the gas control knob to the off position. Turn off the electrical supply to the unit and close the cold water supply valve. Do not operate the water heater again until it has been thoroughly checked by a qualified service technician.

Checking the Draft

After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft. Pass a match flame around the relief opening of the drafthood (See Figure 14). A steady flame drawn into the opening indicates proper draft. If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system.

Burner F lames

Inspect the burner flames through the viewport and compare them to the drawings in Figure 15. A properly operating burner should produce a soft blue flame and be about 50mm (2 in) to 64mm (2 -1/2 in) in height. 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 satisfactory.

Operational Conditions

Condensation

Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces. This will produce a “sizzling” or “frying” noise.

This condensation is normal and should not be confused with a leaking tank. Condensation may increase or

decrease at different times of the year. High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used. Do not confuse this with a “tank leak”. Once the water reaches a temperature of 49°C (120°F) and the tank warms up (usually 1-2 hours), the condensation will stop. 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 production, a leaking tank or piping connections. Under no circumstances is the manufacturer to be held responsible for any water damage in connection with this water heater.

Water Heater Sounds

During the normal operation of the water heater sounds or noises may be heard. These noises are common and may result from the following:

1. Normal expansion and contraction of metal parts during

periods of heat-up and cool-down.

2. Condensation causes sizzling and popping within the

burner area and should be considered normal.

3. Sediment buildup in the tank bottom will create varying

amounts of noise and may cause premature tank failure. Drain and flush the tank as directed under “Draining and Flushing”.

Smoke/Odour

The water heater may give off a small amount of smoke and odour during the initial start-up of the unit. This is due to the burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation.

Safety Shut-off

This water heater is designed to automatically shut-off in the event of the following:

1. The pilot flame is extinguished for any reason.

2. The water temperature exceeds 96°C (205°F).

Burn Hazard

WARNING

Do not touch vent.

Doing so can result in burns.

Figure 14: Vent Draft Test

2 - 2 1/2”

Figure 15: Pilot/Burner Flame

50 - 64mm (2 - 2 1/2 in)

MAINTENANCE OF YOUR WATER HEATER Draining and Flushing

It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup during operation. Note: Warranty is null and void in the event lime & scale deposits are allowed to exceed two inches in depth. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps:

1. Turn off the gas to the water heater at the manual gas shut-off valve and turn off electricity.

2. Close the cold water inlet valve.

3. Open a nearby hot water faucet.

4. Connect a hose to the drain valve and terminate it to an adequate drain.

Note: The drain hose should be rated for at least 93°C (200°F). If the drain hose does not have this rating, open the cold water inlet valve and a nearby hot faucet until the water is no longer hot.

5. Open the water heater drain valve and allow all the water to drain from the tank.

6. Remove the screws holding the cleanout plate, then remove the plate for access.

7. Remove any lime, sediment, or scale from the tank. Be careful not to damage the glass lining.

8. Flush the tank with water as needed to remove any remaining sediment.

9. Check gasket on cleanout plate, replace if necessary.

10. Replace the cleanout plate and screws, tighten sufficiently.

11. Close the drain valve, refill the tank, and restart the water heater as directed under “Operating Your Water Heater”.

If the water heater is going to be shut down for an extended period, the drain valve should be left open. Important: Condensation may occur when refilling the tank and should not be confused with a tank leak.

Routine Preventative Maintenance

At least annually, a visual inspection should be made of the venting and air supply system, piping systems, main burner, and pilot burner. Check the water heater for the following:

• Obstructions, damage, or deterioration in the venting sys-

tem. Make sure the ventilation and combustion air supplies are not obstructed.

• Build-up of soot and carbon on the main burner and pilot

burner. Check for a soft blue flame.

• Leaking or damaged water and gas piping.

• Presence of flammable or corrosive materials in the

installation area.

• Presence of combustible materials near the water heater.

• Verify proper operation after servicing this water heater

Important: If you lack the necessary skills required to properly perform this visual inspection, you should not proceed, but get help from a qualified service technician.

Temper ature and Pressur e Relief Valve

Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly (See Figure 16). To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. If the valve fails to completely reset and continues to release water, immediately shut off the manual gas valve, electric power and the cold water inlet valve and call a qualified service technician.

