Smith Cast Iron Boilers JW527, JWF307V User Manual
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 Oil-Burner
Technician or your oil supplier.
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 Oil-Burner
Technician or your oil supplier.
•Immediately call your oil supplier.
WHAT TO DO IF YOU SMELL OIL
PART NO. 61512 REV. K (08-05)
GSW Water Heating is a division of
A. O. Smith Enterprises Ltd.
JWF307 - JW317 - JW327
JWF507 - JW517 - JW527
JWF307V - JW717 - JW727
JWF657
INSTALLATION RECORD
Record key data here for future reference and prompt service:
Installed By / Purchased From:
Location of Electrical Switch
or Circuit Protector:
Installation Date:
Serial Number
Model Number
Technical Support Line: 1-888-479-8324
OIL FIRED WATER HEATER
INSTALLATION AND OPERATING INSTRUCTIONS
Read and understand these instructions thoroughly before attempting
any installation or service.
– 2 –
TABLE OF CONTENTS
I) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Consumer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II) Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Code Requirements For Installations In Canada . . . . . . . . . . . . . . . . . . . .
Code Requirements For Installations In The United States. . . . . . . . . . . .
Safety Warning (Flammable Vapours) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warning (Scalding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warning (Carbon Monoxide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief Valve Requirements (T&P). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
III) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking The Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Pan Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances And Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent and Exhaust Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blocked Vent Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Of The Aquastat (Temperature Control). . . . . . . . . . . . . . . . . .
Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Temperature Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Heater Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smoke/Odour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anode Rod/Water Odour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Professional Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining And Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature And Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Instructions, Flue Passages Of The JWF657 Heater . . . . . . . . .
Shut Down For Extended Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Re-Starting The Heater After Shut-Down. . . . . . . . . . . . . . . . . . . . . . . . . .
VI) Combination Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Read Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII) Oil Burner Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR
FUTURE REFERENCE
Thank you for purchasing a John Wood Oil Fired Water
Heater. Properly installed and maintained, it will provide
years of trouble free service.
This Oil Fired Water Heater has been developed to supply
domestic hot water for normal residential demands. Any
deviation from this application could affect your warranty.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation and maintenance of your oil fired
water heater and provide important safety information in
these areas. 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
AND UNDERSTAND ALL INSTRUCTIONS BEFORE YOU
ATTEMPT TO INSTALL, OPERATE OR MAINTAIN THIS
HEATER.
Installation and service requires trade knowledge in the
areas of plumbing, electricity, venting, air supply and oil supply. If you lack these skills or have difficulty understanding
these instructions, you should not proceed. Enlist the help of
a qualified service technician to install this water heater.
Examples of qualified service technicians include those
trained in the plumbing and heating industry, local oil supply
personnel or an authorized service person.
The manufacturer and seller of this water heater will not
assume any liability for any property damage, personal
injury or death resulting from improper sizing, installation or
failure to comply with these instructions.
The warranty on this water heater is in effect only when the
water heater is installed and operated in accordance with
these instructions. An identifying data plate can be found at
the front of your water heater. When referring to your water
heater, always have the information listed on the data plate
readily available.
Protect your warranty: Regularly service your water heater
as directed in the "Maintenance" section of this manual.
Retain your original receipt as proof of purchase.
Do not discard this manual. You or future users of this
water heater will need it for reference.
In addition to the installation instructions found in this manual, the water heater must be installed in accordance with all
local and provincial or state codes or, in the absence of
such, with the latest editions of the following specifications.
For Installations in Canada:
“Installation Code for Oil-Burning Equipment (CSA
B139-04)” and
“Canadian Electrical Code Part 1 (C22.1)” available from:
Canadian Standards Association,
5060 Spectrum Way,
Mississauga, Ontario, Canada
L4W 5N6
– 3 –
I) INTRODUCTION
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.
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.
II) SAFETY
For Installations in the United States:
“Standard for the Installation of Oil-Burning Equipment
(NFPA 31)” and
“National Electrical Code (NFPA 70)” available from:
American National Standards Institute,
25 West 43rd Street,
New York, NY 10036
Check your phone listings for the local authorities having
jurisdiction over your installation.
Important: Installation and service of an oil fired water
heater and burner must be performed by a qualified OilBurner Technician to comply with local and provincial or
state codes applicable to this type of equipment. 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.
Safety Warning (Flammable Vapours)
There is a risk of property damage, personal injury or death
from the by-products of combustion (e.g., flue gases), 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. are stored, or where engine-driven equipment or
vehicles are stored, operated or repaired. These, and similar products, should not be stored or used near the water
heater or air intake. Due to the nature of air movement, flammable vapours can be carried some distance from the point
of storage. A water heater igniter or burner flame can ignite
these vapours causing a flashback, fire or explosion, which
may result in severe property damage, serious personal
injury or death. If flammable liquids or vapours have spilled
or leaked in the area of the water heater, leave the area
immediately and call the fire department from a neighbor’s
home. Do not attempt to clean the spill until all ignition
sources have been extinguished.