Pilot Burner and Main Burner Assembly Inspection

To access the pilot burner and main burner for inspection:

1. Turn off gas at main shutoff valve and turn off electrical power.

2. Disconnect the gas supply line from the gas valve.

3. Remove the 2 screws holding the Pilot & Main Burner Assembly in place. See Figure 17 for location of screws.

4. Carefully slide the assembly out of the water heater.

5. If needed, use a brush or vacuum to clean any soot or debris from the burners.

6. Check for correct alignment of burners before sliding assembly back into the water heater.

7. Carefully slide Pilot/Burner Assembly back into the water heater.

Figure 16: T&P Valve Test

Temperature and Pressure Relief Valve

Manual Relief Valve

Discharge line to drain

Explosion Hazard

WARNING

8. Replace and sufficiently tighten the two screws holding the Pilot/Burner Assembly in place.

9. Reconnect the gas supply line to the gas valve.

10. Turn on gas at main shutoff valve.

11. Check for gas leaks and proper operation on the unit after servicing.

Gas Valve Removal and Replacement

It is recommended that this maintenance be performed by a qualified service technician.

1. Turn the thermostat to its lowest setting.

2. Turn off gas at manual gas shut-off valve (see figure 10 for reference) and disconnect electrical power from water heater.

2. Unplug the 4 wires located on the gas valve. Label wire position for correct reattachment.

3. Disconnect pilot tube from the gas valve.

4. Disconnect the main gas line from the gas valve. Use care not to crack the gas valve housing.

5. Carefully unscrew the gas valve from the burner assembly.

Important: When removing gas control valve do not use a pipe wrench or vise to grip the body.

6. When replacing the gas valve, use an approved Teflon® or pipe joint compound on the pipe threads.

7. Screw the new gas valve onto the burner assembly.

8. Reconnect the pilot tube to the gas valve.

9. Reconnect the main gas line to the gas valve.

10. Turn the gas supply on and check for leaks. Use a chlorine-free soap and water solution (bubbles forming indicate a leak) or other approved method.

11. Reconnect the 4 wires to their proper location and restore electrical power to the unit.

11. Verify proper operation after servicing this water heater.

12. If additional information is required, contact the Product Service and Support Group at 1-888-479-8324.

Anode Rod Inspection

Each water heater contains at least one anode rod, which will slowly deplete while protecting the glass-lined tank from corrosion and prolonging the life of the water heater. Cert ain water conditions will cause a reaction between the rods and the water. Once the anodes are depleted, the tank will start to corrode, eventually developing a leak. 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. Do not remove this rod permanently

as it will void any warranties, stated or implied. A special anode is available for this complaint. 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 rods should be removed from the water heater tank every 3 years for inspection. If the rods are more than 50% depleted, the anode rods should be replaced. In replacing the anodes:

1. Turn off gas supply and electrical power to the water heater.

2. Shut off the water supply and open a nearby hot water faucet to depressurize the water tank.

3. Drain approximately 20l (5 gal) of water from tank (Refer to “Draining and Flushing” for proper procedures). Close drain valve.

4. Remove old anode rods.

5. Use Teflon® tape or approved pipe sealant on threads and install new anode rods.

6. Turn on water supply and open nearby hot water faucet to purge air from water system.

7. Restart the water heater as directed under “Operating Your Water Heater.” See the "Repair Parts Illustration" for anode rod location.

Figure 17: Pilot/Burner Assembly Removal

TROUBLESHOOTING FLOWCHART

High water temp.

Will ECO light

reset once temp.

in tank cools?

Check continuity

across ECO.

Replace

ECO.

No hot water.

Power to heater?

Is ECO light “ON”?

Go to next page.

Repair

power

problem.

When thermostat

is turned up does

pilot spark?

Check for 24V

between purple &

white wires on the

ignition control

module (ICM).

Is ground good

from ICM to

incoming ground?

Check for 24V

between PV &

PV/MV terminals

on gas valve.

Does pilot light?

Repair

ground.

Replace

gas valve.

Does sparking

stop?

Check for 24V

between PV &

MV/PV terminals

on ICM

Check for 24V

between orange &

white wires on

damper harness.

Check for 24V

between PV &

MV/PV terminals

on ICM.

Clean flame

sensor - check

ground.

Replace

ICM.

Check spark wire

for damage & con-

tinuity. Check

spark ass’y for

cracks in ceramic

or wrong gap.

Bypass

damper,

orange & purple

wires. If heater

fires, then replace

damper.

Replace

ICM.

Bad

spark ass’y

or wiring

between spark

ass’y and

ICM.

Replace

faulty

parts.

Replace

ICM

Go to next page.

Check gas supply.

Repair

gas supply.

All should

be OK.

Is there 24V

between MV &

MV/PV terminals

at the ICM?

Does main burner

stay lit until ther-

mostat satisfies?

Check for block-

age in burner or

orifice. Also check

incoming gas sup-

ply.

Does main burner

fire?

Is there 24V

between PV &

PV/MV terminals

at gas valve?

Replace

ICM.

Replace

gas valve.

Check and

adjust gas

pressure.

Go to next page.

Does pilot light

shrink or go out

when main burner

fires?

Is gas flex being

used, or other

small gas pipe?

Open

Closed

All OK

Found

damage

Y Y

THERMOSTAT TROUBLESHOOTING FLOWCHART

0123456789

0°C 32648 31026 29495 28049 26682 25389 24166 23010 21915 20879

10°C 19898 18968 18088 17253 16461 15710 14998 14322 13680 13071

20°C 12492 11942 11419 10922 10450 10000 9572 9165 8778 8409

30°C 8057 7722 7403 7099 6808 8532 6268 6016 5775 5546

40°C 5327 5117 4917 4726 4543 4368 4201 4042 3889 3742

50°C 3602 3468 3340 3217 3099 2986 2878 2774 2675 2579

60°C 2488 2400 2316 2235 2157 2083 2011 1942 1876 1813

70°C 1752 1693 1637 1582 1530 1480 1432 1385 1340 1297

80°C 1256 1216 1177 1140 1105 1070 1037 1005 974 944

90°C 916 888 861 835 810 786 763 741 719 698

40°F 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445

50°F 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715

70°F 11884 11592 11308 11032 10763 10502 10248 10000 9760 9526

90°F 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961

100°F 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767

120°F 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112

140°F 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083

160°F 1688 1656 1625 1595 1566 1537 1509 1481 1454 1427

180°F 1170 1150 1129 1110 1090 1071 1053 1035 1017 999

190°F 982 965 949 933 917 901 886 871 857 842

200°F 828 814 801 788 775 762 749 737 725 713

Resistance (K ohms)

Tempe rature

Sensor Resistance vs. Temperature

Table 4

Replace

set pot.

Replace

thermostat

circuit board.

Replace

bad

sensor(s).

Check

damper.

Take ohm reading

from upper and

lower sensors

and compare with

chart in Table 4.

(A temp. reading

from a water

sample taken

from T&P valve is

also needed for

this test).

Check orange

wire from ECO

board to

damper for 24V.

Check purple

wire from ther-

mostat for 24V.

Will ECO board

reset?

High water

temp.

Check ECO

and ICM.

Is ECO light

“ON”?

Replace ECO

board.

Slowly turn set pot from low to

high. Reading

should change

smoothly with

no skips, jumps

or glitches.

With an ohmmeter

set at X1, check orange wires on

set pot. (3,000

ohms at lowest

setting & 0 ohms

at highest setting.)

No voltage or

low voltage from purple

wire between

thermostat

board & ECO

board.

OHMs reading no good

OHMs show OK

Yes

No No

Yes Yes

Yes

OKHas bad spots

REPAIR PARTS ILLUSTRATION

When ordering repair parts always give the following information:

1. Model, serial, and product number

2. Type of gas

3. Item number

4. Parts description

Repair Parts List

No. Pa rt Name a nd De scri ption No. P art Name and Descri ption

1 Drafthood 16 Control B ox Cover 2 Diptube (Top) 17 Transformer 3 Diptube (F ront ) (Opt i onal not pict ured) 18 Igniti on Cont rol M odul e 4 Diptube (B ack ) (Optional not pi ct ured) 19 Thermost at board 5 Flue B affles 20 ECO Res et Board 6 Clean Out Gask et 21 Control B ox 7 Clean Out Cover 22 W i ring Harnes s 8 Clean Out Cover Jack et 23 Anode Rod(s )

9 Drain Valve 24 T&P Valve 10 Main Burner Tube(s) 25 Temp. Control P otent i om et er 11 Burner Tray 26 Upper Temperature Sensor/ECO 12 Pi lot B urner A s sem bl y 27 Lower Tem perature Sensor 13 Main Burner Manifold 28 Flue Damper 14 Gas Valve 29 Power Cord (Opti onal not pi ct ured) 15 Main Burner Orific e(s)

See Rating Label Serial Number prefix for Warranty Code. Reduced warranty period applies to Newfoundland.