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 when water temperatures
exceed 52°C (125°F). Use tempering valves, also known as
mixing valves, 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 flue gases. Such a condition can cause
soot build-up and present a fire hazard. Flow reversal of flue
gases can cause an increase of carbon monoxide inside of
the dwelling that could result in serious bodily harm or death
from asphyxiation.
MAKE SURE THE FLOW OF COMBUSTION AND VENTILATION AIR IS NOT RESTRICTED.
Relief Valve Requirements (T&P)
All water heaters must be fitted with a proper temperature
and pressure relief valve. These valves must be certified as
meeting the requirements of the “Standard For Relief
Valves For Hot Water Supply Systems, ANSI Z21.22/CSA
4.4”.
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 service
technician.
– 4 –
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.
THESE CONDITIONS CAN RESULT IN UNSEEN INTERNAL DAMAGE and are not subject to warranty coverage.
This product contains fiberglass wool and ceramic fiber
materials. Airborne fibers from these materials have been
listed by the State of California as a possible cause of cancer through inhalation. Use special care when handling
ceramic fiber (chamber lining and base insulation) materials.
Ceramic fibers can be converted to chrystobalites, a substance listed as a probable cause of cancer. Suppliers of
fiberglass wool products recommend the following measures be taken when handling these materials:
Precautionary measures:
• Avoid breathing fiberglass dust.
• Avoid contact with skin and eyes.
• Use a National Institute for Occupational Safety and
Health (NIOSH) approved dust/mist respirator.
• Wear long-sleeved, loose fitting clothing, gloves and eye
protection.
• Wash work clothes separately from other clothing. Rinse
washer thoroughly.
Removing the burner may generate airborne fiber concentration requiring additional protection.
First aid measures:
• Eye contact - Flush eyes with sterile water to remove for-
eign objects. If irritation or other symptoms persist, seek
medical attention.
• Skin contact - Wash affected areas gently with soap and
warm water after handling.
Fuel Specifications
All JOHN WOOD brand water heaters are designed to burn
only fuels not heavier than No.2 (furnace) oil.
Unpacking the Water Heater
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
start-up.
• Completely read 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.
• After installation, dispose of packaging material in the
proper manner.
Location Requirements
The water heater must be installed indoors in an area not
subject to freezing temperatures and in a vertical position on
a level surface. Water heaters located in unconditioned
spaces (e.g., attics, basements etc.) may require insulation
of the water piping, drain piping and venting to protect
against condensation.
The water heater must be installed on a non-combustible
floor, as close to the chimney as practical. Select a location
as centralized within the piping system as possible. The
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 (see “IMPORTANT” notice on the following page).
Before installing this water heater, consideration and planning must be given to the following details:
• Proximity to walls and other objects (see Figures 1, 2 &
3).
• Access to oil supply (see “Oil Supply”).
• Routing and support of the vent piping and termination
(see “Venting”).
• Position of water supply and placement of water piping
and floor drain (see “Water Supply”).
• How and where to obtain combustion and ventilation air
supply. (see “Air Requirements”).
• Connection to the electrical service. (see “Electrical
Supply”).
– 5 –
CAUTION:
Possible cancer hazard by inhalation. Can
cause respiratory, skin and eye irritation.
WARNING
• Do not use gasoline, crank case oil or an
oil containing gasoline.
• Do not tamper with unit or controls.
• Do not leave paper or rags around the
burner or heater.
• Do not experiment with the burner.
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.
III) INSTALLATION
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.
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.
Clearances and Accessibility
The minimum clearances between the heater and combustible materials are listed in Figure 1.
Note: These requirements are also listed on the data plate
located on the front of the water heater.
A minimum of 600mm (24 in.) of front clearance and 100mm
(4 in.) on each side should be provided for inspection and
service.
Oil Supply
All aspects of oil tank location and installation, tank size, oil
piping supply and burners, including any fittings, valves, filters or any fuel handling components must comply with:
• “Installation Code for Oil Burning Equipment
(CAN/CSA-B139)”, (Canada).
• “Standard for the Installation of Oil-Burning
Equipment. (NFPA 31)”, (U.S.A).
• Local codes and regulations.
• Information provided with burner and fuel pump.
Install the oil supply tank with fill and vent lines of adequate
capacity as shown in Figure 4. When an appliance using a
float valve between the supply tank and the burner is connected to a supply tank over 9 gallons (Can.) capacity, a
valve operated by a fusible link shall be installed in the fuel
line adjacent to, and upstream from, the float valve. If any
part of fuel the oil tank is above level of the burner, an antisiphon device must be used to prevent flow of oil in case of
an oil line break. Support the oil lines as required by applic-
able codes. Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles. Make
the swing joints so they will tighten as the tank settles. Nonhardening pipe joint compounds should be used on all
threads. Do not use Teflon® tape as an oil pipe sealant as it
can cause valves to fail and create hazards. Do not use
compression fittings. Underground piping must be run in a
casing to prevent oil from leaking into the ground or under
the floor. Check local codes for more information.
Burner Installation
The installation of these units shall be in accordance with
the “Installation Code for Oil-Burning Equipment (CSA
B139-04)” or “Standard for the Installation of OilBurning Equipment (NFPA 31)” (as applicable), local
codes and the manufacturer’s instructions. The burner
should be installed only by a qualified Oil-Burner Technician.
– 6 –
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.
WARNING
This installation must be performed by a
qualified Oil-Burner Technician in accordance with these instructions and diagrams.
The installation and maintenance of the
water heater must follow all of the instructions in preceding sections of this manual.
Improper installation can cause injury or
property damage. Heater failure that is a
result of the heating system is not covered
by warranty.
– 7 –
600mm (24 in.) MIN.
FOR SERVICING
457mm
(18 in.)
MIN.
FLUE
SEE TABLE
TOP
SEE TABLE
FLUE SIZES
SEE TABLE
NON-COMBUSTIBLE FLOOR
COMBUSTIBLE CEILING
DRAFT
REGULATOR
FLUE
SEE TABLE
Figure 1 Rough-In Dimensions
NOTE: JWF307V requires additional
“Through-the-wall Vent Kit” available
in 3 lengths: 5’ (63320), 10’ (63321)
or 20’ (63322). Refer to additional
“Installation Instructions for Throughthe-wall Venting Components" that is
supplied with the JWF307V.
Center Rear
mm in. mm in. mm in. mm in. mm in. mm in. mm in.
JWF307 508 20 X 152 6 610 24 51 2 51 2 457 18 229 9
JWF507 559 22 X 152 6 610 24 51 2 51 2 457 18 229 9
JWF657 660 26 X 152 6 610 24 51 2 51 2 406 16 152 6
JWF307V 508 20 X 152 6 610 24 51 2 51 2 457 18 152 6
JW317 610 24 X 152 6 610 24 152 6 152 6 356 14 457 18
JW327 610 24 X X 152 6 610 24 152 6 152 6 356 14 457 18
JW517 711 28 X 178 7 610 24 152 6 152 6 356 14 457 18
JW527 711 28 X X 178 7 610 24 152 6 152 6 356 14 457 18
JW717 813 32 X 178 7 610 24 152 6 152 6 356 14 457 18
JW727 813 32 X X 178 7 610 24 152 6 152 6 356 14 457 18
Model
Diam.
Flue size
Front
Flue location
Clearance
Rear
Sides
Top
Flue
– 8 –
Figure 2 Installation Dimensions (Center Flue Models)
A
D
C
B
E
F
G
H
Figure 3 Installation Dimensions (Center/Rear Flue
Models)
JW317/JW327 JW517/JW527 JW717/JW727
mm 610 711 813
in.242832
mm 229 222 229
in. 9 8 3/4 9
mm 508 508 495
in. 20 20 19 1/2
mm 1264 1299 1359
in. 49 3/4 51 1/8 53 1/2
mm 1492 1499 1565
in. 58 3/4 59 61 5/8
mm 1575 1386 1486
in. 62 54 9/16 58 1/2
mm 593 584 826
in. 23 1/3 23 32 1/2
mm 1241 1372 1486
in. 48 7/8 54 58 1/2
mm 150 178 178
in.677
GHCDE
F
Model
Diam.AB
A
B
C
D
E
F
G
H
JWF307 JWF507 JWF657 JWF307V
mm 508 559 660 508
in.20222620
mm 229 229 254 229
in. 9 9 10 9
mm 457 457 524 457
in. 18 18 20 5/8 18
mm 699 660 775 699
in. 27 1/2 26 30 1/2 27 1/2
mm 1286 1486 1661 1286
in. 50 5/8 58 1/2 65 3/8 50 5/8
mm 1326 1534 1692 1326
in. 52 3/16 60 3/8 66 5/8 52 3/16
mm 1122 1308 1511 1122
in. 44 3/16 51 1/2 59 1/2 44 3/16
mm 1314 1499 1753 1314
in. 51 3/4 59 69 51 3/4
mm 150 150 150 150
in.6666
Model
Diam.ABGHCDEF
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