Warranty Code: P R S T U V W Y

Standard Warranty Years: 3 5 6 7 8 9 10 12

Reduced Warranty Years: 233555 5 7

~ Certificate of Warranty ~

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 W arranty 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 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 OFGSW OFANY NATURE OR KIND, EXPRESS OR IMPLIED, HOWEVER ARISING (WHETHER BY CONTRACT, CONDUCT, STATEMENT, STATUTE, NEGLIGENCE, PRINCIPLES OFMANUF ACTURER'S LIABILITY, OPERA TION OFLAWOR OTHERWISE) WITH RESPECTTO THE UNIT OR ITS FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, INSTALLATION, OPERATION, REPAIR OR REPLACEMENT. GSW EXPRESSLY DISCLAIMS ANY AND ALLIMPLIED WARRANTIES. IN NO EVENT WILL GSW'S LIABILITIES EXCEED THE COST OF THE DEFECTIVE PART(S) OR UNIT. GSWWILLNOT PAY FOR ANYTRANSPORTATION, 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 affect the remaining provisions. Any and all repair and/or replacement of part(s) or Unit are the sole and exclusive remedy available against GSW.

1. The Unit shall be installed in accordance with all manufacturers' instruc-

tions, all applicable equipment and building codes, ordinances and regulations (hereinafter referred to as the "standards").

2. The Unit must not be installed where water damage can result from a

leak, while provision(s) shall be made for directing any water escaping from the Unit, to a properly operating drainpipe. As all units of this type may eventually leak, you must protect against any potential water damage. GSW accepts no responsibility for such damage, nor any incidental or consequential loss, nor damage(s) related thereto, suffered by the owner of the Unit nor by any third party.

3. The Unit shall not be installed where it will be exposed to adverse or

unusual environmental or corrosive conditions. No warranty extends, for example, and without limitation of the foregoing, to Units exposed to: salts; chemicals; exhausts; pollutants or contaminants. Further, no warranty extends to Units affected by fire, freezing or flood, "Acts of God", or any other contingency beyond the control of GSW.

4. The Unit shall be equipped with a properly operating temperature and

pressure relief valve as specified by GSW and applicable standards. The Unit shall be operated at temperatures not exceeding the maximum setting of the thermostat and/or high limit control provided by GSW, and at water pressures not exceeding the pressure reading stated on the Unit.

5. The Unit must be carefully inspected, maintained, and operated in accor-

dance with the manufacturer's instructions. No warranty extends, for example, and without limitation of the foregoing, to any Unit operated: without the tank being completely filled with water; without an operating anode; with levels of sediment or lime precipitate which cause failure; in connection to any attachment(s), energy saving device(s), or other means of heating, except as approved by GSW for the Unit; other than with potable water without any additives such as salts, chlorine or chemicals, except those added for the sole purpose of rendering the water fit for domestic use.

6. All repairs must be made by a competent and qualified person who is cer-

tified, by GSW or one of its authorized dealers, to work on the Unit, using factory approved replacement parts, and the Unit shall not be otherwise modified, altered or improperly repaired.

7. A properly documented claim shall be received by GSW or one of its authorized dealers, or point of purchase, within the following Warranty Period, except as provided otherwise below*: a) for any defective part, within one (1) year; or b) for any Unit that develops leaks in the inner tank due to rust, corrosion or other chemical reactions caused by the potable domestic water supplied to your home, within the period of time shown in table at the top of this page. * Residential units installed and used in a commercial application carry a warranty period of one (1) year from date of installation; and, Any repair or replacement of any part, tank, or Unit under this Warranty will not extend the Warranty Period beyond that calculated from the date of first installation of the original Unit. The date of first installation will be deemed to be the later of the date indicated by the Unit's serial number, or if supplied with the Warranty claim, the sales receipt, or installer's receipt.

8. A claim under this Warranty must include the model and serial number of the Unit, proof of date on which the Unit was first installed, and the identity of the defective part(s) for which a claim is being made and be submitted within 15 days following discovery of the defect(s), by personal delivery to a GSW authorized dealer, point of purchase, or GSW itself at:

GSW Water Heating

GSW Water Heating is a division of GSW Water Products Inc.

599 Hill Street West

Fergus, ON Canada N1M 2X1 Should you have questions, please call our Technical Support Line at 1888-479-8324.

9. If requested by GSW, information relating to the purchase, transportation, operation and installation of the Unit must be supplied. The defective part(s) or Unit, with all components properly and securely packed, shall be returned transportation pre-paid, to the address designated by GSW in the written request. All claims are subject to validation by GSW.

LIABILITY OF GSW COVERED BY THIS WARRANTY IS CONDITIONAL UPON THE FOLLOWING:

John Wood Commercial AJWS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual